CUMMINS C13N6H, C17N6H, C20N6H, C20N6HC Service Manual

ServiceService ManualManual

Generator Set

Onan Generator Set for Home Standby

C13N6H (Spec A) C17N6H (Spec A) C20N6H (Spec A) C20N6HC (Spec A)

English Original Instructions

6-2017 A053X177 (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 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 6

1.5 Fuel and Fumes Are Flammable ............................................................................................ 7

1.6 Exhaust Gases Are Deadly..................................................................................................... 8

1.7 The Hazards of Carbon Monoxide.......................................................................................... 9

1.8 Earth Ground Connection..................................................................................................... 10

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

2.1 About This Manual................................................................................................................ 11

2.2 Test Equipment..................................................................................................................... 12

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

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

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

2.6 After Sales Services.............................................................................................................. 18

3. STARTUP .................................................................................................................................... 25

3.1 "Establishing Communications" Message ............................................................................ 25

3.2 "Clock Setup" Screen............................................................................................................ 25

3.3 "Exercise" Screen ................................................................................................................ 31

3.4 "Brightness and Contrast" Screen ........................................................................................ 34

3.5 "About" Screen...................................................................................................................... 36

3.6 "Event Log" Screen............................................................................................................... 38

3.7 "Fault Log" Screen................................................................................................................ 39

3.8 "System Status" Screen........................................................................................................ 40

3.9 "Mode" Screen...................................................................................................................... 41

3.10 Automatic Load Management............................................................................................. 44

3.11 Startup ............................................................................................................................... 44

4. OPERATION................................................................................................................................ 47

4.1 Introduction ........................................................................................................................... 47

4.2 General Operating Conditions .............................................................................................. 47

4.3 Generator Set Operation....................................................................................................... 47

4.4 Manual Start Sequence (Local)............................................................................................ 53

4.5 Manual Stop Sequence (Local) ............................................................................................ 54

4.6 Manual Start/Stop Sequence (Remote)................................................................................ 54

4.7 "Fault" and "New Event" Screens......................................................................................... 54

5. MAINTENANCE........................................................................................................................... 59

5.1 Maintenance Safety .............................................................................................................. 59

5.2 Periodic Maintenance ........................................................................................................... 63

Table of Contents 6-2017

5.3 Engine Oil ............................................................................................................................. 65

5.4 Exhaust System Maintenance .............................................................................................. 72

5.5 DC Electrical System............................................................................................................ 73

5.6 Batteries................................................................................................................................ 73

5.7 Spark Plugs .......................................................................................................................... 77

5.8 Cleaning the Generator Set Housing.................................................................................... 77

5.9 Complete System Test ........................................................................................................ 77

6. SERVICE...................................................................................................................................... 79

6.1 Control System ..................................................................................................................... 79

6.2 Fuel System.......................................................................................................................... 88

6.3 Cylinder Head Assembly Replacement................................................................................ 96

6.4 Engine Exhaust..................................................................................................................... 99

6.5 Alternator ............................................................................................................................ 100

6.6 Placing the Generator Set Back in Service ....................................................................... 119

6.7 Transfer Switch................................................................................................................... 119

6.8 Line Circuit Breaker Troubleshooting ................................................................................. 120

7. TROUBLESHOOTING............................................................................................................... 121

7.1 Troubleshooting Procedures............................................................................................... 121

7.2 Safety Considerations......................................................................................................... 121

7.3 GATRR Troubleshooting Approach.................................................................................... 122

7.4 Tools and Parts Required................................................................................................... 123

7.5 Troubleshooting with the Local or Remote Displays ......................................................... 124

7.6 Utility-Powered Battery Charger Troubleshooting .............................................................. 124

7.7 Engine Flywheel Battery Charger Troubleshooting ............................................................ 127

7.8 Fuel Shutoff Solenoid Valve ............................................................................................... 129

7.9 Troubleshooting by Symptom............................................................................................. 130

7.10 Troubleshooting with Fault Codes .................................................................................... 134

7.11 Remote Monitoring Communication Troubleshooting....................................................... 157

APPENDIX A. WIRING DIAGRAMS............................................................................................... 165

A.0 Wiring Diagrams................................................................................................................. 166

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 with specific generator sets. In the event that this manual has been supplied in isolation please contact your authorized distributor.

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

CAUTION

NOTICE

1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

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 INSTRUCTIONS6-2017

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 6-2017

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.

Moving Parts Can Cause Severe Personal Injury or Death

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

• 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.

