CUMMINS QG 4000/3600 LP KY User manual

Brand: CUMMINS

Model: QG 4000/3600 LP KY

Category: Power generators

Type: User manual

Operator Manual

RV Generator Set

KY (Spec J−N)

English

Original Instructions 10-2014 981−0159 (Issue 9)

Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nameplate 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Genset 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Recommendations 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Recommendations 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Batteries 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Control Panel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control Panel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. OPERATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conducting the Pre-Start Checks 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming the Fuel System 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Genset 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Restarting the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loading the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting Circuit Breakers 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting to Utility Power 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Cold Weather 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Hot Weather 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Altitude Adjustment 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Dusty Environments 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Breaking in a New Engine 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercising the Genset 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing the Genset 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Returning the Genset to Service 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION PAGE

3. PERIODIC MAINTENANCE 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conducting General Inspections 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Engine Oil Level 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Engine Oil 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Battery and Battery Connections 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Air Filter Element 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Spark Plug 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Spark Arrestor 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TROUBLESHOOTING 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. SPECIFICATIONS 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. INFORMATION FOR CALIFORNIA GENSET USERS 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . .

7. HOW TO OBTAIN SERVICE 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. MAINTENANCE RECORD 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

SAFETY PRECAUTIONS

Thoroughly read the OPERATOR’S MANUAL

before operating the genset. Safe operation and

top performance can be obtained only when

equipment is operated and maintained properly.

Only trained and experienced service personnel

with knowledge of fuels, electricity, and machin-

ery hazards shall remove, dismantle and dis-

pose of the generator set. See service manual.

Some generator set installation procedures

present hazards that can result in severe per-

sonal injury or death. Only trained and experi-

enced personnel with knowledge of fuels, elec-

tricity, and machinery hazards should perform

generator set installation procedures.

The following symbols in this manual alert you to po-

tential hazards to the operator, service person and

equipment.

DANGER

alerts you to an immediate hazard

which will result in severe personal injury or

death.

WARNING

alerts you to a hazard or unsafe

practice which can result in severe personal in-

jury or death.

CAUTION

alerts you to a hazard or unsafe

practice which can result in personal injury or

equipment damage.

When equipped with an integral or add−on Auto−

matic Generator Starting System (AGS) control,ex-

haust carbon monoxide (CO), electric shock, and-

moving parts hazards are possible due to unex−

pected starting. Turn off AGS whenever performing-

maintenance or service, when the vehicle is stored-

between uses, is awaiting service, or is parked in a

garage or other confined area.

Electricity, fuel, exhaust, moving parts and batteries

present hazards which can result in severe personal

injury or death.

GENERAL PRECAUTIONS

S Keep children away from the genset.

S Do not use evaporative starting fluids. They are

highly explosive.

S To prevent accidental or remote starting while

working on the genset, disconnect the nega-

tive (−) battery cable at the battery.

S Keep the genset and its compartment clean.

Excess oil and oily rags can catch fire. Dirt and

gear stowed in the compartment can restrict

cooling air.

S Make sure all fasteners are secure and torqued

properly.

S Do not work on the genset when mentally or

physically fatigued or after consuming alcohol

or drugs.

S Used engine oil has been identified by some

state and federal agencies as causing cancer

or reproductive toxicity. Do not ingest, inhale, or

contact used oil or its vapors.

S Benzene and lead in some gasolines have

been identified by some state and federal

agencies as causing cancer or reproductive

toxicity. Do not to ingest, inhale or contact gaso-

line or its vapors.

S Keep multi-class ABC fire extinguishers handy.

Class A fires involve ordinary combustible ma-

terials such as wood and cloth; Class B fires,

combustible and flammable liquid fuels and

gaseous fuels; Class C fires, live electrical

equipment. (ref. NFPA No. 10)

S Genset installation and operation must comply

with all applicable local, state and federal codes

and regulations.

S Use personal protective equipment when per-

forming periodic maintenance operations such

as gloves, safety glasses, etc.

S Use caution when working on live electrical

equipment. Remove jewelry, make sure cloth-

ing and shoes are dry, stand on a dry wooden

platform or rubber insulating mat and use tools

with insulated handles.

GENERATOR VOLTAGE IS DEADLY!

S Disable the automatic genset starting fea-

ture(AGS) of an inverter−charger or other auto-

matic starting device before servicing the gen-

set to avoid electric shock from an unexpected

start.

