Operation and Maintenance Manual
Contents
1. scraper on the spots rather than spending time polishing the whole surface with an air sander or disc For those gaskets that do not have the edge molding nearly all have a material that contains release agents to prevent sticking Certainly this is not to say that some gaskets are not difficult to remove because the gasket has been in place a long time has been overheated or the purpose of the release agent has been defeated by the application of some sealant The object however is just to remove the gasket without damaging the surfaces of the mating parts without contaminating the engine don t let the little bits fall where they cannot be removed Page 9 of 27 Bead blasting piston crowns until the dark stain is removed is unnecessary All that is required is to remove the carbon build up above the top ring and in the ring grooves There is more information on bead blasting and piston cleaning later in this document Cummins Inc does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean metal is visible The liner will be ruined and any signs of a problem at the top ring reversal point like a dust out will be destroyed It is necessary to remove the carbon ring to provide for easier removal of the piston assembly A medium bristle high quality steel wire wheel that is rated above the rom of the power tool being used will be just as quick and there will be less damage Yes one must look carefully for b2. For gas fueled generator sets shorter maintenance intervals are also required if operating at loads below 70 for prolonged periods Contact your local Cummins Authorized Repair Location for recommended maintenance intervals Some of these maintenance procedures require special tools or must be completed by qualified personnel Contact your local Cummins Authorized Repair Location for detailed information If your system is equipped with a component or accessory not manufactured or supplied by Cummins Inc refer to the component manufacturer s maintenance recommendations Page 18 of 27 OEM supplied equipment and components can impact on the performance and reliability of the engine if they are not correctly maintained Tool Requirements Most of the maintenance operations described in this manual can be performed with common hand tools metric and SAE wrenches sockets and screwdrivers Each manual has a list of special service tools required for some of the maintenance operations in each Operation and Maintenance Manual Procedure 102 004 in Section 2 Maintenance Schedule Perform maintenance at whichever interval occurs first At each scheduled maintenance interval perform all previous maintenance checks that are due for scheduled maintenance Maintenance Schedules are provided in each Operation and Maintenance Manual in Procedure 102 002 in Section 2 Maintenance Record Form A maintenance record form is provided to recor
3. If not reused dispose of in accordance with local environmental regulations e The catalyst reagent contains urea Do not get the substance in your eyes In case of contact immediately flood eyes with large amounts of water for a minimum of 15 minutes Avoid prolonged contact with skin In case of contact immediately wash skin with soap and water Do not swallow internally In the event the catalyst reagent is ingested contact a physician immediately e The catalyst substrate contains Vanadium Pentoxide Vanadium Pentoxide has been determined by the State of California to cause cancer Always wear protective gloves and eye protection when handling the catalyst assembly Do not get the catalyst material in your eyes In Case of contact immediately flood eyes with large amounts of water for a minimum of 15 minutes Avoid prolonged contact with skin In case of contact immediately wash skin with soap and water e The Catalyst substrate contains Vanadium Pentoxide Vanadium Pentoxide has been determined by the State of California to cause cancer In the event the catalyst is being replaced dispose of in accordance with local regulations e 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 General Repair Instructions This engine or system incorporates the latest technology at the time it was manufactured yet
4. Numerous illustrations and symbols are used to aid in understanding the meaning of the text Refer to Symbols in this section for a complete listing of symbols and their definitions How to Use the Manual The engine O amp M manuals are organized according to intervals at which maintenance on the engine is to be performed A maintenance schedule that states the required intervals and maintenance checks is located in Maintenance Guidelines Section 2 of each engine manual Locate the interval at which you are performing maintenance then follow the steps given in that section for all the procedures Keep a record of all the checks and inspections made A maintenance record form is located in Maintenance Guidelines Section 2 Engine troubleshooting procedures for your engine are located in Troubleshooting Symptoms Section TS Specifications for your engine are located in Maintenance Specifications Section V Symbols The following symbols have been used in the manuals to help communicate the intent of the instructions When one of the symbols appears it conveys the meaning defined below WARNING Serious personal injury or extensive property damage can result if the warning instructions are not followed PERFORM a mechanical or time MEASUREMENT CAUTION Minor personal injury can result or a LUBRICATE the part or assembly part an assembly or the engine can be damaged if the caution instructions are not followed indicates t
5. Ss PONER G SAL E Operation and Maintenance Manual Page 1 of 27 Forward This manual contains information for the correct operation and maintenance of your Cummins engine It also includes important safety information engine systems specifications troubleshooting guidelines listings of Cummins authorized repair locations and component manufacturers Read and follow all safety instructions Refer to the WARNING in the General Safety Instructions in Section i Introduction Keep this manual with the equipment If the equipment is traded or sold give the manual to the new owner The information specifications and recommended maintenance guidelines in this manual are based on information in effect at the time of printing Cummins Inc reserves the right to make changes at any time without obligation If you find differences between your engine and the information in this manual contact your local Cummins authorized repair location or call 1 800 DIESELS 1 800 343 7357 toll free in the U S and Canada The latest technology and the highest quality components were used to produce this engine When replacement parts are needed we recommend using only genuine Cummins or ReCon exchange parts NOTE Warranty information is located in Section W Make sure you are familiar with the warranty or warranties applicable to your engine Page 2 of 27 Table of Contents Section i Introduction Section E Engine Identific