1. IMPORTANT SAFETY INSTRUCTIONS6-2017

• 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.

Alternator Operating Areas

WARNING

Ejected Debris Debris ejected during catastrophic failure can cause serious injury or death

by impact, severing or stabbing. To prevent injury:

• Keep away from the air inlet and air outlet when the alternator is running.

• Do not put operator controls near the air inlet and air outlet.

• Do not cause overheating by running the alternator outside rating plate parameters.

• Do not overload the alternator.

• Do not run an alternator with excessive vibration.

• Do not synchronize parallel alternators outside the specified parameters.

Always wear suitable PPE when working in the hatched areas shown in the diagram or directly in-line with any air inlet/outlet.

FIGURE 1. HATCHED AREAS

Make sure this consideration is captured in your risk assessment.

1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

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

WARNING

Electric Shock Hazard Voltages and currents present an electrical shock hazard that can cause

severe burns or death. Contact with exposed energized circuits with potentials of 50 Volts AC or 75

Volts DC or higher can cause 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 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 are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards.

• 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 or the release of stored energy. Please refer to the lockout/tagout section for more information.

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

• Follow all applicable regional electrical and safety codes.

Guidelines to follow when working on energized electrical systems:

NOTICE

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

NOTICE

Exposed energized electrical work is only allowed as per the relevant procedures and must be undertaken by a Cummins authorized person with any appropriate energized work permit for the work 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.

1. IMPORTANT SAFETY INSTRUCTIONS6-2017

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

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

AC Supply and Isolation

NOTICE

Local electrical codes and regulations (for example, BS EN 12601:2010 Reciprocating internal combustion engine driven generating sets) may

require the installation of a disconnect means for the generator set, either on the generator set or where the generator set conductors enter a facility.

NOTICE

The AC supply must have the correct over current and earth fault protection according to local electrical codes and regulations. This equipment must be earthed (grounded).

It is the sole responsibility of the customer to provide AC power conductors for connection to load devices and the means to isolate the AC input to the terminal box; these must comply with local electrical codes and regulations. Refer to the wiring diagram supplied with the generator set.

The disconnecting device is not provided as part of the generator set, and Cummins accepts no responsibility for providing the means of isolation.

AC Disconnect Sources

WARNING

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

death. The equipment may have more than one source of electrical energy.

Disconnecting one source without disconnecting the others presents a shock hazard. Before starting work, disconnect the equipment, and verify that all sources of electrical energy have been removed.

1.5 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.

1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

• 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.

Gaseous Fuels

Natural gas is lighter than air, and will tend to gather under covered areas. Propane is heavier than air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling propane to be trained and qualified.

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.

1.6 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.

Exhaust Precautions

WARNING

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

1. IMPORTANT SAFETY INSTRUCTIONS6-2017

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 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.

1.7 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.

1. IMPORTANT SAFETY INSTRUCTIONS 6-2017

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.

1.8 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.

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

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

2.1 About This Manual

This manual provides troubleshooting and repair information for the generator sets listed on the front cover.

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

This manual does not include instructions for servicing printed circuit board assemblies. After determining that a printed circuit board assembly is faulty, replace it. Do not repair it. Attempts to repair a printed circuit board can lead to costly damage to the equipment.

This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting. The wiring diagrams and schematics that are maintained with the unit should be updated when modifications are made to the unit.

Operating and basic maintenance instructions are in the applicable generator set operator manual. Read and carefully observe all instructions and precautions in this manual.

2. Introduction 6-2017

2.2 Test Equipment

To perform the test procedures in this manual, the following test equipment must be available:

• True RMS (Root Mean Square) meter for accurate measurement of small AC and DC voltages

• Grounding wrist strap to prevent circuit board damage due to electrostatic discharge (ESD)

• Wheatstone bridge or digital ohmmeter

• Load bank

• Megger or insulation resistance meter

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.

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 MPU Magnetic Pickup ASTM American Society for

Testing and Materials

(ASTM International) ATS Automatic Transfer

Switch AVR Automatic Voltage

Regulator AWG American Wire Gauge NO Normally Open CAN Controlled Area Network NWF Network Failure CB Circuit Breaker OEM Original Equipment

MFM Multifunction Monitor

Mil Std Military Standard

NC Normally Closed

NC Not Connected

NFPA National Fire Protection

Agency

Manufacturer CE Conformité Européenne OOR Out Of Range CCA Cold Cranking Ampere OORH/