WARNING

The genset must not be connected

to shore power or to any other source of electri-

cal power. Back-feed to shore power can cause

electric shock resulting in severe personal inju-

ry or death and damage to equipment. An ap-

proved switching device must be used to pre-

vent interconnections.

S Generator electrical output connections must

be made by a trained and experienced electri-

cian in accordance with applicable codes.

BATTERY GAS IS EXPLOSIVE

S Wear safety glasses.

S Do not smoke.

S To reduce arcing when disconnecting or recon-

necting battery cables, always disconnect the

negative (−) battery cable first and reconnect it

last.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

S Disable the automatic genset starting fea-

ture(AGS) of an inverter−charger or other auto-

matic starting device before servicing the gen-

set to avoid unexpected starting.

S Do not wear loose clothing or jewelry near mov-

ing parts such as PTO shafts, fans, belts and

pulleys.

S Keep hands away from moving parts.

S Keep guards in place over fans, belts, pulleys,

and other moving parts.

ENGINE EXHAUST IS DEADLY!

S Inspect for exhaust leaks at every startup and

after every eight hours of running.

S Prior to every startup and after every eight

hours of running, all carbon monoxide detec-

tors must be tested and confirmed to be work-

ing in accordance with the manufacturer’s in-

structions or owners manual.

S Learn the symptoms of carbon monoxide poi-

soning in this manual.

S Never occupy the vehicle while the genset is

running unless the vehicle is equipped with a

working carbon monoxide detector.

S Make sure there is ample fresh air when operat-

ing the genset in a confined area.

S Disable the automatic genset starting feature of

an inverter-charger or other automatic starting

device before storing the vehicle or parking it in

a garage or other confined space.

S The exhaust system must be installed in accor-

dance with the genset Installation Manual.

S Engine cooling air must not be used for heating

the working or living space or compartment.

THE HAZARDS OF CARBON MONOXIDE

WARNING

Engine−driven generators can pro-

duce harmful level of carbon monoxide that can

injury or kill you.

ONLY YOU CAN PROTECT YOURSELF

FROM CO POISONING!

S Watch constantly for people near the exhaust

of the generator set while it is running.

S Make sure exhaust cannot enter the living

quarters through a window, vent or door.

S Make sure all CO detectors or audible alarms

are working properly.

S Pay attention to the signs of CO poisoning.

S Check the exhaust system for corrosion, ob-

struction and leaks each time you start the gen-

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. Genera-

tor set operators must use appropriate personal

protective equipment (such as clothing, gloves, pro-

tective glasses/goggles, and respiration equip-

ment) when exposed to fuel, oil, coolant, wet batter-

ies, 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 dis-

posal and recycling.

FUEL IS FLAMMABLE AND EXPLOSIVE

S Do not smoke or turn electrical switches ON or

OFF where fuel fumes are present or in areas

sharing ventilation with fuel tanks or equip-

ment. Keep flame, sparks, pilot lights, arc-pro-

ducing equipment and switches and all other

sources of ignition well away.

S Fuel lines must be secured, free of leaks and

separated or shielded from electrical wiring.

S Leaks can lead to explosive accumulations of

gas. Natural gas rises when released and can

accumulate under hoods and inside housings

and buildings. LPG sinks when released and

can accumulate inside housings and base-

ments and other below-grade spaces. Prevent

leaks and the accumulation of gas.

PROPANE

This product is also known as C

or liquified pro-

pane gas. It consists of predominantly C

Hydrocar-

bons (propane and prepane) with typically < 50 ppm

of ethyl mercaptan or other odorizing agent added

to assist leak detection. Contains <0.1% 1, 3 buta-

deine. Hazardous components include c3−4 rich,

petroleum distillate.

The substance has an initial boiling point of −42.1 C

flash point of −104 C (PMCC), and a vapor pres-

sure of 7.5 bar at 15 C.

Keep the container below 50C. The substance

should not be used for any other purpose without

contacting the manufacture or supplier. Installers,

operators and maintainers are likely to encounter

this substance. When doubt exists as to correct

handling procedure, contact supplier.

HAZARDOUS REACTIONS

This liquid is extremely flammable (F+). Readily

forms an explosive air−vapor mixture at ambient

temps. Avoid smoking, heat sources, such as weld-

ing and naked flames, sparks and static electricity

build−up. Thermal decomposition products are haz-

ardous, containing CO

compounds.