6. material and plastic beads after cleaning Rinse with hot water Dry with compressed air A CAUTION A The bead blasting operation must not disturb the metal surface lf the metal surface Is disturbed the engine can be damaged due to increased parts clearance or inadequate surface finish on parts that move against other parts When cleaning pistons it is not necessary to remove all the dark stain from the piston All that is necessary is to remove the carbon on the rim and in the ring grooves This is best done by directing the blast across the part as opposed to straight at the part If the machining marks are disturbed by the blasting process then the pressure is too high or the blast is being held on one spot too long The blast operation must not disturb the metal surface Walnut shell bead blast material is sometimes used to clean ferrous metals iron and steel Walnut shell blasting produces a great amount of dust particularly when the pressure if the air pressure on the blasting machine is increased above media manufacturer s recommendation Cummins Inc recommends not using walnut shell media to clean engine parts due to the risk media embedment and subsequent contamination of the engine Cummins Inc does not recommend you use glass bead media to clean any engine parts Glass media is too easily embedded into the material particularly in soft materials and when air pressures greater than media manufacturer s recommend are used The g
7. on or after January 1 2004 that are certified to CFR 94 1107 Coverage Cummins warrants to the ultimate purchaser and each subsequent purchaser that the Engine is designed built and equipped so as to conform at the time of sale by Cummins with all United States Federal emission regulations applicable at the time of manufacture and that it is free from defects in material or factory workmanship which would cause it not to meet these regulations within the longer of the following periods A Five years or 5 000 hours of operation whichever occurs first as measured from the date of delivery of the engine to the first user or the date the unit is first leased rented or loaned or when the Engine has been operated for 50 hours whichever occurs first or B The Base Engine Warranty Limitations Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or neglect including but not limited to operation without adequate coolants or lubricants over fueling over speeding lack of maintenance of cooling lubrication or intake systems improper storage starting warm up run in or shutdown practices unauthorized modifications to the Engine Cummins is also not responsible for failures caused by incorrect oil or fuel or by water dirt or other contaminants in the fuel or oil Cummins is not responsible for failures resulting from 1 Use or application of the Product inconsis
8. particles can be forced into the liner material which can cause early cylinder wear out or piston ring failures Tape off or plug all openings to any component interior before using abrasive pads or wire brushes If really necessary because of time to use a power tool with abrasive pads tape the oil drillings closed or use plug and clean as much of the surface as possible with the tool but clean around the oil hole opening by hand so as to prevent contamination of the drilling Then remove the tape or plug and clean the remaining area carefully and without the tool DO NOT use compressed air to blow the debris out of oil drilling on an assembled engine More likely than not the debris can be blown further into the drilling Using compressed air is fine if both ends of the drilling are open but that is rarely the case when dealing with an assembled engine Gasket Surfaces The object of cleaning gasket surfaces is to remove any gasket material not refinish the gasket surface of the part Cummins Inc does not recommend any specific brand of liquid gasket remover If a liquid gasket remover is used check the directions to make sure the material being cleaned will not be harmed Air powered gasket scrapers can save time but care must be taken to not damage the surface The angled part of the scraper must be against the gasket surface to prevent the blade from digging into the surface Using air powered gasket scrapers on parts made of soft mate
9. NCIDENTAL OR CONSEQUENTIAL DAMAGES THESE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY CUMMINS IN REGARD TO THESE GENERATOR SETS CUMMINS MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED OR OF MERCHANTABILITY OR FITNESS Last Modified 13 Nov 2006 FOR A PARTICULAR PURPOSE In the United States and Canada this warranty gives you specific legal rights You may also have other rights which vary from state to state Outside the United States and Canada in case of consumer sales in some countries the Owner has statutory rights which cannot be affected or limited by the terms of this warranty Nothing in this warranty excludes or restricts any contractual rights the Owner may have against third parties Locations in the United States and Canada are listed in the Cummins United States and Canada Sales and Service Directory other locations are listed in the Cummins International Sales and Service Directory United States includes American Samoa the Commonwealth of Northern Mariana Islands Guam Puerto Rico and the U S Virgin Islands Copyright 2000 2010 Cummins Inc All rights reserved Page 26 of 27 Section AS Alternator Servicing Each genset has a different alternator which has a manual available on the marine website marine cummins com under the Genset tab Publications and Manuals Below is a list matching the engine packages with an alternator Alternator Model Designati
10. Once embedded in one part it will abrade the other part until contact is no longer being made between the two parts If the damage sufficiently degrades the oil film the two parts will come into contact resulting in early wear out or failure from lack of effective lubrication Abrasive particles can fly about during cleaning it is very important to block these particles from entering the engine as much as possible This is particularly true of lubricating oil ports and oil drilling holes especially those located downstream of the lubricating oil filters Plug the holes instead of trying to blow the abrasive particles and debris with compressed air because the debris is often simply blown further into the oil drilling All old gasket material must be removed from the parts gasket surfaces However it is not necessary to clean and polish the gasket surface until the machining marks are erased Excessive sanding or buffing can damage the gasket surface Many newer gaskets are of the edge molded type a steel carrier with a sealing member bonded to the steel What little sealing material that can adhere is best removed with a blunt edged scraper or putty knife Cleaning gasket surfaces where an edge molded gasket is used with abrasive pads or paper is usually a waste of time A WARNING Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner beyond reuse The surface finish will be damaged and abrasive
11. Power Take Off Rear Gear Train Revolutions Per Minute REPTO RGT D lt lt a co co oO q OJ OJ li Society of Automotive Engineers supplemental Coolant Additive Selective Catalytic Reduction step Timing Control subsystem Identification Descriptions Volts of Direct Current Variable Speed co O Section E Engine and System Identification Engine Identification The engine data plate shows important facts about the engine The engine serial number and CPL provide data for ordering parts and service The engine data plate must not be changed unless approved by Cummins Inc Refer to the appropriate engine Owners and Maintenance Manual Procedure 100 001 in Section E for the correct engine data plate location and information Have the following engine data available when communicating with a Cummins authorized repair location Page 16 of 27 The following information on the data plate is mandatory when sourcing service parts Engine serial number Model Horsepower and rpm rating CPL Emission statement if applicable Engine Diagrams The illustrations contain information about engine components filter locations drain points and access locations for instrumentation and engine controls The information and configuration of components shown in these illustrations are of a general nature Some component locations will vary depending on applications and installations Refer to the app
