CUMMINS C 45 N6, C50 N6, C80 N6, C60 N6, C100 N6 Operating Manual

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OperatorOperator ManualManual

Generator Set with QSJ5.9G Engine and PowerCommand® 1.1 Control

C45 N6 (Spec A) C50 N6 (Spec A) C60 N6 (Spec A) C70 N6 (Spec A) C80 N6 (Spec A) C100 N6 (Spec A)

English Original Instructions

8-2017 A051X877 (Issue 6)

1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1

1.1 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1

1.2 General Information ................................................................................................................ 1

1.3 Generator Set Safety Code .................................................................................................... 4

1.4 Moving Parts Can Cause Severe Personal Injury or Death ................................................... 4

1.5 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 5

1.6 Fuel and Fumes Are Flammable ............................................................................................ 5

1.7 Batteries Can Explode ............................................................................................................ 6

1.8 Exhaust Gases Are Deadly..................................................................................................... 7

1.9 The Hazards of Carbon Monoxide.......................................................................................... 9

1.10 Earth Ground Connection ..................................................................................................... 9

2. INTRODUCTION.......................................................................................................................... 11

2.1 Safety .................................................................................................................................... 11

2.2 About This Manual................................................................................................................ 11

2.3 Schedule of Abbreviations .................................................................................................... 12

2.4 Related Literature ................................................................................................................. 14

2.5 Model Specifications ............................................................................................................. 15

2.6 After Sales Services.............................................................................................................. 19

2.7 General Operating Conditions .............................................................................................. 20

2.8 Generator Set Nameplate .................................................................................................... 21

2.9 Manufacturing Facilities ........................................................................................................ 23

3. CONTROL SYSTEM .................................................................................................................... 25

3.1 Control System Description .................................................................................................. 25

3.2 Display Text or Symbolic Version ......................................................................................... 29

3.3 Exercise Settings ................................................................................................................. 30

3.4 Brightness and Contrast ....................................................................................................... 38

3.5 History and About Menu ....................................................................................................... 40

3.6 Fault Log ............................................................................................................................... 42

3.7 Selecting Operating Modes................................................................................................... 44

3.8 Operating Modes .................................................................................................................. 49

4. OPERATION - POWERCOMMAND 1.1 ...................................................................................... 51

4.1 Introduction ........................................................................................................................... 51

4.2 General Operating Conditions .............................................................................................. 51

4.3 Generator Set Operation....................................................................................................... 51

5. MAINTENANCE ........................................................................................................................... 63

5.1 Maintenance Safety .............................................................................................................. 63

5.2 Periodic Maintenance ........................................................................................................... 66

5.3 Exercising the Generator Set ............................................................................................... 71

5.4 Engine Oil ............................................................................................................................. 71

Table of Contents 8-2017

5.5 Air Intake System.................................................................................................................. 77

5.6 Batteries ................................................................................................................................ 79

5.7 Spark Plugs .......................................................................................................................... 83

6. TROUBLESHOOTING ................................................................................................................. 85

6.1 Avoiding Generator Set Shutdowns ..................................................................................... 85

6.2 Fault Code Introduction......................................................................................................... 85

6.3 Engine Is Difficult to Start or Does Not Start ........................................................................ 85

6.4 Code 143 - Engine Oil Pressure Low (Warning) .................................................................. 86

6.5 Codes 146 and 151 - Engine Coolant Temperature High (Warning or Shutdown) .............. 86

6.6 Code 155 - Intake Manifold Temperature High (Shutdown) ................................................. 87

6.7 Code 197 - Coolant Level Low (Warning) ............................................................................ 87

6.8 Code 415 - Engine Oil Pressure Low (Shutdown)................................................................ 88

6.9 Code 441 - Battery Voltage Low (Warning).......................................................................... 88

6.10 Code 488 - Intake Manifold Temperature High (Warning).................................................. 89

6.11 Code 1438 - Fail to Crank (Shutdown) ............................................................................... 90

6.12 Code 1472 - High AC Current (Shutdown) ......................................................................... 90

6.13 Code 5134 - Unknown Shutdown at Idle ............................................................................ 90

1 IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS. This manual contains important instructions that should be followed during installation and maintenance of the generator set and batteries.

Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions.

1.1 Warning, Caution, and Note Styles Used in This Manual

The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel, or equipment.