The vapor is explosive. High vapor concentrations

can cause respiratory irritation, dizziness, nausea,

and loss of consciousness. Excessive and pro-

longed exposure to the mist can cause chronic in-

flammatory reaction of the lungs and form of pulmo-

nary fibrosis.

Vapor is heavier than air and may travel to remote

sources of ignition. Liquid leaks generate large vol-

umes of flammable vapor (approx 250:1).

Avoid strong oxidizing agents, e.g. chlorates which

may be used in agriculture

Cold burns (frost bite) will result from skin/eye con-

tact with liquid. Toxicity following single exposure to

high level of propane is of low order.

PROTECTIVE MEASURES

Ensure good ventilation and avoid heat sources.

Observance of good housekeeping rules will ensure

general safety. Do not smoke.

When working on, or testing, injection equipment,

special care is required. Use eye protection at all

times.

Adopt a high standard of personal hygiene. In the

case of skin contact, flush with water to normalize

temperature. Use gloves and overalls, and eye

protection goggles. Use oil impervious gloves and

avoid contamination inside the gloves. If overalls

become contaminated, discontinue use and clean

thoroughly. Contaminated clothing should be re-

moved, soaked with water, and laundered before re-

use.

No special respiratory precautions are necessary in

normal use.

STORAGE/TRANSPORT

Store and transport only in correctly marked con-

tainers. 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 trans-

fer.

In case of leak clear people away from area to a safe

place. DO NOT operate electrical equipment unless

flame proof. Summon emergency services and treat

or refer casualties as necessary.

Extinguish all naked lights − AVOID MAKING

SPARKS! Try to stop flow of product. Cover drains

and dispense vapor with water spray. Note: Vapor

may collect in confined spaces.

EMERGENCY ACTION

S Fire

Extinguishing media:

Large fire − None. Product flow must be

stopped and container cooled by water spray.

Water fog should be used to assist approach to

source of the fire.

Small fire − foam/dry powder, CO

Avoid making sparks. Fire fighters to sue self−

contained breathing apparatus. Keep fire ex-

posed containers cool, using water fog/spray.

Prevent run−off from entering waterway, drains

and drinking water supplies. Every precaution

must be taken to keep containers cool to avoid

the possibility of a boiling liquid expanding va-

por explosion (BLEVE).

S Ingestion: Not applicable

S Inhalation (of vapor)

Remove from further exposure. Obtain medical

assistance immediately.

S Eyes

Cold burns should be flushed with water to

normalize temperature. Cover burns with ster-

ile dressings. Do not use ointments or powders.

Obtain medical assistance as necessary.

S Skin

Cold burns should be flushed with water to

normalize temperature. Cover burns with ster-

ile dressings. Do not use ointments or powders.

Obtain medical assistance as necessary.

S Spillage: See Storage/Transport (Section 5, 7,

PETROL (UK) / GASOLINE

This product is also known as Petrol (UK) or Gaso-

line. It can be clear liquid with slight tan or yellow col-

or with a characteristic mild odor. It is a complex

combination of hydrocarbons consisting primarily of

paraffins, napthlenes, aromic and olefinic hydrocar-

bons having carbon numbers predominantly be-

tween C4 and C12.

The substance has an initial boiling point of

25−220C, a flash point greater than <−40C, and a

vapor pressure between 0.5 − 1 bars and has negli-

gible solubility in water.

It is used as a fuel for off−road Petrol powered ve-

hicles and stationary engines, and can be found in

fuel tanks, pipes and injection systems. The sub-

stance should not be used for any other purpose

without contacting the manufacture or supplier. In-

stallers, operators and maintainers are likely to en-

counter this substance.

HAZARDOUS REACTIONS

This liquid is extremely flammable. Avoid smoking,

heat sources, such as welding and naked flames,

sparks and static electricity build−up. Thermal de-

composition products are hazardous, containing

, NO

and SO

compounds.

The vapor is explosive. High vapor concentrations

can result in central nervous system and respiratory

depression with subsequent loss of consciousness.

Where ventilation is poor or temperatures high, va-

por production may be a hazard. Excessive and pro-

longed exposure to the mist can cause chronic in-

flammatory reaction of the lungs and form of pulmo-

nary fibrosis.

Avoid strong oxidizing agents, e.g. chlorates which

may be use in agriculture.

