CUMMINS HDKBB, HDKBC Installation Manual

Installation Manual

Commercial Mobile Generator Set

HDKBB (Spec A−J)
HDKBC (Spec D−J)

English
Original Instructions 10-2016 981−0650 (Issue 9)

California

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

Table of Contents

TABLE OF CONTENTS II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY PRECAUTIONS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outline Drawings 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Codes and Standards for Safety 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Noise 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electromagnetic compatibility 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOUNTING, LOCATION AND VENTILATION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST CONNECTIONS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Muffler 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tailpipe 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL CONNECTIONS 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bio−diesel Fuels B5 − B20 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Power Connections 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control Connections 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Connections 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION REVIEW AND STARTUP 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Air Recirculation Test 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Review 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 15. Outline Drawing—Sheet 1 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 16. Outline Drawing—Sheet 2 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 17. Wiring Diagram—Sheet 1 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 18. Wiring Diagram—Sheet 2 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SAFETY PRECAUTIONS

Thoroughly read the OPERAT OR’S MANUAL be­fore operating the genset. Safe operation and top
performance can only be obtained when equip­ment is properly operated and maintained.

Only trained and experienced service personnel
with knowledge of fuels, electricity , and machin­ery hazards shall remove dismantle and dispose
of the generator set. See service manual.

Some generator set installation procedures
present hazards that can result in severe person­al injury or death. Only trained and experienced
personnel with knowledge of fuels, electricity,
and machinery hazards should perform genera­tor set installation procedures.

The following symbols in this manual alert you to po­tential hazards to the operator, service person and
equipment.

Used to alert you to a lethal hazard
against which you must take steps to prevent se­vere personal injury or death, as when you are in
the vicinity of High Voltage equipment.

WARNING

safe practice that can result in severe personal
injury or death.

CAUTION

safe practice that can result in personal injury or
equipment damage.

Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal
injury or death.

Used to alert you to a hazard or un-

Used to alert you to a hazard or un-

ENGINE EXHAUST IS DEADLY

 Inspect for exhaust leaks at every startup and af-

ter every eight hours of running.

 Prior to every startup and after every eight hours

of running, all carbon monoxide detectors must
be tested and confirmed to be working in accor­dance with the manufacturer’s instructions or
owners manual.

 Learn the symptoms of carbon monoxide poi-

soning in the genset Operator’s Manual.

 Never occupy the vehicle while the genset is

running unless the vehicle is equipped with a
working carbon monoxide detector.

 Do not operate the genset when the vehicle is

parked in a confined space, such as a garage.

 Disable the automatic genset starting feature

(AGS) of an inverter-charger or other automatic
starting device before storing the vehicle or
parking it in a garage or other confined space.

 The exhaust system must be installed in accor-

dance with the genset Installation Manual.

 Engine cooling air must not be used for heating

the vehicle.

GENERATOR VOLTAGE IS DEADLY

 Disable the automatic genset starting feature

(AGS) of an inverter-charger or other automatic
starting device before servicing the genset.

 Generator electrical output connections must be

made by a trained and experienced electrician
in accordance with applicable codes.

WARNING

and shore power can lead to electrocution of util­ity line workers, equipment damage and fire. Use
an approved switching device to prevent inter­connections.

 Use caution when working on live electrical

equipment. Remove jewelry, make sure clothing
and shoes are dry, stand on a dry wooden plat­form or rubber insulating mat and use tools with
insulated handles.

Interconnecting the generator set

DIESEL FUEL IS COMBUSTIBLE

 Do not smoke or turn electrical switches ON or

OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equipment.
Keep flames, sparks, pilot lights, arc-producing
equipment and all other sources of ignition well
away.

 Fuel lines must be secured, free of leaks and

separated or shielded from electrical wiring.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

 Disable the automatic genset starting feature

(AGS) of an inverter-charger or other automatic
starting device before servicing the genset.

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 Do not wear loose clothing or jewelry near mov-

ing parts such as PTO shafts, fans, belts and
pulleys.

 Do not work on the genset when mentally or

physically fatigued or after consuming alcohol or
drugs.

 Keep hands away from moving parts.
 Keep guards in place over fans, belts, pulleys,

and other moving parts.

BATTERY GAS IS EXPLOSIVE

 Wear splash−proof safety glasses.
 Do not smoke or permit flames or sparks to oc-

cur near the battery at any time.

 To reduce arcing when disconnecting or recon-

necting battery cables, always disconnect the
negative (−) battery cable first and reconnect it
last.

FLAMMABLE VAPOR CAN CAUSE A

DIESEL ENGINE TO OVERSPEED

WARNING

genset where a flammable vapor environment
can be created by fuel spill, leak, etc.

Flammable vapor can cause a diesel engine to over­speed and become difficult to stop, resulting in pos­sible fire, explosion, severe personal injury and
death. The owners and operators of the genset are
solely responsible for operating the genset safely.

