InstructionInstruction SheetSheet7-2013A046M783 (Issue 1)

Installation Instructions for Alternator Heater Kits A044G635and A044G637

1 IntroductionThe information contained within is based on information available at the time of going to print.In line with Cummins Power Generation policy of continuous development and improvement,information may change at any time without notice. The users should therefore make sure thatbefore commencing any work, they have the latest information available. The latest version ofthis manual is available on QuickServe Online (https://qsol.cummins.com/info/index.html).

2 Safety Precautions

2.1 General Safety Precautions

WARNINGCoolants under pressure can cause severe scalding. Do not open a radiator or heatexchanger pressure cap while the engine is running. Let the engine cool down beforeremoving the coolant pressure cap. Turn the cap slowly and do not open it fully untilthe pressure has been relieved.

WARNINGMoving parts can cause severe personal injury or death and hot exhaust parts cancause severe burns. Make sure all protective guards are properly in place beforestarting the generator set.

WARNINGUsed engine oils have been identified by some state and federal agencies to causecancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact used oilwhen checking or changing engine oil.

WARNINGOperation of equipment is unsafe when mentally or physically fatigued. Do not operateequipment in this condition, or after consuming any alcohol or drug.

WARNINGSubstances in exhaust gases have been identified by some state and federal agenciesto cause cancer or reproductive toxicity. Do not breath in or come into contact withexhaust gases.

English A046M783 (Issue 1)- Original Instructions

Page 1 of 26© 2013 Cummins Power Generation, Inc. All rights reserved.

WARNINGFlammable liquids can cause fire or explosion. Do not store fuel, cleaners, oil, etc. nearthe generator set.

WARNINGWear hearing protection when going near an operating generator set .

WARNINGHot metal parts can cause severe burns. Avoid contact with the radiator, turbo charger,and exhaust system.

WARNINGMaintaining or installing a generator set can cause severe personal injury. Wearpersonal protective equipment such as safety glasses, protective gloves, hard hats,steel-toed boots, and protective clothing when working on equipment.

WARNINGEthylene glycol, used as engine coolant, is toxic to humans and animals. Clean upcoolant spills and dispose of used antifreeze in accordance with local environmentalregulations.

WARNINGStarting fluids, such as ether, can cause explosion and generator set engine damage.Do not use.

CAUTIONStepping on the generator set can cause parts to bend or break, leading to electricalshorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set whenentering or leaving the generator room.

CAUTIONTo prevent accidental or remote starting while working on the generator set, disconnectthe negative (–) battery cable at the battery using an insulated wrench.

CAUTIONMake sure that rags are not left on or near the engine.

CAUTIONMake sure the generator set is mounted in a manner to prevent combustible materialsfrom accumulating under the unit.

CAUTIONAccumulated grease and oil can cause overheating and engine damage presenting apotential fire hazard. Keep the generator set clean and repair any oil leaks promptly.

A046M783 (Issue 1)Page 2 of 26

CAUTIONBefore performing maintenance and service procedures on enclosed generator sets,make sure the service access doors are secured open.

CAUTIONKeep the generator set and the surrounding area clean and free from obstructions.Remove any debris from the set and keep the floor clean and dry.

NOTICEKeep multi-class ABC fire extinguishers handy. Class A fires involve ordinarycombustible materials such as wood and cloth. Class B fires involve combustible andflammable liquid fuels and gaseous fuels. Class C fires involve live electricalequipment. (Refer to NFPA No. 10 in applicable region.)

2.2 Generator Set Safety CodeBefore operating the generator set, read the manuals and become familiar with them and theequipment. Safe and efficient operation can be achieved only if the equipment is properlyoperated and maintained. Many accidents are caused by failure to follow fundamental rulesand precautions.

WARNINGImproper operation and maintenance can lead to severe personal injury, or loss of life andproperty, by fire, electrocution, mechanical breakdown, or exhaust gas asphyxiation. Read andfollow all Safety Precautions, Warnings, and Cautions throughout this manual and thedocumentation supplied with your generator set.

WARNINGLifting and repositioning of the generator set must only be carried out using suitable liftingequipment, shackles, and spreader bars, in accordance with local guidelines and legislation, bysuitably trained and experienced personnel. Incorrect lifting can result in severe personal injury,death, and/or equipment damage. For more information, contact your authorized distributor.

2.3 Electrical Shocks and Arc Flashes Can Cause Severe PersonalInjury or Death

WARNINGAny work with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC or higherposes a significant risk of electrical shock and electrical arc flash. These silent hazards cancause severe injuries or death. Refer to standard NFPA 70E or equivalent safety standards incorresponding regions for details of the dangers involved and for the safety requirements.

