Upfit Operator Manual

Trailerized Generator Set

Cummins NPower 200kw, QSB6.7

English Version 11/2013 Doc 26596

This manual contains proprietary information to equipment produced by Cummins NPower
LLC and Cummins Inc. and is being supplied solely for the purpose of operating and main-
taining the upfit components for the Trailerized Unit purchased from Cummins NPower LLC.

This equipment has been upfit with the following features by Cummins NPower:

• Engine overspeed Air Shutoff device

• Crankcase ventilation system
• Espar diesel-fueled engine heater
• Transport Trailer
This manual insert provides basic warranty, operating, and maintenance information for these compo-
nents only. For more detailed information regarding any upfit component, contact the component man-
ufacturer For information on all other components, consult the Generator Set Owner’s Manual
provided with your unit.

© Copyright 2013, Cummins Inc.

Non Cummins Warranty

Cummins NPower LLC Limited Warranty

NON-Cummins Warranty Support:

Any non-Cummins part, assembly or component carries that particular manufacturer's warranty
(generally the part is supplied at no charge and labor is not included to replace the defective part).

In certain situations, Cummins NPower LLC will provide labor to replace a defective part, assembly or
component. Labor will be reimbursed according to Cummins SRT (Standard Repair Times) standards.
Each situation will be reviewed on a case by case basis and is done as goodwill policy not associated with
standard warranties. Please consult with Cummins NPower LLC Product Support for further detail.

THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY
CUMMINS NPOWER IN REGARD TO THE PRODUCT. CUMMINS NPOWER MAKES
NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT IS CUMMINS
NPOWER LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
This limited warranty shall be enforced to the maximum extent permitted by applicable law. This limited
warranty gives the owner specific rights that may vary from state to state or from jurisdiction to
jurisdiction.

Cummins NPower LLC 1600 Buerkle Road White Bear Lake, MN 55110 Phone 651 636 1000 www.npower.cummins.com
 Table of Contents
Non Cummins Warranty

Section 1 - Safety
1.1 Advisory and Cautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 General Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2 - Introduction
2.1 About This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Product Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section 3 - Operation
3.1 Transport Trailer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 Transport Trailer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Crankcase Ventilation System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.1 Crankcase Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Engine Overspeed Air Shutoff Device Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3.1 Overspeed Air Shutoff Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Espar Diesel-Fueled Engine Heater Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.1 Manual Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.2 Automatic Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Section 4 - Maintenance
4.1 Crankcase Ventilation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Engine Overspeed Air Shutoff Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Espar Diesel-Fueled Engine Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 Transport Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Section 5 - Wiring Diagrams

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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Table of Contents

TOC-ii Trailerized Generator Set Upfit Operator Manual

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 Section 1 - Safety
IMPORTANT SAFETY INSTRUCTIONS - This
manual contains important instructions that should be
followed during installation, prior to and during opera-
tion, and maintenance of the trailerized generator set.
SAVE THESE INSTRUCTIONS.
Before operating the generator set (genset), read this
manual and all literature supplied with the unit. This
includes the genset owner manual from cummins
power generation and the Felling trailer owner’s
manual. Become familiar with these manuals 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.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the
operator, service personnel, or the equipment.
1.1 Advisory and Cautionary Statements
Advisory and Cautionary Statements are used
throughout this manual to call attention to special
information, correct operating procedures, and safety
precautions.
NOTE: A general advisory statement relating to
equipment operation and maintenance procedures.
IMPORTANT: A specific advisory statement intended
to prevent damage to the equipment or associated
components.
Cautionary Statements consist of three levels:
DANGER
This symbol warns of immediate hazards which
will result in severe personal injury or death.
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WARNING
This symbol refers to a hazard or unsafe practice
which can result in severe personal injury or
death.
CAUTION
This symbol refers to a hazard or unsafe practice
which can result in personal injury or product or
property damage.
CAUTION
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 run-
ning unless the tanks are outside the engine
compartment. Fuel contact with the 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.
• Be sure all fuel supplies have a positive shut-off
valve.
• Be sure the battery area has been well-venti-
lated prior to servicing near it. Lead-acid batter-
ies emit a highly explosive hydrogen gas that
can be ignited by arcing, sparking, smoking, etc.
1-1