Do not operate a diesel-powered

GENERAL PRECAUTIONS

 Keep children away from the genset.
 Do not use evaporative starting fluids. They are

highly explosive.

 To prevent accidental or remote starting while

working on the genset, disconnect the nega­tive (−) battery cable at the battery.

 Let the engine cool down before removing the

coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray out
and cause severe burns.

 Used engine oil has been identified by some

U. S. state and federal agencies as causing can­cer or reproductive toxicity. Do not ingest, in­hale, or contact used oil or its vapors.

 Ethylene glycol, used as engine antifreeze, is

toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor­dance with local environmental regulations.

 Keep multi-purpose fire extinguishers handy.

Multi−purpose fire extinguishers are used for
fires that involve ordinary combustible materials
such as wood and cloth; combustible and flam­mable liquid fuels and gaseous fuels; live electri­cal equipment. (North America or US: ref. NFPA
No. 10)

 Genset installation and operation must comply

with all applicable local, state and federal codes
and regulations.

 Generator sets with a sound shield shall not be

run with the service doors remove/missing.

 Engine components can be hot and cause se-

vere burns. Hot coolant under pressure can
spray and cause severe burns.

 Use personal protective equipment when main-

taining or installing the generator set such as
gloves, safety glasses, etc.

THE HAZARDS OF CARBON MONOXIDE

WARNING

duce harmful level of carbon monoxide that can
injure or kill you.

Engine−driven generators can pro-

ONLY YOU CAN PROTECT YOURSELF

FROM CO POISONING!

 Watch constantly for people near the exhaust of

the generator set while it is running.

 Use personal protective equipment when instal-

ling generator set (gloves, safety glasses, etc).

 Keep the genset and its compartment clean. Ex-

cess oil and oily rags can catch fire. Dirt and gear
stowed in the compartment can restrict cooling
air.

 Make sure all fasteners are secure and torqued

properly.

 Make sure exhaust cannot enter the living quar-

ters through a window, vent or door.

 Make sure all CO detectors and audible alarms

are working properly.

 Pay attention to the signs of CO poisoning.
 Check the exhaust system for corrosion, ob-

struction and leaks each time you start the gen-

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Copyright  2016 Cummins Inc.

erator set and every eight hours if you run it con­tinuously.

SUBSTANCE HAZARDOUS TO HEALTH

Generator sets use substances, and emit and create
wastes that can cause health risks. Generator set
operators must use appropriate personal protective
equipment (such as clothing, gloves, protective
glasses/goggles, and respiration equipment) when
exposed to fuel, oil, coolant, wet batteries, grease,
cleaning agents, or other substances exposed to
lungs, eyes, or skin. use appropriate containers for
transport, storage, and disposal of waste sub­stances. Follow local regulations for disposal and re­cycling.

ANTIFREEZE (FLEETGUARD − ES

COMPLEAT/EG PREMIX)

This antifreeze is also know as an ethylene glycol
based coolant; summer coolant; coolant additive. It
is purple coloured, viscous liquid, with a mild chemi­cal odour, is soluble in water and harmful. It contains
ethylene glycol, and diethylene glycol. Ethylene gly­col is a potentially hazardous constituent.

The substance has a boiling point of 107 C, and a
flash point of 121 C.

It is used as an engine coolant additive, and can be
found in engine cooling systems, and head exchang­ers. Installers, operators and maintainers are likely to
encounter this substance.

HAZARDOUS REACTIONS

Ethylene glycol is combustible when exposed to heat
or flame and can react vigorously with oxidants.
Moderate explosive hazard in form of vapour when
exposed to heat or flame. Hazardous products re­sulting from combustion or decomposition include
carbon monoxide, carbon dioxide and acrid smoke.
Self−contained breathing apparatus must be worn in
the event of fume build up.

Avoid strong oxidizing agents − incompatible with
sulfuric acid, nitric acid, caustics and aliphatic
amines.

It may cause neurological signs and symptoms, and
kidney damage. It is also a skin and eye irritant.

Very toxic in particulate form upon inhalation. Harm­ful if swallowed, lethal dose for humans reported to
be 100ml.

PROTECTIVE MEASURES

Refrain from eating, drinking or smoking when using
the product. Adopt a high standard of personal hy­giene. In ca s e o f s k i n c o n t a c t , w a s h i m m edia t e l y w i t h
soap and water.

Ensure good ventilation and avoid heat sources.
Avoid breathing mist, if there is a risk of vapour, or
particulate, use a suitable organic vapour mask.

Eye protection, gloves, overalls, impervious apron
should be used. Avoid contamination inside the
gloves. If overalls become contaminated, discontin­ue use and clean thoroughly.