Guidelines to follow when working on de-energized electrical systems:

• Use proper PPE. Do not wear jewelry and make sure that any conductive items areremoved from pockets as these items can fall into equipment and the resulting short circuitcan cause shock or burning. Refer to standard NFPA 70E for PPE standards.

A046M783 (Issue 1)Page 3 of 26

• De-energize and lockout/tagout electrical systems prior to working on them.Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment orthe release of stored energy. Please refer to the lockout/tagout section for moreinformation.

• De-energize and lockout/tagout all circuits and devices before removing any protectiveshields or making any measurements on electrical equipment.

• Follow all applicable regional electrical and safety codes.

Guidelines to follow when working on energized electrical systems:

NOTICEIt is the policy of Cummins Inc. to perform all electrical work in a de-energized state. However,employees or suppliers may be permitted to occasionally perform work on energized electricalequipment only when qualified and authorized to do so and when troubleshooting, or if de-energizing the equipment would create a greater risk or make the task impossible and all otheralternatives have been exhausted.

NOTICEExposed energized electrical work is only allowed as per the relevant procedures and must beundertaken by a Cummins authorized person with any appropriate energized work permit for thework to be performed while using proper PPE, tools and equipment.

In summary:

• Do not tamper with or bypass interlocks unless you are authorized to do so.

• Understand and assess the risks - use proper PPE. Do not wear jewelry and make surethat any conductive items are removed from pockets as these items can fall into equipmentand the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E forPPE standards.

• Make sure that an accompanying person who can undertake a rescue is nearby.

3 Instruction

3.1 Installation of Heater Kit A044G637 for CA 115 AlternatorsThese instructions give the procedure for installing Alternator Heater kit A044G637 on generatorsets with CA 115 (120 V, 30 W) alternators.

Read these installation instructions completely and become familiar with safety warnings,cautions and installation procedure before starting

WARNINGIncorrect installation, service, or replacement of parts can result in severe personalinjury or death and/or equipment damage. Only trained and experienced personnel areto perform the following procedures.

WARNINGAC voltages and currents present an electrical shock hazard that can cause severepersonal injury or death. Incorrect installation, service, or parts replacement can resultin severe personal injury, death, and/or equipment damage. Only trained andexperienced personnel are to perform the following procedures.

A046M783 (Issue 1)Page 4 of 26

CAUTIONIf present, always disconnect a battery charger from its AC source before disconnectingthe battery cables. Otherwise, disconnecting the cables can result in voltage spikeshigh enough to damage the DC control circuits of the generator set.

WARNINGAccidental starting of the generator set while working on it can cause severe personalinjury or death. Prevent accidental starting by disconnecting the starting battery cables(negative [−] first). Make certain the battery area has been well ventilated beforeservicing the battery. Wear goggles. Stop the generator set and disconnect the chargerbefore disconnecting battery cables. Arcing can ignite explosive hydrogen gas given offby batteries, causing severe personal injury. Arcing can occur when a cable is removedor re-attached, or when the negative (−) battery cable is connected and a tool used toconnect or disconnect the positive (+) battery cable touches the frame or othergrounded metal part of the generator set. Always remove the negative (−) cable first,

and reconnect it last. Make certain hydrogen from the battery, engine fuel, and otherexplosive fumes are fully dissipated. This is especially important if the battery has beenconnected to a battery charger.

WARNINGIgnition of explosive battery gases can cause severe personal injury or death. Arcing atbattery terminals, light switch or other equipment, flame, pilot lights and sparks canignite battery gas. Do not smoke, or switch trouble light ON or OFF near a battery.Discharge static electricity from body before touching batteries by first touching agrounded metal surface.

1. Make sure the generator set is disabled.

a. Press the STOP button on the operator panel to make sure the control is in the Offmode.

b. If equipped, activate the E-stop button.

c. If equipped, disconnect the battery charger. Remove any other electrical supplysources.

d. Disconnect the negative [-] cable from the battery and secure it from contacting thebattery terminals to prevent accidental starting.

2. Remove the following parts to access the alternator:

• Enclosure end cover and side door as shown in Figure 1

• Terminal box dome cover and alternator screen as shown in Figure 2

• EBS/PMG as shown in Figure 3

A046M783 (Issue 1)Page 5 of 26

No. Description No. Description

1 Enclosure Side Door 2 Enclosure End Cover

FIGURE 1. ENCLOSURE

No. Description No. Description

1 Mesh Screen 2 Terminal Box Dome Cover

FIGURE 2. TERMINAL BOX DOME COVER AND MESH SCREEN

FIGURE 3. EBS/PMG

A046M783 (Issue 1)Page 6 of 26

3. Loosen the terminal box mounting bolts (as shown in the figure below) to be able toreposition the box to create adequate clearance between the alternator and the terminalbox.