Petrol is slightly irritating to the skin and has a defat-

ting action. Toxicity following single exposure to

high level of Petrol is of low order. Prolonged, re-

peated skin contact may de−fat the skin resulting in

possible skin irritation and dermatitis. In some

cases warty, cancerous growths have occurred.

This product contains benzene (<1%) which is clas-

sified as a carcinogen. Exposure to Benzene may

result in blood disorders such as anaemia and leu-

kemia. Toxic to aquatic organisms, may cause

long−term adverse effects in aquatic environment.

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 laun-

dered before use.

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 con-

tainers. 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 trans-

fer.

vii

Contain leak/spill with sand, earth or other suitable

material, and prevent entry of substance into drain-

age/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.

EMERGENCY ACTION

S Fire

Extinguishing media:

Large fire − Foam/water fog. Never use water

jet.

Small fire − foam/dry powder, AAAF,CO

sand,

earth.

Avoid making sparks. Fire fighters to sue self−

contained breathing apparatus. Keep fire ex-

posed containers cool, using water fog/spray.

Prevent run−off from entering waterway, drains

and drinking water supplies.

S Ingestion

Do not induce vomiting. Wash the mouth out

with water, and send to hospital immediately.

S Inhalation (of vapor)

Remove from further exposure. Obtain medical

assistance immediately.

S Aspiration (inhalation of liquid)

If, following ingestion of gas oil, vomiting oc-

curs, 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.

S Eyes

Irrigate copiously with water or preferably eye−

wash solution for at least five minutes. If irrita-

tion persists seek medical advice.

S Skin

Wash thoroughly with soap and water. Change

clothing if necessary.

If high pressure injection has occurred prompt

surgical attention is required.

S Spillage

Absorb using sand, earth or other suitable ma-

terial. Dispose of unwanted or absorbed flam-

mable material as directed under Storage/

Transport (Section 5.7.3). In the event of a ma-

jor spillage, only trained personnel wearing self

contained breathing apparatus should handle

the spill. Any spillage or leak should be treated

as a major fire/explosion hazard. If vehicles

present, switch off engines.

LUBRICATION OIL − PREMIUM BLUE E

15W40

Also known as oil, lube oil, sump oil, new oil is dark,

viscous liquid with a slight, characteristic odor. The

base oil contains: distillates (petroleum), solvent−

dewaxed heavy paraffinic. It is not classified as dan-

gerous according to Directive 1999/45/EC and its

amendments, and is not classified according to the

EU regulations.

It has a boiling point greater than 150C, a flash

point Open Cup of 220C (Cleveland), and is insolu-

ble 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, oper-

ators 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

) and water.

Although harmful if swallowed or aspirated

(breathed in), repeated or prolonged exposure is

not know to aggravate medical conditions.

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 breath vapor/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 wa-

ter.

Use safety glasses, impervious gloves and lab coat.

Avoid contamination inside the gloves. If overalls

become contaminated, discontinue use and clean

thoroughly.

viii

No special respiratory precautions are necessary in

normal use. Do not breath vapor/spray when han-

dling hot materials.

STORAGE/TRANSPORT

Store and transport only in correctly marked con-

tainers. Keep containers tightly sealed when not in

use. Keep in cool, well ventilated area, out of sun-

light and away from naked flames. Store well away

from food − stuffs and drinking water.

Wear splash goggles, full suit, boots and gloves.

Absorb leak/spill with inert material and dispose of

unwanted or absorbed substance through an au-

thorized contractor to a licensed site. Finish clean-

ing by spreading water on the contaminate surface

and allow to evacuate through the sanitary system.

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.

1-1

1. Introduction

ABOUT THIS MANUAL

WARNING

This genset is not a life support sys-

tem. It can stop without warning. Children, per-

sons with physical or mental limitations, and

pets could suffer personal injury or death. A per-

sonal attendant, redundant power or an alarm

system must be used if genset operation is criti-

cal.

WARNING

This generator set is not “ignition

protected” and shall not be used in a flammable

vapor environment.

WARNING

Improper installation can result in

serious injury, death or equipment damage. The

installer must be qualified to perform the instal-

lation of electrical and mechanical equipment.

This manual covers operation and maintenance of

the KY Series of generator sets (gensets). Each op-

erator should study this manual carefully and ob-

serve all of its instructions and safety precautions.

Keep this manual and the Installation Manual with

the other vehicle manuals.