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

1.2 General Information

This manual should form part of the documentation package supplied by Cummins Inc. with specific generator sets. If this manual has been supplied in isolation, please contact your authorized dealer.

It is in the operator's interest to read and understand all warnings and cautions contained in the documentation relevant to the generator set operation and daily maintenance.

CAUTION

NOTICE

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

General Safety Precautions

WARNING

Hot Pressurized Liquid Contact with hot liquid can cause severe burns. Do not open the pressure cap while the engine is running. Let the engine

cool down before removing the cap. Turn the cap slowly and do not open it fully until the pressure has been relieved.

WARNING

Moving Parts Moving parts can cause severe personal injury. Use extreme caution around moving parts. All guards must be properly

fastened to prevent unintended contact.

WARNING

Toxic Hazard Used engine oils have been identified by some state and federal agencies to

cause cancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or

changing engine oil. Wear protective gloves and face guard.

WARNING

Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or

death. Do not operate equipment when fatigued, or after consuming any alcohol or

drug. Make sure that only suitably trained and experienced service personnel

perform electrical and/or mechanical service.

WARNING

Toxic Gases Substances in exhaust gases have been identified by some state and federal

agencies to cause cancer or reproductive toxicity. Do not breathe in or come into contact with exhaust gases.

WARNING

High Noise Level Generator sets in operation emit noise, which can cause hearing damage. Wear appropriate ear protection at all times.

1. IMPORTANT SAFETY INSTRUCTIONS8-2017

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is

minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING

Toxic Hazard Ethylene glycol, used as an engine coolant, is toxic to humans and animals. Wear appropriate PPE. Clean up coolant spills and dispose of used coolant

in accordance with local environmental regulations.

WARNING

Combustible Liquid Ignition of combustible liquids is a fire or explosion hazard which can cause

severe burns or death. Do not store fuel, cleaners, oil, etc., near the generator set. Do not use

combustible liquids like ether.

WARNING

Combustible Gases Generator sets in operation have combustible gases under pressure, which

if ignited can cause eye and ear damage. Wear appropriate eye and ear protection at all times.

WARNING

Combustible Gases Generator sets in operation have combustible gases under pressure, which

if ignited can cause severe injury. Do not operate the generator set with any doors open.

WARNING

Fire Hazard Materials drawn into the generator set, as well as accumulated grease and

oil, are a fire hazard. Fire can cause severe burns or death. Keep the generator set and the surrounding area clean and free from

obstructions. Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit.

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

WARNING

Automated Machinery Accidental or remote starting of the generator set can cause severe personal

injury or death. Isolate all auxiliary supplies and use an insulated wrench to disconnect the

starting battery cables (negative [–] first).

NOTICE

Keep multi-type ABC fire extinguishers close by. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in the applicable region.)

NOTICE

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

NOTICE

Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set when entering or leaving the generator set room.

1.3 Generator Set Safety Code

Before operating the generator set, read the manuals and become familiar with them and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions.

WARNING

Electrical Generating Equipment Incorrect operation and maintenance can result in severe personal injury or

death. Read and follow all Safety Precautions, Warnings, and Cautions throughout

this manual and the documentation supplied with the generator set.

1.4 Moving Parts Can Cause Severe Personal Injury or Death

• Keep hands, clothing, and jewelry away from moving parts.

1. IMPORTANT SAFETY INSTRUCTIONS8-2017

• Before starting work on the generator set, disconnect the battery charger from its AC source, then disconnect the starting batteries using an insulated wrench, negative (–) cable first. This will prevent accidental starting.

• Make sure that fasteners on the generator set are secure. Tighten supports and clamps; keep guards in position over fans, drive belts, etc.

• Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts.

• If any adjustments must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc.

1.5 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death

• Only qualified service personnel certified and authorized to work on power circuits should work on exposed energized power circuits.

• All relevant service material must be available for any electrical work performed by certified service personnel.

• Exposure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a significant risk of electrical shock and electrical arc flash.

• Refer to standard NFPA 70E, or equivalent safety standards in corresponding regions, for details of the dangers involved and for safety requirements.

1.6 Fuel and Fumes Are Flammable

Fire, explosion, and personal injury or death can result from improper practices.

• Do not fill fuel tanks while the engine is running unless the tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.

• Do not permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank.

• Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent.

• Make sure all fuel supplies have a positive shutoff valve.

• Make sure the battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

Do Not Operate in Flammable and Explosive Environments

Flammable vapor can cause an engine to over speed and become difficult to stop, resulting in possible fire, explosion, severe personal injury, and death. Do not operate a generator set where a flammable vapor environment can be created, unless the generator set is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the generator set are solely responsible for operating the generator set safely. Contact your authorized Cummins distributor for more information.

Spillage

Any spillage that occurs during fueling, oil top-off, or oil change must be cleaned up before starting the generator set.

Fluid Containment

NOTICE

Where spillage containment is not part of a Cummins supply, it is the responsibility of the installer to provide the necessary containment to prevent contamination of the environment, especially water courses and sources.

If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals. Any liquid present should be drained out and disposed of in line with local health and safety regulations. Failure to perform this action may result in spillage of liquids which could contaminate the surrounding area.

Any other fluid containment area must also be checked and emptied, as described above.

1.7 Batteries Can Explode

Batteries can explode, causing severe skin and eye burns and can release toxic electrolytes.

Combustible Gases Batteries can explode, causing severe skin and eye burns, and can release

toxic electrolytes. Do not dispose of the battery in a fire, because it is capable of exploding. Do

not open or mutilate the battery. Do not charge frozen batteries.

WARNING

1. IMPORTANT SAFETY INSTRUCTIONS8-2017

WARNING

Electric Shock Hazard Batteries present the risk of high short circuit current. When servicing the generator set:

• Remove watches, rings, or other metal objects.

• Use tools with insulated handles.

NOTICE

Servicing of batteries must be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

• Wear safety glasses.

• Do not smoke.

• Do not charge frozen batteries.

• To prevent arcing when disconnecting the battery:

1. Press the Off switch from the display and then press the E-Stop button.

2. Disconnect AC power from any battery chargers.

3. Remove the negative (-) battery cable to prevent starting.

• To prevent arcing when reconnecting the battery:

1. Reconnect the positive (+) cable.

2. Reconnect the negative (-) cable.

3. Reconnect the battery charger to AC power supply.

• When replacing the generator set battery, always replace it with a battery as specified in this manual.

1.8 Exhaust Gases Are Deadly

• Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas, and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust system daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment.

• Make sure the unit is well ventilated.

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

Exhaust Precautions

WARNING

Hot Exhaust Gases Contact with hot exhaust gases can cause severe burns. Wear personal protective equipment when working on equipment.

WARNING

Hot Surfaces Contact with hot surfaces can cause severe burns. The unit is to be installed so that the risk of hot surface contact by people is

minimized. Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING

Toxic Gases Inhalation of exhaust gases can cause asphyxiation and death. Pipe exhaust gas outside and away from windows, doors, or other inlets to

buildings. Do not allow exhaust gas to accumulate in habitable areas.

WARNING

Fire Hazard Contaminated insulation is a fire hazard. Fire can cause severe burns or

death. Remove any contaminated insulation and dispose of it in accordance with

local regulations.

The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust.

The exhaust pipes may have some insulating covers fitted. If these covers become contaminated they must be replaced before the generator set is run.

To minimize the risk of fire, make sure the following steps are observed:

• Make sure that the engine is allowed to cool thoroughly before performing maintenance or operation tasks.

• Clean the exhaust pipe thoroughly.

1. IMPORTANT SAFETY INSTRUCTIONS8-2017

1.9 The Hazards of Carbon Monoxide

Carbon monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas. You cannot see it or smell it. Red blood cells, however, have a greater affinity for CO than for oxygen. Therefore, exposure even to low levels of CO for a prolonged period can lead to asphyxiation (lack of oxygen) resulting in death. Mild effects of CO poisoning include eye irritation, dizziness, headaches, fatigue and the inability to think clearly. More extreme symptoms include vomiting, seizures and collapse.

Engine-driven generator sets produce harmful levels of carbon monoxide that can injure or kill you.

Special Risks of CO near the Home

WARNING

Toxic Gases Carbon monoxide (CO) gas can cause nausea, fainting, or death. Residents

can be exposed to lethal levels of CO when the generator set is running. Depending on air temperature and wind, CO can accumulate in or near the home.