12. aint can enter the fuel system whenever a fuel line or other component is loosened or removed from the engine In many instances a good practice is to loosen a line or fitting to break the rust and paint loose and then clean off the loosened material When removing fuel lines or fittings from a new or newly painted engine make sure to remove loose paint flakes chips that can be created when a wrench contacts painted line nuts or fittings or when quick disconnect fittings are removed Fuel filters are rated in microns The word micron is the abbreviation for a micrometer or one millionth of a meter The micron rating is the size of the smallest particles that will be captured by the filter media As a reference a human hair is 76 microns 0 003 in in diameter One micron measures 0 001 mm 0 00004 in The contaminants being filtered out are smaller than can be seen with the human eye a magnifying glass or a low powered microscope The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination Like fuel system parts tools that are coated with oil or fuel attract airborne contaminants Remember the following points regarding your fuel system tools Fuel system tools are to be kept as clean as possible Clean and dry the tools before returning them to the tool box If possible store fuel system tools in sealed containers Make sure fuel system tools are clean before use Page 15 of 27 Acr
13. ation Section 1 Operating Instructions Section 2 Maintenance Guidelines Section 3 Maintenance Procedures At Daily Intervals Section 4 Maintenance Procedures Section A Adjustment Repairs and Replacement Section D System Diagrams Section L Service Literature Section S Service Assistance Section SS Seasonal Storage Marine Only Section TS Troubleshooting Symptoms Section V Maintenance Specifications Section W Cummins C Power C Safe Warranty 4082004 Section AS Alternator Servicing Section C Control Panels Page 3 of 27 Section i Introduction General Information Preventive maintenance is the easiest and least expensive type of maintenance Follow the maintenance schedule recommendations outlined in Maintenance Guidelines Section 2 Keep records of regularly scheduled maintenance Use the correct fuel lubricating oil and coolant in your engine as specified in Maintenance Specifications Section V Blending engine oil with fuel is prohibited for engines with an aftertreatment system Cummins Inc uses the latest technology and the highest quality components to produce its engines Cummins Inc recommends using genuine Cummins new parts and ReCon exchange parts Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support If you have a problem that cannot be resolved by a Cummins authorized repair location follow the steps outlined i
14. d service intervals in each Operation and Maintenance Manual Procedure 102 001 in Section 2 The same record is used for all engines Section 3 Maintenance Procedures at Daily Intervals Preventative maintenance begins with day to day awareness of the system Before starting the system check the appropriate fluid levels and look for items listed below Leaks Loose or damaged parts Worn or damaged belts Worn or damage low and high voltage harnesses Any change in system appearance Odor of fuel Odor of electronic devices System Operation Report The system must be maintained in top mechanical and electronic condition if the operator is to get optimum satisfaction from its use The maintenance department needs daily running reports from the operator to make necessary adjustments in the time allocated The daily running report also helps to make provisions for more extensive maintenance work as the reports indicate the necessity Comparison and intelligent interpretation of the daily report along with a practical follow up action will eliminate most failures and emergency repairs Report to the maintenance department any of the following conditions that may apply Low lubricating oil pressure Low power Power increases or engine surge Erratic or no accelerator control or response Any warning lights flashing or staying on Page 19 of 27 Abnormal water or oil temperature Unusual system noise Excessive smoke Excessive us
15. duct failure Owner is responsible for the cost of towing the boat to the repair dock and for all associated docking and harbor charges Page 24 of 27 Owner is responsible for communication expenses meals lodging and similar costs incurred as a result of a Warrantable Failure Owner is responsible for maintaining the Engine hour meter in good working order at all times and ensuring that the hour meter accurately reflects the total hours of operation of the Product Owner is responsible for the costs to investigate complaints unless the problem is caused by a defect in Cummins material or factory workmanship Owner is responsible for non Engine repairs downtime expensed cargo damage fines all applicable taxes all business costs and other losses resulting from a Warrantable Failure CUMMINS RIGHT TO FAILED COMPONENTS Failed components claimed under warranty remain the property of Cummins Inc Cummins has the right to reclaim any failed component that has been replaced under warranty Cummins Inc reserves the right to interrogate Electronic Control Module ECM data for purposes of failure analysis Emission Warranty Products Warranted This Emission Warranty applies to new Engines sold by Cummins that are used in the United States in marine propulsion and marine auxiliary applications and that are required by United States CFR 94 1107 to have an Emission Warranty This Warranty applies to Engines built
16. e all types of dirt that can contaminate the cleaning tank It is a good method for cleaning the oil drillings and coolant passages Page 12 of 27 A WARNING When using a steam cleaner wear safety glasses or a face shield as well as protective clothing Hot steam can cause serious personal injury Do not steam clean the following components Electrical Components Wiring Harnesses Injectors Fuel Pump Belts and Hoses Bearings ball or taper roller Electronic Control Module ECM ECM Connectors Dosing Control Unit Nox Sensor Plastic Bead Cleaning Cummins Inc does not recommend the use of glass bead blast or walnut shell media on any engine part Cummins Inc recommends using only plastic bead media part number 3822735 or equivalent on any engine part Never use sand as a blast media to clean engine parts Glass and walnut shell media when not used to the media manufacturer s recommendations can Cause excess dust and can embed in engine parts that can result in premature failure of components through abrasive wear Plastic bead cleaning can be used on many engine components to remove carbon deposits The cleaning process is controlled by the use of plastic beads the operating pressure and cleaning time A CAUTION A Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston piston skirt or piston crown Small particles of the media will embed in the aluminum or other soft