WARNING
Exhaust Gases Are Deadly.The engine exhaust
from this product contains chemicals known to
the State of California and some of its constitu-
ents cause cancer, birth defects, or other repro-
ductive harm.
• 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 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.
• Be sure the unit is well ventilated.
WARNING
Moving Parts Can Cause Severe Personal Injury
or Death.
• Keep your hands, clothing, and jewelry away
from moving parts.
1.2 General Safety Precautions
• Before starting service work on the generator
set, disconnect the battery charger from its AC
source, then disconnect the starting batteries,
negative (-) cable first. This will prevent acciden-
tal 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 vicin-
ity of moving parts, or while working on electrical
equipment. Loose clothing and jewelry can
become caught in moving parts. Jewelry can
short out electrical contacts and cause shock or
burning.
• If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.
WARNING
Electrical Shock Can Cause Severe Personal
Injury or Death.
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• Disconnect electric power before removing pro-
tective shields or touching electrical equipment.
Use rubber insulative mats placed on dry wood
platforms over floors that are metal or concrete
when around electrical equipment. Do not wear
damp clothing (particularly wet shoes) or allow
skin surface to be damp when handling electrical
equipment.
• Use extreme caution when working on electrical
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.
• Follow all applicable state and local electrical
codes. Have all electrical installations performed
by a qualified licensed electrician. Tag and lock
open switches to avoid accidental closure.
• DO NOT CONNECT GENERATOR SET
DIRECTLY TO ANY BUILDING ELECTRICAL
SYSTEM. Hazardous voltages can flow from the
generator set into the utility line. This creates a
potential for electrocution or property damage.
Connect only through an approved isolation
switch or an approved paralleling device.
• Coolants under pressure have a higher boiling
point than water. DO NOT open a radiator or
heat exchanger pressure cap while the engine is
running. Allow the generator set to cool and
bleed the system pressure first.
• Used engine oils have been identified by some
state or federal agencies as causing cancer or
reproductive toxicity. When checking or chang-
ing engine oil, take care not to ingest, breathe
the fumes, or contact used oil.
• Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible mate-
rials such as wood and cloth; Class B fires
involve combustible and flammable liquid fuels
and gaseous fuels; Class C fires involve live
electrical equipment. (Ref. NFPA No. 10).
• Make sure that rags are not left on or near the
engine.
• Make sure the generator set is mounted in a
manner to prevent combustible materials from
accumulating under the unit.
• Remove all unnecessary grease and oil from the • Substances in exhaust gases have been identi-
unit. Accumulated grease and oil can cause fied by some state or federal agencies as caus-
overheating and engine damage which present ing cancer or reproductive toxicity. Take care not
a potential fire hazard. to breath or ingest or come into contact with
exhaust gases.
• Keep the generator set and the surrounding area
• Do not store any flammable liquids, such as fuel,
clean and free from obstructions. Remove any
cleaners, oil, etc., near the generator set. A fire
debris from the set and keep the floor clean and
or explosion could result.
dry.
• Wear hearing protection when going near an
• Do not work on this equipment when mentally or operating generator set.
physically fatigued, or after consuming any alco-
• To prevent serious burns, avoid contact with hot
hol or drug that makes the operation of equip-
metal parts such as the radiator, turbo charger,
ment unsafe.
and exhaust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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 Section 2 - Introduction
2.1 About This Manual
This manual provides upfit information for the traile-
rized generator set models listed on the front cover.
This includes the following information:
Upfit operating instructions
Maintenance information
You must read all manuals that came with your unit
prior to operating or towing the unit.
2.2 Safety Considerations
The generator set has been carefully designed to
provide safe and efficient service when properly
installed, maintained, and operated. However, the
overall safety and reliability of the complete system is
dependent on many factors outside the control of the
generator set manufacturer. To avoid possible safety
hazards, make all mechanical and electrical connec-
tions to the generator set exactly as specified in this
manual. All systems external to the generator (fuel,
exhaust, electrical, etc.) must comply with all applica-
ble codes. Make certain all required inspections and
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tests have been completed and all code requirements
have been satisfied before certifying the installation is
complete and ready for service.
2.3 Product Modifications