Operation, Periodic Maintenance and Trouble-

shooting provide the instructions necessary for op-

erating the genset and maintaining top perfor-

mance. The owner is responsible for maintenance

in accordance with the PERIODIC MAINTENANCE

SCHEDULE (Page 3-1). This manual also includes

genset specifications, information on how to obtain

service, and information for California users.

WARNING

This genset is not a life support sys-

tem. It can stop without warning. Children, per-

sons with physical or mental limitations, and

pets could suffer severe personal injury or

death. A personal attendant, redundant power

or an alarm system must be used if genset op-

eration is critical.

WARNING

Improper service or replacement of

parts can lead to severe personal injury or death

and to damage to equipment and property. Ser-

vice personnel must be qualified to perform

electrical and mechanical service.

WARNING

This generator set is not “ignition

protected” and shall not be used in a flammable

vapor environment.

MODEL IDENTIFICATION

Model and Serial Numbers: Refer to Figure 1-1 for

the location of the genset nameplate. Record the

model and serial numbers in the designated boxes

in Figure 1-1 so that they are handy when calling for

parts, service or product information. Each charac-

ter, including the last letter in the model number, is

important for obtaining the right parts.

Genuine Onan replacement parts are recom-

mended for best performance and safety.

Federal Emissions Compliance Period: The

Federal Emissions Compliance Period referred to

on the nameplate indicates the number of operating

hours for which the engine has been shown to meet

Federal emissions requirements. Category

C = 250 hrs, B = 500 hrs, A = 1000 hrs.

1-2

RECORD NUMBERS HERE

MODEL NUMBER:

SERIAL NUMBER:

The engine family designation, engine displacement, statement of

compliance with the applicable EPA and / or California emissions

regulations, including the compliance period or category, appear in

this block on the actual nameplate on the genset.

FIGURE 1-1. TYPICAL NAMEPLATE

1-3

NOISE

Generator sets emit noise. As noise level and timing

of exposure increase, risk of hearing damage in-

creses. The Specifications page in the Operator

manual states noise level for this generator set. Se-

lect and use personal hearing protection appropri-

ate for your exposure to generator set noise.

Note for use in countries where compliance to the

EU Noise directive is required: This generator set

has not been evaluate and is not marked for use in

open air. Install the generator set in accordance with

the Installation manual. Obey local noise restric-

tions when you operate the generator set.

ELECTROMAGNETIC COMPATIBILITY

Generator sets emit and receive electromagntic (ra-

dio frequency) energy. If the generator set affects

operation of nearby devices, or nearby devices af-

fect generator set operation, increase the distance

between them.

Note for use in countries where compliance to the

EMC directive is required: This generator set has

been evaluated for use in residential, commercial,

and light industrial environments.

TYPICAL GENSET

Figure 1-2 illustrates a typical genset and the fea-

tures requiring attention during operation and peri-

odic maintenance.

Removing the access cover: Turn the two cover

latches counterclockwise to OPEN and pull the top

of the cover outwards.

Securing the access cover: Position the bottom of

the cover so that its lip catches the top edge of the

base tray, rotate the top of the cover towards the

genset and turn the two cover latches clockwise to

CLOSED, making sure the latches catch.

WARNING

Operating the genset with the ac-

cess cover off can lead to severe burns and en-

gine damage due to overheating. Always secure

the cover after starting the genset.

1-4

MUFFLER WITH

CLEANOUT PLUGS

(accessible from below)

AIR CLEANER

COVER

ALTITUDE

ADJUST KNOB

OIL FILL CAP

& DIPSTICK

SPARK PLUG

(not shown)

CONTROL

PANEL

(See Figure 1-3)

OIL DRAIN PLUG

(accessible from below)

MAINTENANCE

ACCESS COVER

OUTPUT

LEADS

POS (+) BATTERY

CONNECTION

(inside)

NEG (−) BATTERY

& GROUND

CONNECTION

REMOTE

CONTROL

CONNECTION

(inside)

FUEL INLET

& FILTER

FIGURE 1-2. TYPICAL GENSET

FUEL RECOMMENDATIONS

WARNING

Gasoline and LPG are highly flam-

mable and explosive and can cause severe per-

sonal injury or death. Do not smoke or turn elec-

trical switches ON or OFF where fuel fumes,

tanks or equipment are present or in areas shar-

ing ventilation. Keep flames, sparks, pilot lights,

arc-producing equipment, switches and all oth-

er sources of ignition well away. Keep a type

ABC fire extinguisher in the vehicle.