17. e end of the periods of Coverage Cummins ___ Responsibilities During Base Generator Set Warranty Cummins will pay for all parts and labor needed to repair the damage to the Product resulting from a Warrantable Failure when performed during normal business hours All labor costs will be paid in accordance with Cummins published Standard Repair Time guidelines When it is necessary for mechanics to make on site warranty repairs Cummins will cover reasonable travel expenses including meals mileage and lodging for mechanics to travel to and from the repair dock Cummins will pay for the lubricating oil antifreeze filter elements and other maintenance items that are not reusable due to the Warrantable Failure Cummins will pay for reasonable labor costs for Generator Set removal and reinstallation when necessary to repair a Warrantable Failure During the Engine Extended Major Components Warranty Cummins will pay for the repair or at its option replacement of the defective Covered Part and any Covered Part damaged by a Warrantable Failure of the defective Covered Part Owner Responsibilities During base generator set warranty Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenance items replaced during warranty repairs unless such items are not reusable due to the Warrantable Failure During the Engine Extended Major Components Warranty Owner is responsible fo
18. e of coolant fuel or lubricating oil Any fuel coolant or lubricating oil leaks Loose or damaged parts Worn or damaged belts Worn or damaged low or high voltage harnesses Unusual System Noise During daily maintenance checks listen for any unusual system noise s that can indicate that service Is required Follow the Maintenance Procedures at Daily Intervals in Section 3 in the appropriate Operation and Maintenance Manual Section 4 Maintenance Procedures Maintenance procedures and intervals are different for each engine Information for each procedure and interval can be found on line at https quickserve cummins com qs2 portal index html in the appropriate Operation and Maintenance Manual listed below C Power C Safe Base Engine Bulletin Numbers Operation and Troubleshooting and Repair Parts Manual Genset Maintenance Bulletin Bulletin n ENa 6B CP 6B CS 402138 3006087 4050538 Section 5 Adjustment Repairs and Replacement Adjustments Repairs and Replacement of parts are different for each engine Information for each procedure and interval can be found in Section 5 of the appropriate Operation and Maintenance Manual Page 20 of 27 Section D System Diagrams The following drawings show the flow through the engine systems Although the parts can be different for various applications and installations the flow remains the same The systems shown are Fuel system Lubricating oil system C
19. enuine Cummins or Cummins ReCon replacement parts e Always use the same fastener part number or equivalent when replacing fasteners Do not use a fastener of lesser quality if replacements are necessary e When necessary the removal and replacement of any guards covering rotating components drives and or belts should only be carried out be a trained technician Before removing any guards the engine must be turned off and any starting mechanisms must be isolated All fasteners must be replaced on re fitting the guards e Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair functioning e Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity Avoid inhalation of vapors ingestion and prolonged contact with used engine oil e Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring This can cause electrical damage to the ignition or governor e Always torque fasteners and fuel connections to the required specifications Over tightening or under tightening can allow leakage This is critical to the natural gas and liquefied petroleum gas fuel and air systems e Always test for fuel leaks as instructed as odorant can fade e Close the manual fuel valves prior to performing maintenance and repairs and when storing the vehicle inside e Coolant is toxic
20. first and discharge any capacitors before beginning any repair work Disconnect the air starting motor if equipped to prevent accidental engine starting Put a Do Not Operate tag in the operator s compartment or on the controls e Use ONLY the proper engine barring techniques for manually rotating the engine Do not attempt to rotate the crankshaft by pulling or prying on the fan This practice can cause serious personal injury property damage or damage to the fan blade s causing premature fan failure e fan engine has been operating and the coolant is hot allow the engine to cool before slowly loosening the filler cap to relieve the pressure from the cooling system e Always use blocks or proper stands to support the product before performing any service work Do not work on anything that is supported ONLY by lifting jacks or a hoist e Relieve all pressure in the air oil fuel and cooling systems before any lines fittings or related items are removed or disconnected Be alert for possible pressure when disconnecting any device from a system that utilizes pressure Do not check for pressure leaks with your hand High pressure oil or fuel can cause personal injury e To reduce the possibility of suffocation and frostbite wear protective clothing and ONLY disconnect liquid refrigerant Freon lines in a well ventilated area To protect the environment liquid refrigerant systems must be properly emptied and filled using equipment that
21. h such substances Always use good safety practices with tools and equipment Provide a clean environment and follow the cleaning instructions specified in the procedures The engine or system and its components must be kept clean during any repair Contamination of the engine system or components will cause premature wear All components must be kept clean during any repair Contamination of the components will cause premature wear Perform the inspections specified in the procedures Replace all components or assemblies which are damaged or worn beyond the specifications Use genuine Cummins new or ReCon service parts and assemblies Page 8 of 27 e The assembly instructions have been written to use again as many components and assemblies as possible When it is necessary to replace a component or assembly the procedure is based on the use of new Cummins or Cummins ReCon components All of the repair services described in this manual are available from all Cummins Distributors and most Dealer locations e Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the components Welding on a Vessel with an Electronic Controlled Fuel System A CAUTION A Disconnect both the positive and negative battery cables from the low voltage battery before welding on the vehicle Attach the welder ground cable no more than 0 61 meters 2 feet from the part being welded Do not connect the ground clam