FIGURE 4. TERMINAL BOX MOUNTING BOLTS

4. Make sure enough clearance is available between the alternator and the ground forinstallation, using appropriate lifting equipment or tools. A minimum of 145 mm (5.7 in)clearance is recommended from the ground to the bottom surface of the alternator, asshown in the figure below.

FIGURE 5. MINIMUM CLEARANCE

NOTICEProper precautions need to be taken while operating lifting equipment.

5. Locate the grill installed around the NDE bracket of the alternator as shown in the figurebelow. Remove the grill. Save the hardware.

A046M783 (Issue 1)Page 7 of 26

No. Description No. Description

1 Detail Shown in 3 and 4 5 Alternator Heater

2 Grill 6 NDE Bracket

3 Heater Element 7 Cable Tie

4 Hex Nut, Lock Washer, Thread Sealant 8 Cable TieBase, Hex Head Screw, Flat Washer(Approximate Location)

FIGURE 6. NDE BRACKET AND GRILL

6. Locate the heater mounting holes, as shown in the figure below.

A046M783 (Issue 1)Page 8 of 26

FIGURE 7. HEATER MOUNTING HOLES

7. Verify accessibility of the heater holes to install hardware from under the alternator frame.

8. Carefully insert the alternator heater (as shown in the figure below) through the opening.

• Use the heater studs to guide the heater through the mounting holes.

• Use an appropriate hand tool if necessary.

CAUTIONBe careful not to touch or damage alternator wires when positioning the heater.

FIGURE 8. INSERTING THE ALTERNATOR HEATER

9. Move the studs through the heater holes, as shown in Figure 9. Studs should extendbelow the alternator, as shown in Figure 10.

A046M783 (Issue 1)Page 9 of 26

FIGURE 9. MOVING THE STUDS THROUGH THE HEATER HOLES

FIGURE 10. STUDS EXTENDING BELOW THE ALTERNATOR

10. Use two M5 lock washers and two M5 X 0.8 nuts (included in the kit) to secure the heaterto the alternator frame. Torque the fasteners 6 - 6.5 Nm.

11. Apply thread sealant to the stud at the indicated location in Figure 6.

12. Use cable ties to tie wrap the heater harness to the alternator frame and route the harnessalong as shown in the end view of the alternator in Figure 6.

• Make sure that the cable tie is not pulled too tight to prevent it from rubbing against asharp edge.

• Leave enough harness length so that the harness is not subjected to excessivepressure.

CAUTIONMake sure that no excess harness is left inside the alternator that can wrap aroundrotating parts.

13. Route the heater harness along the NDE bracket and out of the NDE bracket opening ontop, as shown in the figure below. Install a cable tie base on the top of the NDE bracket tohold the harness in place.

A046M783 (Issue 1)Page 10 of 26

CAUTIONImproper installation of wiring can result in equipment damage and improperoperation. Make sure wires cannot contact any hot, sharp, or abrasive or rotatingsurface. Do not kink wires.

No. Description No. Description

1 Cable Tie Base

FIGURE 11. HEATER HARNESS ROUTING

14. Remove box covers from the terminal box, shown in the figure below.

A046M783 (Issue 1)Page 11 of 26

FIGURE 12. BOX COVERS

15. Route the harness into the area between alternator and terminal box (shown in the figurebelow).

A046M783 (Issue 1)Page 12 of 26

FIGURE 13. AC CABLE ENTRY

16. Wrap and secure any extra length on the harness behind the terminal box. Use a cable tieto secure the extra length.

17. Pass the harness through the AC cable entry opening.

CAUTIONEnsure that AC power to the terminal box has been de-energized and locked out toprevent accidental energizing of circuit.

CAUTIONMake sure the harness is not rubbing against any sharp corners and does not haveany sharp bends.

18. Connect the harness terminals to the AC terminal block as shown in the wiring diagram forthe alternator heater (shown below).

NOTICEPolarity does not matter, so either wire can be connected to neutral or line.