To protect yourself and others from the dangers of CO poisoning, it is recommended that reliable, approved, and operable CO detector alarms are installed in proper locations in the home as specified by their manufacturer.

Protecting Yourself from CO Poisoning

• Locate the generator set in an area where there are no windows, doors, or other access points into the home.

• Make sure all CO detectors are installed and working properly.

• Pay attention for signs of CO poisoning.

• Check the exhaust system for corrosion, obstruction, and leaks every time you start the generator set and every eight hours when you run it continuously.

1.10 Earth Ground Connection

The neutral of the generator set may be required to be bonded to earth ground at the generator set location, or at a remote location, depending on system design requirements. Consult the engineering drawings for the facility or a qualified electrical design engineer for proper installation.

NOTICE

The end user is responsible to make sure that the ground connection point surface area is clean and free of rust before making a connection.

1. IMPORTANT SAFETY INSTRUCTIONS 8-2017

NOTICE

The end user is responsible for making sure that an earthing arrangement that is compliant with local conditions is established and tested before the equipment is used.

2 Introduction

2.1 Safety

Hazardous Voltage Contact with high voltages can cause severe electrical shock, burns, or

death. Make sure that only a trained and experienced electrician makes generator

set electrical output connections, in accordance with the installation instructions and all applicable codes.

Electrical Generating Equipment Faulty electrical generating equipment can cause severe personal injury or

death. Generator sets must be installed, certified, and operated by trained and

experienced person in accordance with the installation instructions and all applicable codes.

WARNING

2.2 About This Manual

The purpose of this manual is to provide the users with sound, general information. It is for guidance and assistance with recommendations for correct and safe procedures. Cummins Inc. cannot accept any liability whatsoever for problems arising as a result of following recommendations in this manual.

The information contained within the manual is based on information available at the time of going to print. In line with Cummins Inc. policy of continuous development and improvement, information may change at any time without notice. The users should therefore make sure that they have the latest information available before starting any work. The latest version of this manual is available on QuickServe Online (https://quickserve.cummins.com).

Users are respectfully advised that, in the interests of good practice and safety, it is their responsibility to employ competent people to carry out any installation work. Consult your authorized dealer for further installation information. It is essential that the utmost care is taken with the application, installation, and operation of any generator set due to their potentially hazardous nature. Careful reference should also be made to other Cummins Inc. literature. You must operate and maintain your generator set properly if you are to expect safe and reliable operation.

For further assistance, contact your authorized Cummins dealer.

2. Introduction 8-2017

NOTICE

This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions:

• This device may not cause harmful interferences.

• This device must accept any interference received, including interference that may cause undesired operation.

2.3 Schedule of Abbreviations

This list is not exhaustive. For example, it does not identify units of measure or acronyms that appear only in parameters, event/fault names, or part/accessory names.

AmpSentry, INSITE, and InPower are trademarks of Cummins Inc. PowerCommand is a registered trademark of Cummins Inc.

ABBR. DESCRIPTION ABBR. DESCRIPTION

AC Alternating Current LED Light-emitting Diode

AMP AMP, Inc., part of Tyco

Electronics

ANSI American National

Standards Institute

ASOV Automatic Shut Off Valve MFM Multifunction Monitor

ASTM American Society for

Testing and Materials (ASTM International)