ORH

Out Of Range High

Abbr. Description Abbr. Description

CFM Cubic Feet per Minute OORL/ORL Out Of Range Low

2. Introduction6-2017

CGT Cummins Generator

PB Push Button

Technologies CMM Cubic Meters per Minute PCC PowerCommand®Control CT Current Transformer PGI Power Generation

Interface

DC Direct Current PGN Parameter Group

Number DEF Diesel Exhaust Fluid PI Proportional/Integral DPF Diesel Particulate Filter PID Proportional/Integral/

Derivative EBS Excitation Boost System PLC Programmable Logic

Controller ECM Engine Control Module PMG Permanent Magnet

Generator ECS Engine Control System PPE Personal Protective

Equipment EMI Electromagnetic

PT Potential Transformer

Interference EN European Standard PTC Power Transfer Control EPS Engine Protection

PWM Pulse-Width Modulation

System E-Stop Emergency Stop RFI Radio Frequency

Interference FAE Full Authority Electronic RH Relative Humidity FMI Failure Mode Identifier RMS Remote Monitoring

System FSO Fuel Shutoff RMS Root Mean Square Genset Generator Set RTU Remote Terminal Unit GCP Generator Control Panel SAE Society of Automotive

Engineers GND Ground scfh Standard Cubic Feet of

gas per Hour HMI Human-Machine

Interface

SCR Selective Catalytic

Reduction

2. Introduction 6-2017

Abbr. Description Abbr. Description

IC Integrated Circuit SPN Suspect Parameter

Number ISO International Organization

for Standardization

LBNG Lean-Burn Natural Gas UL Underwriters

LCD Liquid Crystal Display UPS Uninterruptible Power

LCT Low Coolant

Temperature

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 familiarize themselves with the warnings and operating procedures.

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, as well as the Warranty Statements.

SW_B+ Switched B+

Laboratories

Supply

NOTICE

The literature provided with the generator set is as follows:

• Installation Manual (A053X172)

• Operator Manual (A053X174)

• Quick Start Installation Guide (A053X181)

• Quick Start Operator Guide (A053X183)

• Health and Safety Manual (0908-0110-00)

• Global Warranty Statement (A056F206)

• Emission Warranty Statement (Federal Emissions EPA Title 40 CFR Part 90 Component Warranty) (A028X278)

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

• Generator Set Service Manual (A053X177)

• RA Series RA112L1 Automatic Transfer Switch Owner Manual (A052S254) - if applicable

• RA Series 100A/200A/400A Automatic Transfer Switch Owner Manual (A046S594) - if applicable

• Parts Manual (A053X179)

• Standard Repair Times - HO Family (A053X186)

• Service Tool Manual (A043D529)

• Warranty Failure Code Manual (F1115C)

• Engineering Application Manual T-030: Liquid Cooled Generator Sets (A040S369)

2.5 Model Specifications

TABLE 1. MODEL VARIATIONS

2. Introduction6-2017

Model

C13N6H Both 13 54.2 C17N6H Both 17 70.8

C20N6H,

C20N6HC

Maximum load imbalance allowed is 50% of generator set rating.

TABLE 2. COLD WEATHER SPECIFICATIONS (ALL MODELS)

Temperature Description

Above 4 °C (40 °F) No starting aids required

-17 to 4 °C (0 to 40 °F) Alternator and regulator heaters (supplied with the generator set)

Natural Gas or

Propane Vapor

Natural Gas Only 18 75

Propane Vapor

Only

kW Amps Frequency Voltage

20 83.3

NOTICE

60 Hz

120/240 VAC Single Phase

Below -17 °C (0 °F)

• Alternator and regulator heaters

• 0W30 oil (see the oil recommendation below)

• Extreme cold weather kit (A045B984) (includes battery and oil heaters)

2. Introduction 6-2017

TABLE 3. FUEL SPECIFICATIONS (AT FULL LOAD) (ALL MODELS)

C13N6H C17N6H C20N6H, C20N6HC

Type

scfh BTU/hr scfh BTU/hr scfh BTU/hr

Natural Gas 253 260,000 289 297,000 300 309,000 Propane 85 212,000 101 252,000 116 290,000

Natural Gas: 3.5 - 12 inch water column (0.9 - 3.0 kPa)

Fuel Pressure

Propane Vapor: 1.5 - 3.0 kPa (6 - 12 inch water column) Maximum pressure for either fuel under any condition: 3.2 kPa (13

inch water column)

TABLE 4. ENGINE SPECIFICATIONS (ALL MODELS)