22. hat a WRENCH or TOOL SIZE will be given Indicates a REMOVAL or DISASSEMBLY step As TIGHTEN to a specific torque Indicates an INSTALLATION or ASSEMBLY step PERFORM an electrical MEASUREMENT OA INSPECTION is required Refer to another location in this manual or another gt publication for additional information The component weighs 23 kg 50 lbs or more To reduce the possibility of personal injury use a hoist or get assistance to lift the component CLEAN the part or assembly GOLV e gt amp Page 5 of 27 General Safety Instructions A WARNING amp Improper practices carelessness or ignoring the warnings can cause burns cuts mutilation asphyxiation or other personal injury or death Read and understand all of the safety precautions and warnings before performing any repair This list contains the general safety precautions that must be followed to provide personal safety Special safety precautions are included in the procedures when they apply e Work in an area surrounding the product that is dry well lit ventilated and free from clutter loose tools parts ignition sources and hazardous substances Be aware of hazardous conditions that can exist Always wear protective glasses and protective shoes when working Rotating parts can cause cuts mutilation or strangulation Do not wear loose titting or torn clothing Remove all jewelry when working Disconnect the battery negative cable
23. ins Engine alternator and accessories which are approved and supplied by Cummins have a Cummins part number and which are either fitted by Cummins or a Cummins authorized distributor Base Generator Set Warranty This warranty covers failures of the Product under normal use and service which result from defects in Cummins material or factory workmanship Warrantable Failure Coverage begins with the sale of the Engine by Cummins and continues for one year with unlimited hours The Duration commences on either the date of delivery of the Product to the first end user or the date the unit is first leased rented or loaned or when the product has been operated for 50 hours whichever occurs first The warranty is valid subject to appropriate usage under the generator set power rating below Prime Power Engines with this rating are available for an unlimited number of hours per year in variable load applications Variable load is not to exceed a 0 percent average of the Prime Power rating during any operating period of 250 hours Total operating time at 100 percent Prime Power shall not exceed 500 hours per year Equipment Covered by the Base Warranty The Generator Set consists of 1 The engine and all components mounted on it with a valid Cummins part number 2 All items with a Cummins part number mounted on the Generator Set and or generator set base frame as shipped from the producing factory 3 Cummins sup
24. iston groove or rim have been disturbed then there has not been enough movement of the nozzle and or the air pressure is too high Never bead blast valve stems Tape or use a sleeve to protect the stems during bead blasting Direct the nozzle across the seat surface and radius rather than straight at them The object is to remove any carbon build up and continuing to blast to remove the stain is a waste of time Fuel System When servicing fuel system components that can be exposed to potential contaminants prior to disassembly clean the fittings mounting hardware and the area around the component lf the surrounding areas are not cleaned dirt or contaminants can be introduced into the fuel system The internal drillings of some injectors are extremely small and susceptible to plugging from contamination Some fuel injection systems can operate at very high pressures High pressure fuel can convert simple particles of dirt and rust into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors Electrical contact cleaner can be used if steam cleaning tools are not available Use electrical contact cleaner rather than compressed air to wash dirt and debris away from fuel system fittings Diesel fuel on exposed fuel system parts attracts airborne contaminants Choose lint free towels for fuel system work Cap and plug fuel lines fittings and ports whenever the fuel system is opened Rust dirt and p
25. it is designed to be repaired using normal repair practices performed to quality standards Page 7 of 27 A WARNING Cummins Inc does not recommend or authorize any modifications or repairs to components except for those detailed in Cummins Service Information In particular unauthorized repair to safety related components can cause personal injury or death Below is a partial listing of components classified as safety related E oe a Air Compressor Air Controls Air Shutoff Assemblies Balance Weights Cooling Fan Fan Hub Assembly Fan Mounting Bracket s Fan Mounting Capscrews Fan Hub Spindle Flywheel Flywheel Crankshaft Adapter Flywheel Mounting Capscrews Fuel Shutoff Assemblies Fuel Supply Tubes Lifting Brackets Throttle Controls Turbocharger Compressor Casing Turbocharger Oil Drain Line s Turbocharger Oil Supply Line s Turbocharger Turbine Casing Vibration Damper Mounting Capscrews Manual Service Disconnect High Voltage Interlock Loop High Voltage Connectors Connections and Harnesses High Voltage Battery System Power Inverter Generator Motor Clutch Pressure Plate Follow all safety instructions noted in the procedures Follow the manufacturer s recommendations for cleaning solvents and other substances used during repairs Some solvents have been identified by government agencies as toxic or carcinogenic Avoid excessive breathing ingestion and contact wit
26. lass is an abrasive so when it is in a moving part that part is abrading all the parts in contact with it When higher pressures are used the media is broken and forms a dust of a very small size that floats easily in the air This dust is very hard to control in the shop particularly if only compressed air and not hot water is used to blow the media after it is removed from the blasting cabinet blowing the part off inside the cabinet may remove large accumulations but never removes all the media Bead blasting is best used on stubborn dirt carbon build up that has not been removed by first steam higher pressure washing then washing in a heated wash tank This is particularly true of pistons Steam and soak the pistons first then use the plastic bead method to safely remove the carbon remaining in the grooves instead of running the risk of damaging the surface finish of the groove with a wire wheel or end of a broken piston ring Make sure the parts are dry and oil free before bead blasting to prevent clogging the return on the blasting machine Always direct the bead blaster nozzle across rather than directly at the part This allows the bead to get under the unwanted material Page 14 of 27 Keep the nozzle moving rather than hold on one place Keeping the nozzle directed at one place too long causes the metal to heat up and be moved around Remember that the spray is not just hitting the dirt or carbon If the machining marks on the p