ATS Automatic Transfer Switch MLD Masterless Load Demand

AVR Automatic Voltage

Regulator

AWG American Wire Gauge NC Not Connected

CAN Controlled Area Network NFPA National Fire Protection

CB Circuit Breaker NO Normally Open

CE Conformité Européenne NWF Network Failure

LTS Long Term Storage

LVRT Low Voltage Ride Through

Mil Std Military Standard

NC Normally Closed

Agency

CFM Cubic Feet per Minute OEM Original Equipment

Manufacturer

CGT Cummins Generator

Technologies

OOR Out of Range

2. Introduction8-2017

ABBR. DESCRIPTION ABBR. DESCRIPTION

CMM Cubic Meters per Minute OORH /

Out of Range High

ORH

CT Current Transformer OORL /

Out of Range Low

ORL

D-AVR Digital Automatic Voltage

PB Push Button

Regulator

DC Direct Current PCC PowerCommand®Control

DEF Diesel Exhaust Fluid PGI Power Generation

Interface

DPF Diesel Particulate Filter PGN Parameter Group Number

ECM Engine Control Module PI Proportional/Integral

ECS Engine Control System PID Proportional / Integral /

Derivative

EMI Electromagnetic

interference

PLC Programmable Logic

Controller

EN European Standard PMG Permanent Magnet

Generator

EPS Engine Protection System PPE Personal Protective

Equipment

E-Stop Emergency Stop PT Potential Transformer

FAE Full Authority Electronic PTC Power Transfer Control

FMI Failure Mode Identifier PWM Pulse-width Modulation

FRT Fault Ride Through RFI Radio Frequency

Interference

FSO Fuel Shutoff RH Relative Humidity

Genset Generator Set RMS Root Mean Square

GCP Generator Control Panel RTU Remote Terminal Unit

GND Ground SAE Society of Automotive

Engineers

LCT Low Coolant Temperature SCR Selective Catalytic

Reduction

HMI Human-machine Interface SPN Suspect Parameter

Number

IC Integrated Circuit SWL Safe Working Load

ISO International Organization

for Standardization

SW_B+ Switched B+

2. Introduction 8-2017

ABBR. DESCRIPTION ABBR. DESCRIPTION

LBNG Lean-burn Natural Gas UL Underwriters Laboratories

LCD Liquid Crystal Display UPS Uninterruptible Power

Supply

2.4 Related Literature

Before any attempt is made to operate the generator set, the operator should take time to read all of the manuals supplied with the generator set, and to familiarize themselves with the warnings and operating procedures.

The literature provided with the generator set is as follows:

• Operator Manual (A051X877)

• Installation Manual (A051X873)

NOTICE

A generator set must be operated and maintained properly if you are to expect safe and reliable operation. The Operator manual includes a maintenance schedule and a troubleshooting guide.

The Health and Safety manual must be read in conjunction with this manual for the safe operation of the generator set:

• Health and Safety Manual (0908-0110)

• Warranty Statement (A028U870)

• C45 N6, C50 N6 and C60 N6 models only: Emissions Component Defect Warranty Statement (A028X278)

• C70 N6, C80 N6 and C100 N6 models only: Emissions Component Defect Warranty Statement (A028X279)

The relevant manuals appropriate to your generator set are also available. The documents below are in English:

• Service Manual (A051X880)

• Parts Manual (A051X891)

• EControls, Inc., Global Control Platform (GCP) Software Service Manual (A035C596)

• EControls, Inc., 4G Software Service Manual (A052G032)

• EControls, Inc., GCP Engine Display Interface Software (EDIS) Training Manual (A035C608)

• EControls, Inc., 4G Software Operator Manual (A052G024)

• Engine Operation & Maintenance Manual for QSJ5.9G (4388606)

• RA Series Transfer Switch Owner Manual (A046S594) - if applicable

• PowerCommand® 1302 Controller Owner's Manual (900-0661)

• Service Tool Manual (A043D529)

• Standard Repair Times - HL Family (A053K365)

• T-030: Liquid Cooled Generator Set Application Manual (A040S369) - for application information

2.5 Model Specifications

Damage caused by failure to follow the manufacturer's recommendation will not be covered by the warranty. Please contact your authorized distributor.

TABLE 1. 5.9L MODEL VARIATIONS

Models Description

2. Introduction8-2017

NOTICE

C45 N6, C50 N6, C60 N6, C70 N6, C80 N6, C100 N6 60 Hz, 1800 RPM

TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS)

Temperature Description

Battery

Type

Group

Above 4 °C (40 °F) Battery charger Standard 34

-17 to 4 °C (0 to 40 °F)

Battery charger, coolant heater (1000W), CCV heater

Standard 34

Battery charger, coolant heater (1500W),

Below -17 °C (0 °F)

CCV heaters are provided as part of the cold and extreme cold coolant heater packages.

The cold weather starter is provided as part of the extreme cold coolant heater package.

oil heater, battery heater, CCV heater1, cold weather starter

NOTICE

Larger 4D

For NFPA 110 applications, a coolant heater is required. A factory option is available.