Type Value

Engine

2 cylinder v-twin, OHV, air-cooled, 4-stroke, spark

ignited Displacement 999 cc (60.9 in3) Spark Plug Gap 0.7 - 0.8 mm (0.027 - 0.031 in) Spark Plug Torque (Cold Engine) 25 - 30 Nm (18 - 22 ft-lb) RPM 3600 Lubricating Oil Pressure at Rated

Speed (Minimum)

310 kPa (45 psi)

Full synthetic gasoline engine oil which meets or

exceeds API service SN/SN-RC and ILSAC GF-5: Oil Recommendation

• 5W30: Temperatures above -17 °C (0 °F)

• 0W30: All temperatures, required below -17 °C (0 °F)

Lubricating Oil Capacity:

Lubricating Oil Pressure at Rated Speed (Minimum)

310 kPa (45 psi)

--Full at High Mark on Dipstick 2.3 L (2.4 qt)

--Low Mark on Dipstick 1.3 L (1.4 qt)

Model

2. Introduction6-2017

TABLE 5. GENERATOR SET SIZE (ALL MODELS)

Dimension Value

Length 865 mm (34.1 in) Width 915 mm (36 in) Height 694 mm (27.3 in)

TABLE 6. GENERATOR SET WET WEIGHT (INCLUDING BATTERY)

Model Value

C13N6H 218 kg (479 lb) C17N6H, C20N6H, C20N6HC 241 kg (531 lb)

TABLE 7. GENERATOR SET DERATING GUIDELINES

Engine Power Available Up To... Derate At…

Elevation Ambient Temperature Elevation Temperature

C13N6H 2100 m (6900 ft) 25 °C (77 °F) C17N6H 300 m (1000 ft) 25 °C (77 °F)

C20N6H,

C20N6HC

0 m (0 ft) 15 °C (60 °F)

NOTICE

Derating guidelines: This product's output power is limited by factors such

as BTU content of fuel, ambient temperature, altitude, humidity, engine condition, etc. The derating guidelines are based on properly maintained product, using the appropriate fuel. Derate values are based on expected engine power changes from elevation and temperatures listed.

TABLE 8. ALTERNATOR SPECIFICATIONS (ALL MODELS)

Type Specification

Design Rotating field

Poles 2

3.5% per 300 m

(1000 ft)

1% per

5.5 °C (10 °F)

RPM 3600

Voltage 240

Hz 60

2. Introduction 6-2017

TABLE 9. CONTROL SPECIFICATIONS (ALL MODELS)

Control

Integrated Microprocessor-Based Engine, Alternator, Transfer Switch Controller

TABLE 10. DC SYSTEM SPECIFICATIONS (ALL MODELS)

Type Value

Nominal Battery Voltage 12 VDC Battery Group 51 R Battery Type Lead Acid Minimum Cold Crank Amps (CCA) 450

2.6 After Sales Services

Cummins offers a full range of maintenance and warranty services.

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 Global Warranty Statement listed in the Related Literature section.

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.

Extended warranty coverage is also available. For further warranty details, contact your authorized service provider.

2. Introduction6-2017

NOTICE

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

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

When a product requires service, contact the nearest authorized Cummins Inc. service provider. To locate the service provider, refer to power.cummins.com and select Sales & Service Locator. When contacting the service provider, always supply the complete model, specification, and serial number as shown on the nameplate.

Service Technician Support

For technical support for service technicians, call 1-855-TECH711 (1-855-832-

4711) to reach the Channel One Technical Support Hotline in the United States or Canada. Distributors should contact their Cummins Inc. service contact.

Fuel Information Needed for Service Issue

When servicing is needed on a failed fuel tank, the following questions must be answered and conveyed via the submission of the Technical Support Request form (TSR).

1. Is there an actual confirmed leak?

• Has the rupture basin alarm gone off?

• What Fault Code(s) are present?

• Is the sensor functioning properly?

• Is there visible fuel in the basin or outside the tank (i.e. is there an EPA concern)?

• If so, what is the leak rate?

• Is the fluid fuel and NOT water?

• What is the level of the fuel, in inches, in the tank and basin? A dipstick may be required to obtain an accurate reading.

• Can the leak locale be identified?

2. Introduction 6-2017

CAUTION

High Pressure Excessive pressurization can rupture tanks or basins which

can result in severe personal injury or death. Remove all liquids before pressure testing. Do not exceed 2

psig when testing a tank or basin.

• Has the tank been previously repaired?

• Is there evidence of physical damage that may be contributing to the leak?

• Pictures may convey a great deal of information and should be considered.