27. ls These devices and their use are described in separate individual manuals Page 17 of 27 Cold Weather Starting Follow the Normal Starting Procedures in this section in cold weather A WARNING Do not use starting fluids with this engine Use of starting fluid can cause an explosion fire personal injury severe damage to the engine and property damage Starting Procedure after Extended Shutdown or Oil Change Follow the Normal Starting Procedures in this section in cold weather Operating the Engine Follow the Operating Instructions in the appropriate Operation and Maintenance Manual Procedure 101 015 in Section 1 Engine Operating Range Follow the instructions for the Engine Operating Range in the appropriate Operation and Maintenance Manual Procedure 101 008 in Section 1 Engine Shutdown Follow the engine shutdown procedures in the appropriate Operation and Maintenance Manual Procedure 101 009 in Section 1 Section 2 Maintenance Guidelines Overview General Information Cummins Inc recommends that the system be maintained according to the Maintenance Schedule Procedure 102 002 in Section 2 in the appropriate Operation and Maintenance Manual lf the system is operating in ambient temperatures below 18 C 0 F or above 38 C 100 F perform maintenance at shorter intervals Shorter maintenance intervals are also required if the system is operated in a dusty environment or if frequent stops are made
28. metal and result in premature wear of the cylinder liner piston rings pins and pin bores Valves turbocharger shafts etc can also be damaged Follow the cleaning directions listed tn the procedures A CAUTION A Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic beads Remove the foreign material and plastic beads with compressed air hot high pressure water or steam before placing them in tanks or cleaners The foreign material and plastic beads can contaminate the tank and any other engine parts cleaned in the tank Contaminated parts may cause failures from abrasive wear Page 13 of 27 Plastic bead blasting media part number 3822735 can be used to clean all piston ring grooves Do not sure any bead blasting media on piston pin bores or aluminum skirts Follow the equipment manufacturer s cleaning instructions Make sure to adjust the air pressure in the blasting machine to the bead manufacturer s recommendations Turning up the pressure can move material on the part and cause the plastic bead media to wear out more quickly The following guidelines can be used to adapt to manufacturer s instructions 1 Bead size U S size Number 16 20 for piston cleaning with plastic bead media Part Number 3822735 2 Operating Pressure 270 kPa 40 psi for piston cleaning Pressure should not cause beads to break 3 Steam clean or wash the parts with solvent to remove all of the foreign
29. n the Service Assistance Section S Product coverage warranty limitations and owner responsibilities are available in Warranty Section W About the Manual This manual covers all C Power and C Safe gensets Each engine has its own Operation and Maintenance Manual referred to here for specific procedures The manuals and procedures can be found online at https quickserve cummins com qs2 portal index html in the appropriate Operation and Maintenance Manual listed below C Power C Safe Base Engine Bulletin Numbers sar Operation and Troubleshooting and Repair __ O Maintenance Bulletin Bulletin Parts Manual 6B CP 6B CS 402136 66608 4056556 NOTE The control panels and alternators have their own Manuals that explain their operation and maintenance procedures where applicable It is extremely important that the operator becomes familiar with these manuals before attempting to operate the genset The manuals are available online at marine cummins com under the genset tab Page 4 of 27 The manuals contain information needed to correctly operate and maintain the engine alternator and control panels as recommended by Cummins Inc For additional service literature and ordering locations refer to Service Literature Section L in the appropriate Operation and Maintenance Manual Both metric and U S customary values are listed in this manual The metric value is listed first followed by the U S customary in brackets
30. on 6B C Power and C Safe UCM274E 6C C Power and C Safe UCM2 74H 0SM11 C Power HCM434F1 K19 C Power HCM534E Power PM 34B2 K50 C Power PM 34D 2 Section C Control Panels There are three different control panel options available for the gensets each one having its own procedures for starting and stopping the genset Information on how each panel operates is available on the marine website at marine cummins com under the Genset tab Publications and Manuals Page 27 of 27
31. onyms and Abbreviations The following list contains some of the acronyms and abbreviations used in this manual American National Standards Institute JAHE American Petroleum Institute American Society of Testing and Materials British Thermal Unit Before Top Dead Center a oO OJOJ S Carbon Monoxide Cold Cranking Amperes California Air Resources Board Customer Interface Box Cubic Inch Displacement Compressed Natural Gas Control Parts List ssid Parts List eeen o ooo cre as Exhaust Fluid Diesel Oxidation Catalyst Diesel Particulate Filter Engine Control Module sid Engine Control Module sid Module Electronic Fuel Control ss Fuel Control Eao ooa Gas Recirculation J 0 Environmental Protection Agency Fahrenheit ss Force pane Mode Indentifier Grass Vehicle lt _ a p aoo R moo pee of r aoe Inches of Water lgnition Control Module International Electrotechnical Commission Kilometers per Liter Kilopascal Liquid Natural Gas Liquified Petroleum Gas Low Temperature Aftercoaling Malfunction Indicator Lamp Megapascal Miles Per Hour Miles Per Quart Newton meter Mono Nitrogen Oxides Natural Gas On Board Diagnostics Oo m Original Equipment Manufacturer Occupational Safety and Health Administration Parameter Identification Descriptions Parts Per Million Pounds Per Square Inch OSHA ID U Power Takeoff Rear
32. oolant system Intake air system Exhaust system Knowledge of the engine systems can help in troubleshooting servicing and general maintenance of the engine Refer to Section D in the appropriate engine Operation and Maintenance Manual for the system diagrams Section L Service Literature For additional service literature literature ordering location and a customized parts catalog refer to Section L in the appropriate engine Operation and Maintenance Manual Section S Service Assistance For routine service and parts assistance emergency and technical service help in problem solving division and regional offices distributors and branches international regional offices and distributors refer to Section S in the appropriate manual Section SS Seasonal Storage This section includes procedures for short term shorter than 6 months and long term longer than 6 months storage for marine engines Follow the Long Term Storage Procedure 000 005 and the Short Term Storage Procedure 000 006 in the Operation and Maintenance Manual in Section SS or contact the nearest Cummins Authorized Repair Location for additional information Section TS Trouble Shooting Symptoms This guide describes some typical operating problems their causes and some acceptable corrections to those problems Unless noted otherwise the problems listed are those which an operator can diagnose and repair Follow the suggestions below f
33. or troubleshooting e Study the complaint thoroughly before acting e Refer to the engine system diagrams e Do the easiest and most logical things first e Find and correct the cause of the complaint Refer to the appropriate Operation and Maintenance Manual Section TS for the trouble shooting trees for each engine Page 21 of 27 Section V Maintenance Specifications This section has the general engine specifications fuel lubricating oil cooling system air intake exhaust and electrical system specifications along with fuel filter lubricating oil coolant recommendations This section also includes fraction decimal and millimeter conversion charts newton meter to foot pound conversion table torque values and belt tension charts Refer to the proper Operation and Maintenance Manual for the specifications and values for the engine Page 22 of 27 Section W Cummins C Power C Safe Warranty Cummins Warranty for Marine Generator Sets 4082004 Coverage Product Warranted This warranty applies to new marine generator sets sold by Cummins Inc herein after Cummins branded as C Power and C Safe products and used in marine generator set applications anywhere in the world where Cummins approved service is available and delivered to the first user on or after January 1 2006 This warranty excludes all generator sets branded and sold as Onan or Cummins Power Generation The Product consists of a new Cumm