A046M783 (Issue 1)Page 13 of 26

FIGURE 14. WIRING DIAGRAM FOR THE ALTERNATOR HEATER

19. Use a cable tie to secure the harness.

20. Place a marking label on each wire with respect to Line and Neutral as shown in the figurebelow.

A046M783 (Issue 1)Page 14 of 26

No. Description No. Description

1 Line and Neutral Marking Labels

FIGURE 15. LOCATION OF MARKING LABELS

21. Reposition the terminal box in its location and tighten the bolts. Torque to 12.3 - 15 Nm.

22. Re-install the NDE bracket cover, alternator screen and terminal box cover.

23. Reconnect all of the required power wires.

24. Start the unit and check for unusual noises.

25. Energize the AC circuit to make sure that everything works. This should be done after theterminal box cover is re-installed, but before the remaining parts are re-installed.

26. Re-install all remaining parts that were removed.

3.2 Installation of Heater Kit A044G635 for CA 125 and CA 135AlternatorsThese instructions give the procedure for installing Alternator Heater kit A044G635 on generatorsets with CA 125 and CA 135 (120 V, 100 W) alternators.

Read these installation instructions completely and become familiar with safety warnings,cautions and installation procedure before starting.

WARNINGIncorrect installation, service, or replacement of parts can result in severe personalinjury or death and/or equipment damage. Only trained and experienced personnel areto perform the following procedures.

A046M783 (Issue 1)Page 15 of 26

WARNINGAC voltages and currents present an electrical shock hazard that can cause severepersonal injury or death. Incorrect installation, service, or parts replacement can resultin severe personal injury, death, and/or equipment damage. Only trained andexperienced personnel are to perform the following procedures.

CAUTIONIf present, always disconnect a battery charger from its AC source before disconnectingthe battery cables. Otherwise, disconnecting the cables can result in voltage spikeshigh enough to damage the DC control circuits of the generator set.

WARNINGAccidental starting of the generator set while working on it can cause severe personalinjury or death. Prevent accidental starting by disconnecting the starting battery cables(negative [−] first). Make certain the battery area has been well ventilated beforeservicing the battery. Wear goggles. Stop the generator set and disconnect the chargerbefore disconnecting battery cables. Arcing can ignite explosive hydrogen gas given offby batteries, causing severe personal injury. Arcing can occur when a cable is removedor re-attached, or when the negative (−) battery cable is connected and a tool used toconnect or disconnect the positive (+) battery cable touches the frame or othergrounded metal part of the generator set. Always remove the negative (−) cable first,

and reconnect it last. Make certain hydrogen from the battery, engine fuel, and otherexplosive fumes are fully dissipated. This is especially important if the battery has beenconnected to a battery charger.

WARNINGIgnition of explosive battery gases can cause severe personal injury or death. Arcing atbattery terminals, light switch or other equipment, flame, pilot lights and sparks canignite battery gas. Do not smoke, or switch trouble light ON or OFF near a battery.Discharge static electricity from body before touching batteries by first touching agrounded metal surface.

1. Make sure the generator set is disabled.

a. Press the STOP button on the operator panel to make sure the control is in the Offmode.

b. If equipped, activate the E-stop button.

c. If equipped, disconnect the battery charger. Remove any other electrical supplysources.

d. Disconnect the negative [-] cable from the battery and secure it from contacting thebattery terminals to prevent accidental starting.

2. Remove the following parts to access the alternator:

• Enclosure end cover and side door as shown in Figure 16

• Terminal box dome cover and alternator screen as shown in Figure 17

• EBS/PMG as shown in Figure 18

A046M783 (Issue 1)Page 16 of 26

No. Description No. Description

1 Enclosure Side Door 2 Enclosure End Cover

FIGURE 16. ENCLOSURE

No. Description No. Description

1 Mesh Screen 2 Terminal Box Dome Cover

FIGURE 17. TERMINAL BOX DOME COVER AND MESH SCREEN

FIGURE 18. EBS/PMG

A046M783 (Issue 1)Page 17 of 26

3. Loosen the terminal box mounting bolts (as shown in ) to be able to reposition the box tocreate adequate clearance between the alternator and the terminal box.

FIGURE 19. TERMINAL BOX MOUNTING BOLTS

4. Make sure enough clearance is available between the alternator and the ground forinstallation, using appropriate lifting equipment or tools. A minimum of 145 mm (5.7 in)clearance is recommended from the ground to the bottom surface of the alternator, asshown in the figure below.

NOTICEProper precautions need to be taken while operating lifting equipment.

FIGURE 20. MINIMUM CLEARANCE

5. Locate and remove only the NDE bracket cover of the alternator as shown in Figure 21and Figure 22. Save the hardware.

NOTICERemoval of the NDE bracket and/or PMG (if equipped) is not required.

NOTICEParts are separated in the illustration for the purpose of clarity. Not all parts needto be separated and/or removed.