Gasoline Models

Use clean, fresh unleaded gasoline having a mini-

mum octane rating (Anti-Knock Index) of 87.

Leaded gasoline may be used but will result in the

extra maintenance required for removing combus-

tion chamber and spark plug deposits. Do not use

gasoline or gasoline additives (de-icers) containing

methanol because methanol can be corrosive to

fuel system components.

1-5

CAUTION

Do not use gasoline or gasoline ad-

ditives containing methanol because methanol

can be corrosive to fuel system components.

CAUTION

Avoid using highly leaded gaso-

lines and lead additives because of the extra en-

gine maintenance that will be required.

LPG Models

Use clean, fresh HD-5 grade liquified petroleum gas

(LPG) or equivalent product consisting of at least

90 percent propane. Commercial liquified petro-

leum gas fuels may contain more than 2.5 percent

butane, which can result in poor fuel vaporization

and poor engine starting in ambient temperatures

below 32 F (0 C).

Satisfactory performance requires that the LPG va-

por be supplied at a pressure within the range indi-

cated in Specifications (Page 5-1).

WARNING

High LPG supply pressure can

cause gas leaks which can lead to fire and se-

vere personal injury or death. LPG supply pres-

sure must be adjusted to Specifications by qual-

ified personnel.

ENGINE OIL RECOMMENDATIONS

Use API (American Petroleum Institute) perfor-

mance Class SJ engine oil or better. Also look for

the SAE (Society of Automotive Engineers) viscos-

ity grade. Referring to Table 1-1, choose the viscos-

ity grade appropriate for the ambient temperatures

expected until the next scheduled oil change.

Single-grade SAE 30 oil is preferable when temper-

atures are consistently above freezing. Multigrade

oils are better when wide temperature variations are

expected.

TABLE 1-1. OIL VISCOSITY VS. TEMPERATURE

EXPECTED AMBIENT

TEMPERATURES

SAE VISCOSITY

GRADE

32 F (0 C) and higher 30

10 F to 100 F (−12 C to 38 C) 15W-40

0 F to 80 F (−18 C to 27 C)

10W-30

10W-40

−20 F to 50 F (−28 C to 10 C) 5W-30

STARTING BATTERIES

See Specifications (Page 5-1) regarding minimum

battery ratings for reliable genset cranking, espe-

cially in cold weather. Also see PERIODIC MAINTE-

NANCE SCHEDULE (Page 3-1) and the battery

manufacturer’s instructions regarding battery main-

tenance. Reliable genset starting and starter ser-

vice life depend upon adequate battery capacity

and proper maintenance.

1-6

GENSET CONTROL PANEL

The genset control panel (Figure 1-3) is located be-

hind the maintenance access cover (Figure 2) and

has the following features:

Control Switch − This switch is used to prime the

fuel system, start and stop the genset and display

the fault code. Hold the switch in its START position

to crank and start the genset. Press the switch to its

STOP position to stop the genset. Hold the switch in

its STOP/PRIME position to prime the fuel system

(gasoline models only). See Troubleshooting

(Page 4-1) about displaying fault codes.

Status Indicator Light − This light is an LED (light

emitting diode) in the control switch that blinks rap-

idly during cranking and stays on continuously when

the genset is running. If the genset shuts down ab-

normally, the light will blink a numerical code to indi-

cate the cause of the shutdown. See Troubleshoot-

ing (Page 4-1).

Line Circuit Breaker − The line circuit breaker pro-

tects the AC power leads connected to the genset

from overloads and equipment short circuits.

REMOTE CONTROL PANEL

The vehicle probably has a control panel inside the

vehicle for remote control of the genset. Onan offers

three remote control kits:

S Remote switch with status indicator light only

(Figure 1-4).

S Remote switch with status indicator light and

hour meter (Figure 1-5).

S Remote switch with status indicator light and

DC voltmeter (Figure 1-6).

The hour meter records genset operating time in

hours. It cannot be reset. See the PERIODIC MAIN-

TENANCE SCHEDULE (Page 3-1).

The DC voltmeter indicates whether voltage across

the 12 VDC control system and battery is normal. If

the indicator consistently stays above or below the

normal zone, see MAINTAINING THE BATTERY

AND BATTERY CONNECTIONS (Page 3-5).