2. Introduction 8-2017

TABLE 3. FUEL SPECIFICATIONS 60 HZ, 1800 RPM

Type Unit C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6

Liquid Propane

scfh 289.6 321.6 370.2 384.2 420.8 518.7

BTU/hr 651,600 723,600 832,950 864,450 946,800 1,167,075

Full Load

Natural Gas

scfh 711.2 806.3 933.8 988.4 1,083.5 1,317.7

BTU/hr 721,868 818,395 947,807 1,003,226 1,099,753 1,337,466

Full Load

Fuel

6-13 inches of water column (1.5 - 3.2 kPa) under any condition

Pressure

TABLE 4. ENGINE SPECIFICATIONS (ALL MODELS)

Type Specification

Engine

6 cylinder-in-line, single-cam, liquid-cooled, 4-stroke, spark ignited

Bore 102 mm 94.02 in)

Stroke 120 mm (4.72 in)

Displacement 5.88 L (359 in3)

Compression Ratio (Natural Gas & LPG)

8.5:1

Firing Order 1-5-3-6-2-4

Spark Plug Gap 45, 50, 60 kW) 0.508 mm (0.020 in)

Spark Plug Gap (70, 80, 100 kW)

0.40 mm (016 in)

Spark Plug Torque 38 Nm (8 ft-lb)

Crankshaft Rotation (Viewed from the Front of the Engine)

Engine Weight (Dry, Long Block Only)

Clockwise

413 kg (911 lb)

Valve Clearance (Intake) 0.305 mm (0.012 in)

Valve Clearance (Exhaust) 0.610 mm (0.024 in)

• 50/50 coolant solution (50% pure water and 50% anti-

Coolant

freeze)

• 16 L (4.23 gal) capacity

Oil Capacity 15 L (4 gal)

Oil Standards

2. Introduction8-2017

Type Specification

• Must adhere to Cummins®Engineering Standard (CES) 20085

• Use of improper oils can result in engine damage. Use only the required oils:

◦ 5W-40 (all ambient temperatures)

◦ 15W-40 (above 4 °C [40 °F] ambient temperature)

(use of GEO 15W-40 oil in ambient temperatures below 4 °C (40 °F] could result in engine turbocharger damage)

• A sulfated ash limit of 0.6% mass has been placed on all engine lubricating oils recommended for use in Cummins® B, natural gas engines. Higher ash oils can cause valve and/or piston damage, cause spark plug fouling, and lead to excessive oil consumption and degradation of the catalyst.

TABLE 5. LUBRICATING OIL SYSTEM SPECIFICATIONS

Type Specification

Lubricating Oil Pressure at Idle (Minimum) 104 kPa (15 psi)

Lubricating Oil Pressure at Rated Speed (Minimum)

Filter Bypass Valve-Opening Pressure 311 kPa (45 psi)

Pressure Regulator Valve-Opening Pressure 449 kPa (65 psi)

Lubricating Oil Capacity (Standard Sump):

--High 14.2 L (15 qt)

--Low 12.4 L (13 qt)

--Total System 15.1 L (16 qt)

TABLE 6. GENERATOR SET SIZE SPECIFICATIONS

Enclosure

Type

Open/Weather

2489 x 1016 x 1473 mm (98 x 40 x 58 in); does not include exhaust

Size (L x W x H)

discharge elbow

Sound Level 1 3023 x 1016 x 1473 mm (119 x 40 x 58 in)

Sound Level 2 3454 x 1016 x 1473 mm (136 x 40 x 58 in)

2. Introduction 8-2017

TABLE 7. GENERATOR SET WET WEIGHT (POUNDS) (60 HZ, 1800 RPM)

Configuration C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6

Open 2180 2180 2431 2449 2587 2719

Weather 2359 2359 2610 2628 2766 2898

Sound Level 1 2455 2455 2706 2724 2862 2994

Sound Level 2 2485 2485 2736 2754 2892 3024

NOTICE

Weights are approximate and can be affected by selected options. Refer to outline drawings for specific weight information.

TABLE 8. ALTERNATOR SPECIFICATIONS 60 HZ, 1800 RPM

Type C45 N6 C50 N6 C60 N6 C70 N6 C80 N6 C100 N6

Generator Brushless, 4-pole rotating field, single bearing

Power (kVA) 1 Phase 45 50 60 70 80 100

Power (kVA) 3 Phase 56.3 62.5 75 87.5 100 125

120/240, 1 Ph

227/480, 3 Ph

347/600, 3 Ph

Rated Voltages (V)

120/240, 3 Ph

120/208, 3 Ph

127/220, 3 Ph

F1PO (Reconnectable, Full Single Phase Output)

NOTICE

Maximum I2= 8%. Generator set load unbalance must not exceed 25% between any phases.