Agency certified products purchased from Cummins
NPower comply only with those specific requirements
and as noted on company product specification
sheets. Subsequent modifications must meet com-
monly accepted engineering practices and/or local,
state and national codes and standards. Product
modifications must be submitted to the local authority
having jurisdiction for approval.
The information, specifications, and recommended
guidelines in this manual are based on information in
effect at the time of printing. Cummnis Npower, LLC.
and Cummins, Inc. reserves the right to make
changes at any time without obligation. If you find dif-
ferences between your engine and the information in
this manual, contact your local Cummins Authorized
Repair Location or call 1-800-DIESEL (1-800-343-
7357) toll free in the U.S. and Canada.
2-1
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 Section 3 - Operation
This section provides an overview and operating
instructions for the upfit parts of the trailerized gener-
ator set.
3.1 Transport Trailer Overview
Manufacturer: Felling Trailer (www.felling.com)
Manufacturer part number: 1008042
Location: N/A
The trailer provides a means for transporting the
genset. The trailer is equipped with a 3” Lunette eye
for towing with a pintle hitch system and contains (2)
6000 lb. Dexter axles with electric brakes.
1
1. Trailer
Figure 3-1 Felling Transport Trailer
3.1.1 Transport Trailer Operation
For full operation instructions, consult the trailer man-
ufacturer’s owner’s manual (available online and/or
directly from the manufacturer).
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3.2 Crankcase Ventilation System
Overview
Manufacturer: Fleetguard (www.cumminsfiltra-
tion.com).
Manufacturer part number: CV52019
Location: Rear/LH side of engine
For optimal engine performance and to support emis-
sions regulations compliance, diesel engine blow-by
should contain minimal oil aerosol before venting to
atmosphere.
The crankcase ventilation manager system separates
blow-by oil mist before venting to atmosphere. Along
with reducing emissions, this system helps to reduce
oil consumption, mist, fumes and drips in the engine
compartment, resulting in a cleaner and safer operat-
ing environment. For use in cold-weather environ-
ments, the unit is heated with engine coolant.
1
1. Crankcase Ventilation Manager
Figure 3-2 Crankcase Ventilation Manager
3.2.1 Crankcase Operation
During operation, the coalescer should not exceed a
45 degree angle from vertical. This ensures proper
draining of oil from the coalescer back into the
engine.
3-1
3.3 Engine Overspeed Air Shutoff Device
Overview
Manufacturer: Roda Deaco by AMOT
(www.rodadeaco.com)
Manufacturer part number: RB3A-1917-E1LA
Location: LH side of engine near intake manifold
If flammable gas or vapor is present in the atmo-
sphere surrounding a diesel engine, it can be
ingested into the engine and become an ungoverned
fuel supply, resulting in an overspeed condition,
which can lead to mechanical failure or explosion.
The air shutoff valve, which is electrically controlled
via the engine ECM, provides emergency overspeed
shutdown of a diesel engine by starving the engine of
air and shutting down the engine.
1
1. Air Shutoff Valve
Figure 3-3 Engine Overspeed Air Shutoff Device
3.3.1 Overspeed Air Shutoff Operation
The valve is electrically controlled via the engine
ECM. If an overspeed condition occurs, and the
device is activated, it can be manually reset by rotat-
ing the actuation lever in the clockwise direction until
the lever clicks into place.
NOTE: Pressing the emergency stop button will
activate the air shutoff device and the device
must be manually reset before operation of the
unit can resume.
NOTE: If the unit shuts down due to an overspeed
fault, check the air shut-off valve (and reset if nec-
essary) before attempting to restart the engine.
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3.4 Espar Diesel-Fueled Engine Heater
Overview
Manufacturer: Espar (www.espar.com)
Manufacturer part number: 25 2822 19 0540 OZ H5
Location: RH side of engine
The diesel-fueled engine heater is capable of heating
the engine without the use of an external power
source. The unit regulates the coolant temperature
between a low of 149ºF and 176ºF by automatically
cycling the heater between heat levels. The heater
offers both automatic and manual controls.
1
1. Engine Heater
Figure 3-4 Espar Diesel- Fueled Engine Heater
3.4.1 Manual Mode Operation
1. Press the center button on the heater controller.
In manual mode (and/or operating without the
SD card), the default runtime is 10 hours (this
cannot be increased or decreased).
2. To stop the heater at any time during manual
mode operation, press the center button on the
heater controller.
NOTE: The heater contains various controls that
may cause the heater to shut-down (low voltage,
overheating, etc.). For definitions of various fault
codes, please consult the heater manufacturer’s
operator manual (available online and/or directly
from the manufacturer).
NOTE: The heater will operate with fuel from the
genset mounted fuel tank only . If an auxiliary fuel
tank is used, and the genset mounted fuel tank is
empty, the heater may not operate.
3.4.2 Automatic Mode Operation