2. What are the CPG and manufacturer's details associated with the tank? Include the following in the Issue:

• CPG part number.

• Manufacturer's part number, model, serial number and date of manufacture.

3. What time frame is required for the needed repair or replacement (i.e. how sensitive of an issue is this with the client and do they have any flexibility in the repair timing)?

• If replacement, has there been an order placed for a new tank?

• If ordered, is it categorized as machine down?

• If not, then please update the order accordingly.

• If an order has been placed, the Issue is to reflect this data (order number) as well.

Obtaining Information Needed for Fuel Tank Service Issues

CAUTION

High Pressure Excessive pressurization can rupture tanks or basins which can result

in severe personal injury or death. Remove all liquids before pressure testing. Do not exceed 2 psig when

testing a tank or basin.

To aid in identifying/isolating the leak or obtaining some of the information needed for Fuel Tank Service Issues:

1. Seal all penetrations/fittings with plugs except for one.

2. For the remaining penetration, fit up a regulated pressure source with a calibrated pressure gauge and a pressure relief valve (set to no more than 2.5 psig).

2. Introduction6-2017

3. Pressurize the tank or basin to 2 psig and observe for the following:

• For secondary tank (basin) work, spray all exterior weld seams with a soap water solution. Observe the pressure gauge for no change in a 30 minute period and visually observe the exterior seams for bubbling. Results are to be conveyed in the Issue details.

• For the primary fuel tank, spray all exterior weld seams with a soap water solution. Observe the pressure gauge for no change in a 30 minute period and visually inspect the interior of the basin to the maximum extent possible. Results are to be conveyed in the Issue details.

NOTICE

For further questions or concerns regarding the information stated above, please contact (in the following order):

1. Your local Service Manager

2. DFSE-Counterpart

3. The Cummins Distributor Technical Support Line (1-812-377-6517)

2. Introduction 6-2017

Manufacturing Facilities

Facility Address Phone Numbers

U.S. and CANADA

EMEA, CIS Cummins Inc.

ASIA PACIFIC

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

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

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

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

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

Phone +44 1843 255000 Fax +44 1843 255902

Phone +65 6417 2388 Fax +65 6417 2399

BRAZIL Rua Jati, 310, Cumbica

Guarulhos, SP 07180-900 Brazil

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 +55 11 2186 4195 Fax +55 11 2186 4729

Phone 86 10 59023001 Fax +86 10 5902 3199

Phone +91 021 66305514

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

Facility Address Phone Numbers

MEXICO Eje 122 No. 200 Zona Industrial

San Luis Potosi, S.L.P. 78395

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

Mexico

2. Introduction6-2017

2. Introduction 6-2017

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3 Startup

3.1 "Establishing Communications" Message

NOTICE

Once the battery is connected to the generator set and any display button is pressed, the local display shows an "establishing communications" message for approximately 5 seconds. (This may take longer if the signal integrity is poor between the control and display due to a bad wire or Electro-Magnetic Interference [EMI].) Once communication is established, the display shows the HOME screen.

The “establishing communications” message will also be displayed whenever the control is brought out of “sleep” mode by pressing any button on the display. Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30-minute timer is reset with any button press on the display.

3.2 "Clock Setup" Screen

The Clock needs to be reset whenever the battery power is lost or disconnected, or the control has entered “sleep” mode. Sleep mode is entered after 30 minutes without utility or generator set power to preserve battery energy since the battery charger will not have AC power. The 30minute timer is reset with any button press on the display.

The optional Remote Monitoring System (RMS) uses the generator set's clock. The clock must be set accurately for the RMS to function properly.

To set up the generator set clock for the current date and time:

1. From the Main screen, select Menu.

2. Use the arrow keys to highlight Clock. Select the Enter key.

3. Use the arrow keys to set the time and date.

NOTICE

3. Startup 6-2017

FIGURE 2. CLOCK SETUP SCREEN

4. Select the Next key to go to the Daylight Savings screen.

+ 152 hidden pages

CUMMINS C13N6H, C17N6H, C20N6H, C20N6HC Service 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 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death

1.5 Fuel and Fumes Are Flammable

1.6 Exhaust Gases Are Deadly

1.7 The Hazards of Carbon Monoxide

1.8 Earth Ground Connection

2 Introduction

2.1 About This Manual

2.2 Test Equipment

2.3 Schedule of Abbreviations

2.4 Related Literature

2.5 Model Specifications

2.6 After Sales Services

3 Startup

3.1 "Establishing Communications" Message

3.2 "Clock Setup" Screen