TABLE 9. GENERATOR SET DERATING GUIDELINES

Engine Power Available Up To... Derate At…

Model Phase

Elevation

C45 N6 Both 675 m (2200 ft) 40 °C (104 °F)

C50 N6 Both 150 m (490 ft) 25 °C (77 °F)

C60 N6 Both 1000 m (3280 ft)

Ambient

Temperature

2. Introduction8-2017

Elevation Temperature

C70 N6

C80 N6

C100 N6

1 2575 m (8450 ft)

3 3048 m (10000 ft)

1 1825 m (5985 ft)

3 2500 m (8200 ft)

1 700 m (1560 ft) 25 °C (77 °F)

3 1000 m (3280 ft) 40 °C (104 °F)

TABLE 10. CONTROL SPECIFICATIONS (ALL MODELS)

Control Purpose

PC 1.1 Generator Set

Enovations I28 EPR Engine (45, 50, 60 kW Generator Sets)

Enovations 4G LDI Engine (70, 80, 100 kW Generator Sets)

TABLE 11. DC SYSTEM SPECIFICATIONS (ALL MODELS)

Type Specification

40 °C (104 °F)

per 300 m (985 ft)

per 10 °C (18

°F)

Nominal Battery Voltage 12 VDC

Battery Group

Battery Type Maintenance-free

Minimum Cold Crank Amps

34 standard, 4D high capacity (requires large battery tray)

850 standard, 1080 high capacity (requires large battery tray)

2.6 After Sales Services

Cummins offers a full range of maintenance and warranty services.

2. Introduction 8-2017

Maintenance

WARNING

Electrical Generating Equipment Incorrect service or parts replacement can result in severe personal injury,

death, and/or equipment damage. Make sure service personnel are qualified to perform electrical and

mechanical service.

For expert generator set service at regular intervals, contact your Cummins Inc. service provider. See power.cummins.com/sales-service-locator for service locations that service this application. Maintenance tasks should only be undertaken by trained and experienced technicians provided by your Cummins Inc. service provider.

Warranty

For details of the warranty coverage for your generator set, refer to the Warranty Statement listed in the Related Literature section.

Extended warranty coverage is also available. In the event of a breakdown, prompt assistance can normally be given by factory trained service technicians with facilities to undertake all minor and many major repairs to equipment on site.

For further warranty details, contact your authorized dealer.

NOTICE

Damage caused by failure to follow the manufacturer's recommendations will not be covered by the warranty. Please contact your authorized dealer.

Warranty Limitations

For details of the warranty limitations for your generator set, refer to the warranty statement applicable to the generator set.

How to Obtain Service

For parts, service, and product information, contact the nearest authorized Cummins Inc. dealer. To easily locate the nearest certified distributor/dealer for Cummins generator sets in your area, or for more information, contact us at 1-800CUMMINSTM(1-800-286-6467) or visit http://www.cummins.com/support.

2.7 General Operating Conditions

The area surrounding the generator set is critical for safety and its performance. Follow the guidelines below.

• Do not stack anything on top of the generator set.

2. Introduction8-2017

• Do not store anything inside of the generator set.

• Keep areas clear in front of the cool air in and hot air out (free of obstructions, debris, plants, etc.).

NOTICE

All maintenance procedures must be performed or supervised by authorized and trained service personnel only.

No. Description No. Description

1 Cool Air In 3 Hot Air Out (Weather Enclosure)

2 Hot Air Out (Sound Level Enclosure)

FIGURE 1. EXAMPLE OF GENERATOR SET LOCATION

2.8 Generator Set Nameplate

WARNING

Electrical Generating Equipment Improper service or replacement of parts can lead to severe personal injury

or death and to damage to equipment and property. Make sure service personnel are qualified to perform electrical and

mechanical service.

2. Introduction 8-2017

NOTICE

Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California.

Model, Spec, and Serial Numbers: Be ready to provide the model, spec, and

serial numbers on the generator set nameplate when contacting Cummins Inc. for information, parts, and service. The nameplate is located on the inside of the control access door on enclosed products or on the side of the radiator for open products.