34. p of the welder to any of the sensors wiring harness electronic control units or the components Direct welding of any electronic components must not be attempted Sensors wiring harness and electronic control unit should be removed if nearby welding will expose these components to temperatures beyond normal operation Additionally all electronic control unit connectors must be disconnected Complete rebuild instructions are available in the service manual which can be ordered or purchased from a Cummins Authorized Repair Location Refer to Service Literature Section L for ordering instructions General Cleaning Instructions Description of Clean Parts must be free of debris that can contaminate any engine system This does not necessarily mean they have to appear as new Sanding gasket surfaces until the factory machining marks are disturbed adds no value and Is often harmful to forming a seal It is important to maintain surface finish and flatness tolerances to form a quality sealing surface Gaskets are designed to fill small voids in the specified surface finish Sanding gasket surfaces where edge molded gaskets are used is most often unnecessary Edge molded gaskets are those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal portion forms a metal to metal joint for stability Any of the small amounts of sealing material that can stick to the parts are better removed with a blunt edged
35. plied Generator set control panel GCP including items shipped loose which are part of the GCP Engine Extended Major Components Warranty The Extended Major Components Warranty applies to engines other than B and C Series used in Cummins branded generator sets It covers Warrantable Failures of the engine cylinder block camshaft crankshaft and connecting rods Covered Parts Bushing and bearing failures are not covered This coverage begins with the expiration of the Base Generator Set Warranty and ends after three years or 10 800 hours of operation whichever occurs first from the date of delivery to the first end user or the date the unit is first leased rented or loaned or when the Product has been operated for 50 hours whichever occurs first Consumer Products This warranty on Consumer Products in the United States is a limited warranty CUMMINS IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES Any implied warranties applicable to Consumer Products terminate concurrently with the expiration of the express warranties applicable to the product Page 23 of 27 In the United States some states do not allow the exclusion of incidental or consequential damages or limitations on how long an implied warranty lasts so the limitations or exclusions herein may not apply to you These warranties are made to all Owners in the chain of distribution and Coverage continues to all subsequent Owners until th
36. prevents the release of refrigerant gas fluorocarbons into the atmosphere Federal law requires capturing and recycling refrigerant e To reduce the possibility of personal injury use a hoist or get assistance when lifting components that weigh 23 kg 50 Ib or more Make sure all lifting devices such as chains hooks or slings are in good condition and are of the correct capacity Make sure hooks are positioned correctly Always use a spreader bar when necessary The lifting hooks must not be side loaded e Corrosion inhibitor a component of SCA and lubricating oil contains alkali Do not get the substance in eyes Avoid prolonged or repeated contact with skin Do not swallow internally In case of contact immediately wash skin with soap and water In case of contact immediately flood eyes with large amounts of water for a minimum of 15 minutes IMMEDIATELY CALL A PHYSICIAN KEEP OUT OF REACH OF CHILDREN Page 6 of 27 e Naptha and Methyl Ethyl Ketone MEK are flammable materials and must be used with caution Follow the manufacturer s instructions to provide complete safety when using these materials KEEP OUT OF REACH OF CHILDREN e To reduce the possibility of burns be alert for hot parts on products that have just been turned off exhaust gas flow and hot fluids in lines tubes and compartments e Always use tools that are in good condition Make sure you understand how to use the tools before performing any service work Use ONLY g
37. r the cost of all labor needed to repair the Engine including the labor cost for Engine removal and reinstallation When Cummins elects to repair a part instead of replacing it the Owner is not responsible for the labor needed to repair the part Owner is responsible for the cost of all parts required for the repair except for the defective Covered Part and any Covered Part damaged by a Warrantable Failure of the defective Part Owner is responsible for the cost of lubricating oil antifreeze filter elements and other maintenance items replaced during repair of a warrantable failure During the Base Generator Set and Engine Extended Major Components Warranties Owner is responsible for the operation and maintenance of the Product as specified in the applicable Cummins Operation and Maintenance Manual including the provision of Cummins approved fuels oils and coolant Owner is also responsible for providing proof that all recommended maintenance has been performed Before the expiration of the applicable warranty Owner must notify a Cummins distributor authorized dealer or other repair location approved by Cummins of any Warrantable Failure and makes the Generator Set available for repair by such facility Locations in the United States and Canada are listed in the Cummins U S and Canada Sales and Service Directory other locations are listed in the Cummins International Sales and Service Directory In the event of any Pro
38. rials takes skill and care to prevent damage Do not scrape or brush across the gasket surface if at all possible Page 11 of 27 Solvent amp Acid Cleaning Several solvent and acid type cleaners can be used to clean the disassembled engine parts other than pistons See Below Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95 Celsius 180 to 200 Fahrenheit Kerosene emulsion based cleaners have different temperature specifications see below A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results Cummins Inc does not recommend any specific cleaners Always follow the cleaner manufacturer s instructions Remove all the gasket material o rings and the deposits of sludge carbon etc with a wire brush or scraper before putting the parts in a cleaning tank Be careful not to damage any gasket surfaces When possible steam clean the parts before putting them in the cleaning tank A WARNING When using solvents acids or alkaline materials for cleaning follow the manufacturers recommendati ons for use Wear gogales and protective clothing to reduce the possibility of personal injury Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons These cleaners should not be heated to temperature in excess of 77 C 170 F The solution begins to break down at temperatures in exces