LINE CIRCUIT

BREAKER

CONTROL SWITCH &

STATUS INDICATOR LIGHT

FIGURE 1-3. GENSET CONTROL PANEL

FIGURE 1-4. REMOTE SWITCH

FIGURE 1-5. REMOTE SWITCH / HOUR METER

FIGURE 1-6. REMOTE SWITCH / DC VOLTMETER

1-7

BUILD STANDARDS

The generator set and its control system have been designed, constructed and tested generally in accordance

with the following Standards where applicable refer to Table 1.

TABLE 1. BUILD STANDARDS

BS EN 1037:1995+A1:2008 Safety of machinery − Prevent of unexpected start up.

BS EN ISO 14121−1:2007 Safety of machinery. Risk assessment. Principles

BS EN ISO 13857:2008

Safety of machinery. Safety distance to prevent hazard zones be-

ing reached by upper and lower limbs.

BS EN 349:1993+a1:2008

Safety of machinery − Minimum gaps to avoid crushing parts on

the human body.

BS EN 547−1: 1996+A1:2008

Safety of machinery − Human body dimensions − Part 1: Prin-

ciples of determining the dimensions required for openings for

whole body access into machinery.

BS EN 547−2:1996+A1:2008

Safety of machinery − Human body dimensions − Part 2: Prin-

ciples for determining the dimensions required for access open-

ings.

BS EN 547−3:1996+A1:2008

Safety of machinery − Human body dimensions − Part 3: Anthro-

pomorphic data.

BS EN 60204−1:2006+A1:2009

Safety of machinery. Electrical equipment of machines. General

requirements

BS EN 614−1:2006+A1:2009

Safety of machinery. Ergonomic design principles. Terminology

and general principles

BS EN 953:1997+A1:2009

Safety of machinery − Guards − General requirements for the de-

sign and construction of fixed and movable guards.

BS EN ISO 12100−1:2003+A1:2009

Safety of machinery. Basic concepts, general principles for de-

sign. Basic terminology, methodology

BS EN ISO 12100−2:2003+A1:2009

Safety of machinery. Basic concepts, general principles for de-

sign. Technical principles

BS EN ISO 13732−1:2008

Ergonomics of the thermal environment. Methods for the assess-

ment of human responses to contact with surfaces. Hot surfaces

BS EN ISO 13849−1:2008 Safety of machinery − Safety related parts of control systems

BS EN ISO 13850:2006 Safety of machinery − Emergency stop. Principles for design.

BS EN 61310−1:2008

Safety of machinery − Indication, marking and actuation − Part 1:

Requirements for visual, auditory and tactile signals.

BS EN 61310−2:2008

Safety of machinery − Indication, marking and actuation − Part 2:

Requirements for marking.

BS EN 61000−6−1:2007

Electromagnetic compatibility (EMC). Generic standards. Immu-

nity standard for residential, commercial and light−industrial envi-

ronments

1-8

BS EN 61000−6−3:2007

Electromagnetic compatibility (EMC). Generic standards. Emis-

sion standard for residential, commercial and light−industrial en-

vironments

BS EN 1299:1997+A1:2008

Mechanical vibration and shock − Vibration isolation of machines

− Information for the application of source isolation

BS EN 12601:2001

Reciprocating internal combustion engine driven generating sets

− Safety

2-1

2. Operation

WARNING

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous

and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:

 Dizziness  Throbbing in Temples  Nausea

 Muscular Twitching  Headache  Vomiting

 Weakness and Sleepiness  Inability to Think Clearly

IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH

AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the genset and do not op-

erate it until it has been inspected and repaired.

Never occupy the vehicle with the genset running unless the vehicle is equipped with a working car-

bon monoxide detector. Primary protection against inhaling carbon monoxide, however, is proper

installation of the exhaust system, daily (every eight hour) inspection for visible and audible exhaust

system leaks.

CONDUCTING THE PRE-START CHECKS

Before the first start of the day and after every eight

hours of operation, inspect the genset as instructed

under CONDUCTING GENERAL INSPECTIONS

(Page 3-2). Keep a log of maintenance and the

hours run and perform any maintenance that may

be due. See RETURNING THE GENSET TO SER-

VICE (Page 2-6) if the vehicle has been in storage.

Before each start:

1. Make sure all vehicle CO detectors are work-

ing.

2. Check for signs of fuel and exhaust leaks and

for damage to the exhaust system.

3. Turn off the air conditioner and other large ap-

pliances.