Record these numbers so that they are easy to find when needed. Each character in these numbers is significant for obtaining the right parts listed in the Parts Catalog. Genuine Cummins Inc. replacement parts are recommended for best results.

My Generator Set Information

Model

Spec

Serial Number

2.9 Manufacturing Facilities

Facility Address Phone Numbers

U.S. and CANADA

Cummins Inc. 1400 73rd Ave. NE Minneapolis, MN 55432 USA

Toll Free 1-800-CUMMINS (1-800-286-6467) Phone +1 763-574-5000 Fax +1 763-574-5298

2. Introduction8-2017

EMEA, CIS Cummins Inc.

Columbus Avenue Manston Park Manston, Ramsgate Kent CT12 5BF United Kingdom

Cummins Inc. Royal Oak Way South Daventry Northamptonshire NN11 8NU United Kingdom

ASIA PACIFIC

Cummins Inc. 10 Toh Guan Road #07-01 TT International Tradepark Singapore 608838

BRAZIL Rua Jati, 310, Cumbica

Guarulhos, SP 07180-900 Brazil

Phone +44 1843 255000 Fax +44 1843 255902

Phone +65 6417 2388 Fax +65 6417 2399

Phone +55 11 2186 4195 Fax +55 11 2186 4729

CHINA Cummins Inc.

2 Rongchang East Street, Beijing Economic – Technological Development Area Beijing 100176, P.R. China

INDIA Cummins Inc.

Power Generation Business Unit, Plot No B-2, SEZ Industrial Area, Village-Nandal & Surwadi, Taluka- Phaltan Dist- Satara, Maharashtra 415523 India

LATIN AMERICA

3350 Southwest 148th Ave. Suite 205 Miramar, FL 33027 USA

Phone 86 10 59023001 Fax +86 10 5902 3199

Phone +91 021 66305514

Phone +1 954 431 551 Fax +1 954 433 5797

2. Introduction 8-2017

Facility Address Phone Numbers

MEXICO Eje 122 No. 200 Zona Industrial

San Luis Potosi, S.L.P. 78395 Mexico

Phone +52 444 870 6700 Fax +52 444 824 0082

3 Control System

3.1 Control System Description

The control system is used to start and stop the generator set, and provides full generator set monitoring capability and protection in a stand-alone situation (nonparalleling) from the display screen. It monitors the engine for temperature, as well as oil pressure and speed. It also provides voltage and current metering. In the event of a fault, the unit indicates the fault type and, on critical faults, automatically shuts down the generator set.

All indicators, control buttons, and the display screen are on the face of the operator panel, as illustrated in the figure below.

There are three fault level signals generated by the control system:

• Event: Signals that a temporary condition exists.

• Warning: Signals an imminent or non-critical fault for the engine. The control provides an indication only for this condition.

• Shutdown: Signals a potentially critical fault for the engine. The control immediately takes the engine off-load and automatically shuts it down.

The standard control system operates on 12 VDC (or 24 VDC if applicable) battery power. History data is stored in non-volatile memory and is not deleted if battery power is lost.

Standard Operator Panel

The operator panel includes indicator lights (LEDs), display buttons used to navigate through the menus, control mode buttons, and an LCD display. The display enables the operator to check the status, adjust the settings, and start and stop the generator set. The standard operator panel (show below) is located on every generator set. An optional in-home operator panel accessory is also available for location inside the home.

+ 67 hidden pages

CUMMINS C 45 N6, C50 N6, C80 N6, C60 N6, C100 N6 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 IMPORTANT SAFETY INSTRUCTIONS

1.1 Warning, Caution, and Note Styles Used in This Manual

1.2 General Information

1.3 Generator Set Safety Code

1.4 Moving Parts Can Cause Severe Personal Injury or Death

1.5 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death

1.6 Fuel and Fumes Are Flammable

1.7 Batteries Can Explode

1.8 Exhaust Gases Are Deadly

1.9 The Hazards of Carbon Monoxide

1.10 Earth Ground Connection

2 Introduction

2.1 Safety

2.2 About This Manual

2.3 Schedule of Abbreviations

2.4 Related Literature

2.5 Model Specifications

2.6 After Sales Services

2.7 General Operating Conditions

2.8 Generator Set Nameplate

2.9 Manufacturing Facilities

3 Control System

3.1 Control System Description