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 Section 4 - Maintenance
4.1 Crankcase Ventilation System
The coalescing filter should be changed as indicated
by the display panel, every 6 months, or every 1000
hours, whichever comes first.
Service kit part number (includes O-ring and ele-
ment): Fleetguard p/n CV52053.
To replace filter:
1. Remove the collar using collar wrench or strap
wrench. Remove shell and used filter. Remove
used O-ring from shell.
2. Lubricate new O-ring with clean engine oil and
install new O-ring onto the reusable shell.
3. Install new filter into the head, being sure to align
the yellow diamond on the filter with the yellow
diamond on the label. Insert the shell, being sure
to align the yellow diamond on the shell with the
yellow diamond on the label and filter.
4. Tighten the reusable collar on the assembly by
hand.
5. Use a collar wrench or strap wrench to fully
secure the collar (minimum 1/15 additional turn;
each rib on the collar represents 1/15 turn).
6. Perform a post-installation check.
NOTE: The oil dipstick can act as a pressure-
relief location and may become dislodged if
excess crankcase pressure exists. If the dipstick
becomes dislodged, check the coalescer filter to
see if it has become plugged or dirty and replace
as necessary.
4.2 Engine Overspeed Air Shutoff Device
The valve should be operated at least once a week or
before regular use of the engine to assure that the
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moving parts are free and operational. Exercise the
valve by manually depressing the plunger and ensur-
ing the valve operates. To reset the unit, rotate the
actuation lever clockwise until the lever clicks into
place.
NOTE: This should be performed with the engine
off.
Lubricate the reset lever shaft when normal engine
service work is done.
4.3 Espar Diesel-Fueled Engine Heater
Run the heater at least once per month during the
year for a minimum of 15 minutes. In addition,
perform the following checks:
• Visually check all coolant and fuel hoses and
clamps for leaks
• Visually check all electrical lines and connec-
tions for corrosion
• Check all batteries and electrical connections
and replace if necessary
• Check glow pin (replace if necessary)
NOTE: For more in-depth maintenance and trou-
bleshooting information, including a complete
parts list, please consult the heater manufac-
turer’s operator manual.
4.4 Transport Trailer
For full maintenance instructions, consult the trailer
manufacturer’s owner’s manual (available online and/
or directly from the manufacturer).
4-1
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 Section 5 - Wiring Diagrams
5.1 General
This section consists of the schematic and connec-
tion wiring diagrams referenced in the text. The fol-
lowing drawings are included.

Wiring Diagrams

Drawing Title Drawing No.

Schematic, Rental Genset, 200kW United Rental, C200D6RT 26634

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AUTO CAD
Cummins NPower, LLC
1600 Buerkle Rd
White Bear Lake, MN 55110
Customer Assistance Center: 1 866 831 7620
www.cumminsnpower.com