PRIMING THE FUEL SYSTEM

If the genset ran out of fuel (gasoline models only)

prime the fuel system by holding the control switch

at STOP/PRIME for 30 seconds. (The status indica-

tor light will stay on while the pump is on.)

STARTING THE GENSET

Start the genset from the genset control panel or re-

mote control panel inside the vehicle (Page 1-6).

1. Visually inspect for fuel and exhaust leaks. Do

not start the genset if there is a fuel or exhaust

leak and have it repaired.

2. Push and hold the switch at START until the

genset starts. The status indicator light on the

switch flashes while cranking. It will stay on

continuously when the genset is running.

3. The genset will shut down in 15 to 20 seconds

if it does not start and the status indicator light

will blink Fault Code No. 4. See Troubleshoot-

ing (Page 4-1). Wait 5 seconds for the control

to reset before trying again. After five tries let

the starter motor cool down for 30 seconds be-

fore trying again.

CAUTION

The starter motor can be dam-

aged by overheating if not allowed to cool

down for at least 30 seconds after every fifth

crank.

4. See Troubleshooting (Page 4-1) if the engine

shuts down and the status indicator light blinks.

5. For top performance and engine life, especially

in colder weather, let the engine warm up for

two minutes before connecting appliances.

6. Always secure the access cover after starting

the genset at the genset control panel.

2-2

WARNING

Operating the genset with the

access cover off can lead to severe burns

and engine damage due to overheating. Al-

ways secure the cover after starting the

genset.

STOPPING THE GENSET

Turn off the air conditioner and other large ap-

pliances and let the genset run for two minutes to

cool down. This reduces backfiring and run-on.

Then press the switch to STOP to stop the genset.

RESTARTING THE GENSET

See Troubleshooting (Page 4-1) if the genset shuts

down abnormally.

LOADING THE GENSET

The genset can power AC motors, air conditioners,

AC/DC converters and other appliances. How much

appliance load* can be powered depends upon the

genset power rating. The genset will shut down or its

circuit breakers will trip if the sum of the loads ex-

ceeds genset power.

To avoid overloading the genset and causing shut-

downs, compare the sum of the loads of the ap-

pliances that are likely to be used at the same time to

the power rating of the genset. Use Table 2-1 or the

ratings on the appliances themselves (if so marked)

to obtain the individual appliance loads. It may be

necessary to run fewer appliances at the same

time—the sum of the loads must not be greater

than genset rating.

Note that the genset may shut down due to over-

load—even though the sum of the loads is less than

genset rating—when a large motor or air conditioner

is started last or cycles off and then on again. The

reason for this is that a motor’s startup load is much

larger than its running load. It may be necessary to

run fewer appliances when large motors and air

conditioners are cycling on and off.

TABLE 2-1. TYPICAL APPLIANCE LOADS

Appliance

Load (watts)

Air Conditioner 1400-2000

Battery Charger Up to 800

DC Converter 300-500

Refrigerator 600-1000

Microwave Oven 1000-1500

Electric Frying Pan or Wok 1000-1500

Electric Stove Element 350-1000

Electric Water Heater 1000-1500

Electric Iron 500-1200

Electric Hair Dryer 800-1500

Coffee Percolator 550-750

Television 200-600

Radio 50-200

Electric Drill 250-750

Electric Broom 200-500

Electric Blanket 50-200

Note also that air density decreases as altitude in-

creases, causing genset engine power to de-

crease.** Power decreases approximately 3.5 per-

cent of rated power each 1000 feet (305 m) of in-

crease in elevation. See Table 2-2 for typical cal-

culations. It may be necessary to run fewer ap-

pliances at higher altitudes.

TABLE 2-2. POWER VS. ALTITUDE

Elevation above Mean

Sea Level

Maximum Genset

Power*

up to 500 ft (152 m) 4000 watts (rated)

2500 ft (762 m) 3720 watts

5500 ft (1676 m) 3300 watts

above 5500 ft

(1676 m)

3300 watts minus 140 watts

each 1000 ft (305 m)

* This table does not take into account the effect cir-

cuit breakers may have in limiting maximum power.

* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).

** Power decreases even though the altitude adjust knob is set correctly (Page 2-4).

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CUMMINS QG 4000/3600 LP KY User manual

Brand: CUMMINS

Model: QG 4000/3600 LP KY

Category: Power generators

Type: User manual

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CUMMINS QG 4000/3600 LP KY User manual

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