39. roken wires after the piston is removed but the wires are more visible and can be attracted by a magnet Oil on parts that have been removed from the engine will attract dirt in the air The dirt will adhere to the oil If possible leave the old oil on the part until it is ready to be cleaned inspected and installed and then clean it off along with any attracted dirt If the part is cleaned then left exposed it can have to be cleaned again before installation Make sure parts are lubricated with clean oil before installation They do not need to be oiled all over but do need oil between moving parts or a good lube system priming process conducted before cranking the engine Bead blasting parts to remove exterior paint is also usually unnecessary The part will most likely be painted again so all that needs happen is remove any loose paint Abrasive Pads and Abrasive Paper The keyword here is abrasive There is no part of an engine designed to withstand abrasion That is they are all supposed to lock together or slide across each other Abrasives and dirt particles will degrade both functions A WARNING A Abrasive material must be kept out of or removed from oil passages and parts wear points Abrasive material in oll passages can cause bearing and bushing failures that can progress to major component damage beyond reuse This is particularly true of main and rod bearings Cummins Inc does not recommend the use of emery cloth or
40. ropriate engine Operation and Maintenance Manual Procedure 100 002 in Section E for the correct engine diagrams Cummins Service Engine Model Nomenclature The Cummins Service Engine Model Nomenclature procedure describes how engines are identified within Cummins service organization This method was introduced for models after and including manufacture year 2007 Section 1 Operating Instructions General Information Correct care of the engine will result in longer life better performance and more economical operation Use the following procedure for daily maintenance checks Refer to the appropriate Operation and Maintenance Manual Procedure 102 002 in Section 2 The new Cummins engine associated with this manual does not require a break in procedure While a break in procedure is not required a new engine can be more sensitive than a used engine when it comes to improper operation Before starting the engine for the first time please familiarize yourself with proper engine operation procedures U S legislation requires that stationary compression ignition internal combustion engines designated for emergency use are limited to emergency operations and required maintenance and testing Normal Starting Procedure Refer to the appropriate Operation and Maintenance Manual for the Normal Starting Procedure Procedure 101 014 in Section 1 NOTE The engine can possibly be equipped with electronic monitoring and contro
41. s of 82 C 180 F and will be less effective Do not use solutions composed mainly of chlorinated hydrocarbons with cresols phenols and or cresylic components They often do not do a good job of removing deposits from the ring groove and are costly to dispose of properly Solutions with a pH above approximately 9 5 will cause aluminum to turn black therefore do not use high alkaline solutions Chemicals with a pH above 7 0 are considered alkaline and those below 7 0 are acidic As you move further away from the neutral 7 0 the chemicals become highly alkaline or highly acidic Remove all the gasket material o rings and the deposits of sludge carbon etc with a wire brush or scraper before putting the parts in a cleaning tank Be careful to not damage any gasket surfaces When possible use hot high pressure water or steam clean the parts before putting them in the cleaning tank Removing the heaviest dirt before placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer Rinse all the parts in hot water after cleaning Dry completely with compressed air Blow the rinse water from all the cap screw holes and the oil drillings lf the parts are not to be used immediately after cleaning dip them in a suitable rust proofing compound The rust proofing compound must be removed from the parts before assembly or installation on the engine Steam Cleaning Steam cleaning can be used to remov
42. sand paper on any part of an assembled engine or component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or counterbores Great care must be taken when using abrasive products to clean engine parts particularly on partially assembled engines Abrasive cleaning products come in many forms and sizes All of them contain aluminum oxide particles silicon carbide or sand or some other similar hard material These particles are harder than most of the parts in the engine Since they are harder if they are pressed against softer material they will either damage the material or become embedded in it These materials fall off the holding media as the product is used If the products are used with power equipment the particles are thrown about the engine If the particles fall between two moving parts damage to the moving parts is likely If particles that are smaller than the clearance between the parts while they are at rest engine stopped but larger than the running clearance then damage will occur when the parts move relative to each other engine started Page 10 of 27 While the engine is running and there is oil pressure particles that are smaller than the bearing clearance are likely to pass between the parts without damage and be trapped in the oil filter However particles larger than the bearing clearance will remove material from one part and can become embedded in one of the parts
43. tent with its rating designation set forth above 2 Incorrect Installation Before a claim for excessive oil consumption will be considered Owner must submit adequate documentation to show that oil consumption exceeds Cummins published standards Cummins is not responsible for failures of maintenance components supplied by Cummins beyond 90 days after the coverage duration start date Maintenance components include but are not limited to sea water pump impellers zinc plugs oil filters fuel filters air filters water filters fuel water separator filters expansion tank pressure caps Page 25 of 27 Failures of belts and hoses supplied by Cummins are not covered beyond 90 days after the date of delivery of the Product to the first user or the date the unit is first leased rented or loaned or when the product has been operated for 50 hours whichever occurs first Except for the accessories noted previously Cummins does not warrant accessories which bear the name of another company Cummins parts Cummins approved rebuilt parts or repaired parts Cummins is not responsible for failures resulting from the use of parts not supplied by Cummins A new Cummins or Cummins approved rebuilt part used to replace a warranted part assumes the identity of the Warranted Part it replaces and is entitled to the remaining coverage there under CUMMINS DOES NOT COVER WEAR OR WEAROUT OF COVERED PARTS CUMMINS IS NOT RESPONSIBLE FOR I
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