STORAGE/TRANSPORT

Store and transport only in correctly marked contain­ers. Keep containers closed when not in use. Keep
cool, out of sunlight, away for naked flames and
strong acids, do not freeze. Store well away from
food−stuffs and drinking water. Take special care to
avoid discharge into drains, sewers and water−
courses.

Contain leak/spill with sand, earth or non−combus-
tible, absorbent material to prevent entry of sub­stance into drainage/sewerage system, water−
courses and land. Eliminate all ignition sources, use
plastic shovel to transfer to suitable container and
dispose of unwanted or absorbed substance through
and authorized contractor to a licensed site.

EMERGENCY ACTION

 Fire

Extinguishing media: CO
foam, dry powder, or water spray.
Fire fighters to use self contained breathing ap­paratus. Keep fire exposed containers cool.
Prevent run−off from entering waterways,
drains and drinking water supplies.

 Ingestion

Toxic by ingestion. If swallowed induce vomiting
only

under the advice of a Doctor or poison con­trol centre. Delayed treatment may result in fa­tality.

 Inhalation (of vapour)

Remove from further exposure. In case of irrita­tion to lungs or throat, seek medical advice.

 Aspiration (inhalation of liquid)

Obtain immediate medical assistance.

alcohol resistant

2,

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 Eyes

Flush copiously with water or preferably eye−
wash solution for at least five minutes. Seek
medical advice.

 Skin

Wash thoroughly with soap and water, and seek
medical attention if irritation develops. Change
clothing if necessary and wash before re−use.

 Spillage

Soak−up using an absorbent material and dis­pose of this as directed under Storage/Trans­port (Section 5.1.3)

GAS OIL

This product is also known as Red Diesel, Fuel Oil,
and type A1 or A2. It can be pale red or a clear liquid
with a characteristic mild odour. It contains catalyti­cally cracked oil, petroleum distillates, quinizarin,
and gas oil maker dye red. The catalytically cracked
oil and petroleum distillates are potentially hazard­ous constituents.

The substance has an initial boiling point of 180C, a
flash point greater than 56C, and a vapour pressure
less than 0.7mm Hg at 2 0C and has negligible solu­bility in water.

Gas oil is slightly irritating to the skin and has a de−
fatting action. Toxicity following single exposure to
high level of gas oil is of low order. Prolonged, re­peated skin contact may de−fat the skin resulting in
possible skin irritation and dermatitis. In some cases
warty, cancerous growths have occurred.

PROTECTIVE MEASURES

Ensure good ventilation and avoid heat sources. Ob­servance of good housekeeping rules will ensure
general safety. Do not smoke. Avoid breathing mist.

When working on, or testing, injection equipment,
special care is required to avoid perforation of skin by
high pressure fuel. Use eye protection in the event of
suspected high pressure leak.

Adopt a high standard of personal hygiene. In the
case of skin contact, wash well with soap and water.

Use glove and overalls, and eye protection goggles if
there is a risk of splashing. Use oil impervious gloves
and avoid contamination inside the gloves. If over­alls become contaminated, discontinue use and
clean thoroughly. Contaminated clothing should be
removed, soaked with water, and laundered before
re−use.

It is used as a fuel for off−road diesel powered ve­hicles and stationary engines, and can be found in
fuel tanks, pipes and injection systems. The sub­stance should not be used for any other purpose
without contacting the manufacturer or supplier. In­stallers, operators and maintainers are likely to en­counter this substance.

HAZARDOUS REACTIONS

This liquid is flammable. Avoid smoking, heat
sources, such as welding and naked flames, sparks
and static electricity build−up. Thermal decomposi-
tion products are hazardous, containing CO
and SOX compounds.

The vapour is explosive. High vapour concentrations
can cause respiratory irritation, dizziness, nausea,
and loss of consciousness. Excessive and pro­longed exposure to the mist can cause chronic in­flammatory reaction of the lungs and form of pulmo­nary fibrosis.

Avoid strong oxidizing agents, e.g. chlorates which
may be use in agriculture.

, NO

X

No special respiratory precautions are necessary in
normal use.

DO NOT use as a solvent for removing dirt/grease
etc, from skin.

STORAGE/TRANSPORT

Store and transport only in correctly marked contain­ers. Keep containers closed when not in use. Keep
cool, out of sunlight and away from naked flames.
Electrical continuity is required between the trans­port and storage vessels during product transfer.

X

Contain leak/spill with sand, earth or other suitable
material, and prevent entry of substance into drain­age/sewerage system, water−courses and land.
Dispose of unwanted or absorbed substance
through an authorized contractor to a licensed site.

Inform local and fire authorities should the product
reach waterways, drains etc.