A046M783 (Issue 1)Page 18 of 26

No. Description No. Description

1 Detail Shown in 2, 3 and 4 5 Service Window

2 Lock Washer 6 Alternator Heater

3 Heater Element 7 NDE Cover

4 Hex Nut, Thread Sealant 8 Cable Tie

FIGURE 21. NDE BRACKET FOR CA125 ALTERNATOR

A046M783 (Issue 1)Page 19 of 26

No. Description No. Description

1 Detail Shown in 2, 3 and 4 5 Service Window

2 Lock Washer 6 Alternator Heater

3 Heater Element 7 NDE Cover

4 Hex Nut, Thread Sealant 8 Cable Tie

FIGURE 22. NDE BRACKET FOR CA135 ALTERNATOR

6. Locate the heater mounting holes, as shown in the figure below.

FIGURE 23. HEATER MOUNTING HOLES

7. Verify accessibility of the heater holes to install hardware from under the alternator frame.

A046M783 (Issue 1)Page 20 of 26

8. Carefully insert the alternator heater (as shown in the figure below) through the servicewindow opening.

• Use the heater studs to guide the heater through the mounting holes.

• Use an appropriate hand tool if necessary.

CAUTIONBe careful not to touch or damage alternator wires when positioning the heater.

FIGURE 24. INSERTING THE ALTERNATOR HEATER

9. Move the studs through the heater holes, as shown in Figure 25. Studs should extendbelow the alternator, as shown in Figure 26.

FIGURE 25. MOVING THE STUDS THROUGH THE HEATER HOLES

A046M783 (Issue 1)Page 21 of 26

FIGURE 26. STUDS EXTENDING BELOW THE ALTERNATOR

10. Use two M5 lock washers and two M5 X 0.8 nuts (included in the kit) to secure the heaterto the alternator frame. Torque the fasteners 6 - 6.5 Nm.

11. Apply thread sealant to the stud at the indicated location in Figure 21 or Figure 22.

12. Use cable ties to tie wrap the heater harness to the alternator frame and route the harnessalong as shown in the end view of the alternator in Figure 21 and Figure 22.

• Make sure that the cable tie is not pulled too tight to prevent it from rubbing against asharp edge.

• Leave enough harness length so that the harness is not subjected to excessivepressure.

CAUTIONMake sure that no excess harness is left inside the alternator that can wrap aroundrotating parts.

13. Insert the grommet (which comes with the alternator) into the harness as shown in thefigure below.

FIGURE 27. GROMMET FOR HARNESS

A046M783 (Issue 1)Page 22 of 26

14. Insert the grommet and the harness through the service window hole as shown in thefigure below.

FIGURE 28. SERVICE WINDOW HOLE

15. Re-install the service window in its location with existing hardware.

CAUTIONImproper installation of wiring can result in equipment damage and improperoperation. Make sure wires cannot contact any hot, sharp, or abrasive or rotatingsurface. Do not kink wires.

16. Remove box covers (shown in the figure below) from the terminal box.

A046M783 (Issue 1)Page 23 of 26

FIGURE 29. BOX COVERS

17. Route the harness into the area between the alternator and the terminal box (shown in thefigure below).

FIGURE 30. AC CABLE ENTRY

18. Wrap and secure any extra length on the harness behind the terminal box. Use a cable tieto secure the extra length.

19. Pass the harness through the AC cable entry opening.

A046M783 (Issue 1)Page 24 of 26

CAUTIONEnsure that AC power to the terminal box has been de-energized and locked out toprevent accidental energizing of circuit.

CAUTIONMake sure the harness is not rubbing against any sharp corners and does not haveany sharp bends.

20. Connect the harness terminals to the AC terminal block as shown in the wiring diagram forthe alternator heater (shown below).

NOTICEPolarity does not matter, so either wire can be connected to neutral or line.

FIGURE 31. WIRING DIAGRAM FOR THE ALTERNATOR HEATER

21. Use a cable tie to secure the harness.

22. Place a marking label on each wire for Line and Neutral as shown in the figure below.

A046M783 (Issue 1)Page 25 of 26

No. Description No. Description

1 Line and Neutral Marking Labels

FIGURE 32. LOCATION OF MARKING LABELS

23. Reposition the terminal box in its location and tighten the bolts. Torque to 12.3 - 15 Nm.

24. Re-install the NDE bracket cover, alternator screen and terminal box cover.

25. Reconnect all of the required power wires.

26. Start the unit and check for unusual noises.

27. Energize the AC circuit to make sure that everything works. This should be done after theterminal box cover is re-installed, but before the remaining parts are re-installed.

28. Re-install all remaining parts that were removed.

A046M783 (Issue 1)Page 26 of 26