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EMERGENCY ACTION

 Fire

Extinguishing media:
Large fire − Foam/water fog. Never use water
jet.
Small fire − foam/dry powder, AAAF, CO
earth.
Avoid making sparks. Fire fighters to use self−
contained breathing apparatus. Keep fire ex­posed containers cool, using water fog/spray.
Prevent run−off from entering waterway, drains
and drinking water supplies.

 Ingestion

Do not induce vomiting. Wash the mouth out
with water, and send to hospital immediately.

 Inhalation (of vapour)

Remove from further exposure. Obtain medical
assistance immediately.

2

, sand,

It has a boiling point greater than 150C, a flash point
Open Cup of 220C (Cleveland), and is insoluble in
cold water.

It is used in engine lubricant oil systems, sump pan
and filters, make−up tanks and piping systems as a
lubrication oil for use in wide range of diesel engines
operating under severe conditions. Installers, opera­tors and maintainers are likely to encounter this prod­uct.

HAZARDOUS REACTIONS

This product is stable although slightly re−active with
oxidizing agents. Results of decomposition are car­bon oxides (CO, CO

Although harmful if swallowed or aspirated (breathed
in), repeated or prolonged exposure is not known to
aggravate medical conditions.

) and water.

2

 Aspiration (inhalation of liquid)

If, following ingestion of gas oil, vomiting occurs,
there is danger of aspiration into the lungs. This
would cause intense local irritation and chemi­cal pneumonitis that can be fatal. Obtain imme­diate medical assistance.

 Eyes

Irrigate copiously with water or preferably eye−
wash solution for at least five minutes. If irritation
persists seek medical advice.

 Skin

Wash thoroughly with soap and water. Change
clothing if necessary.
If high pressure injection has occurred prompt
surgical attention is required.

 Spillage

Absorb using sand, earth or other suitable mate­rial. Dispose of unwanted or absorbed flam­mable material as directed under Storage/
Transport (Section 5.7.3).

LUBRICATION OIL − PREMIUM BLUE E

15W40

Used oil may contain harmful combustion by−prod-
ucts and unburnt fuel that will cause skin reactions as
detailed for fuel. Particular care must be taken if oil
form a severely overheated engine is handled − use
impervious gloves, lab coat and safety glasses.

Do not breathe vapour/spray.

PROTECTIVE MEASURES

Ensure good ventilation and avoid heat sources.
Adopt a high standard of personal hygiene. In case of

skin contact, wash thoroughly with soap and water.
Use safety glasses, impervious gloves and lab coat.

Avoid contamination inside the gloves. If overalls be­come contaminated, discontinue use and clean thor­oughly.

No special respiratory precautions are necessary n
normal use. Do no breathe vapour/spray when han­dling hot materials.

STORAGE/TRANSPORT

Also known as oil, lube oil, sump oil, new oil is dark,
viscous liquid with a slight, characteristic odour. T he
base oil contains: distillates (petroleum), solvent−
dewaxed heavy paraffinic. It is not classified as dan­gerous according to Directive 1999/45/EC and its
amendments, and is not classified according to the
EU regulations.

Copyright  2016 Cummins Inc.

Store and transport only in correctly marked contain­ers. Keep containers tightly sealed when not in use.
Keep in a cool, well ventilated area, out of sunlight
and away from naked flames. Store well away from
food−stuffs and drinking water.

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Wear splash goggles, full suit, boots and gloves. Ab­sorb leak/spill with an inert material and dispose of
unwanted or absorbed substance through an autho­rized contractor to a licensed site. Finish cleaning by
spreading water on the contaminated surface and al­low to evacuate through the sanitary system.

EMERGENCY ACTION

 Fire

Extinguishing media:
Large fire − Use water spray, fog or foam. Do not
use water jet.

Small fire − Use dry chemical powder or CO
Fire−fighters to use self contained breathing ap­paratus and full turnout gear. Keep fire exposed
containers cool.

 Ingestion

Do not induce vomiting, Obtain medical advice
immediately.

 Inhalation (of vapour)

Remove from further exposure. Obtain medical
attention.

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Copyright  2016 Cummins Inc.

Generator Set Warning Labels

Warning signs are provided on the generator set at or near the point of risk. To avoid injury,
always take the necessary precautions – as indicated on the sample signs shown below:

Caution / Warning.
Indicates a risk of personal injury.

Caution / Warning of Temperature Hazard.
Indicates a risk of personal injury from high temperature.

Caution / Warning of High Voltage Hazard.
Indicates a risk of personal injury from electric shock/electrocution.

Caution / Warning.
Indicates a risk of personal injury from equipment that may be subject to
automatic starting or remote starting.

Caution / Warning.
Indicates to read Operator manual for additional information.

Caution / Warning of Belt and Rotating Part Hazard.
Indicates a risk of personal injury from entanglement in moving parts.

Caution / Warning of Pressure Hazard.
Indicates a risk of personal injury from pressurized fluids.

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Copyright  2016 Cummins Inc.