Owner's Manual

Diesel Generator Set

DXP 35 D5
DXP 40 D5

English – Original Instructions 02 - 2015 A046V007 (Issue 3)

Owner’s Manual Publication A046V007
Model: DXP35 D5 TO DXP40 D5 Issue 3 - 02 - 2015

Table of Contents
Description Page

1. Safety Instruction..................................................... .. .............................................................................. 4

2. 10 Installation Steps.................................................. ................................................................................ 5

3. Load cables and grounding cables sizes................................................................................................... 5

4. Best Maintenance Practices....................................................................................................................... 6

5. Maintenance Schedule................................................... ........................................................................... 7

Page 2 2013 Copyright Cummins Power Generation

Owner’s Manual Publication A046V007
Model: DXP35 D5 TO DXP40 D5 Issue 3 - 02 - 2015

1. Safety Instruction
• Refer to the accompanying documentation for more detailed technical and safety information,
which includes scheduled inspections and daily maintenance of the Genset. If in ANY doubt refer
to the operator manuals.
• This machine MUST be installed and commissioned by a Cummins certified technician according
to local codes and regulations. No attempt should be made to start the set prior to
commissioning.
• Initial start up and commissioning: Set-up, calibration and adjustment must be performed by
technically qualified personnel only. Improper set-up, calibration or adjustments may cause
equipment malfunction and/or damage which will affect warranty.

Routine Maintenance Checks

• Warning: All checks MUST ONLY be carried out on a switched off, isolated and cold Generator
set!
• Personnel working on generator plant must be familiar with normal operating procedures and
hazards!
• Failure to observe safety precautions may result in severe personal injury or death!
• Ear protection must be used at all times!

To Immobilize the set for Safe working

• Press the STOP button.

• Engage the Emergency Stop button before disconnecting the Starter and Control
system batteries.

Manual Startup - PS0500

Reset The Control Rolling Display ON

Estop =Inactive
Cust IN =Inactive

Breaker Open STOP

Genset Running Manual Start- Up

(Green LED Blink) Manual Mode

L1N=232 L2N 000 Battvolts = 11.5 I1=00 KVA=00.0 KVA1 kVA2 kVA3
L3N=000 Hz=50.0 Genset Hrs=001.5 I2=00 I3=00.0 00.0 00.0 00.0

Performance ? I1=000 kVA=000

I2=000 I3=000

Sound?
Englne Close Breaker
Appearance?

Page 3 2013 Copyright Cummins Power Generation

Publication A046V007 Owner’s Manual
Issue 3 - 02 - 2015 Model: DXP35 D5 TO DXP40 D5

2. 10 Installation Steps

1. Install and commission through authorized technicians only

2. Install enclosed Generator set on leveled foundation

3. Keep adequate space all around the Generator set for safe working

4. Ensure cross ventilation

5. Route exhaust outlet in wind flow direction

6. Use recommended load cable size(refer table below) & route through the hole provided on the
canopy
7. Ensure proper earthing to the Generator set and panel

8. Remove the red colored shipping brackets after installation

9. Charge the battery before starting

10. Check fuel, coolant & lubricating oil level

3. Load Cables and Grounding Cables Sizes

Copper Cable Copper Cable

Size sq.mm. Size sq.mm. Body Earthing Battery sugested for Battery Cable
kVA 3 phase 1 phase
for 3ph for 1ph starting and AMF + Diameter in
Rating Amp Amp
(core size x (core size x electronic system load sq.mm
No. of runs) No.of runs)
Copper GI

35 49 10 x 1 152 70 x 2 8 SWG Copper 12V65Ah 50

40 56 16 x 1 174 90 x 2 8 SWG Copper 12V65Ah 50

NOTE : - Use 2 core XLPE insulated power cable with copper conductor for rating from 7.5 to 62.5 kVA 1 Ph.
- Use 4 core power cable with copper conductor for rating from 7.5 to 40 kVA 3 Ph.
- Earthing as per IEC rules to be provided.

2013 Copyright Cummins Power Generation Page 4

Owner’s Manual Publication A046V007
Model: DXP35 D5 TO DXP40 D5 Issue 3 - 02 - 2015

4. Best Maintenance Practices

- Keep the Generator set and surrounding neat and clean.

- Use recommended oil, coolant & fuel only.

- Check & maintain oil, coolant & fuel levels periodical ly (see following schedule).

- Run the generator set weekly for dependable operation.

- Schedule and control your maintenance.

- Clean / replace air filter element when vacuum indicator shows red band

- Check fan belt tension periodically & adjust if required(see following schedule).

- Ensure balanced load on each phase.

- Use genuine parts & services through Cummins network.

Note - Do not operate on low load below 30% and avoid overloading.

Page 5 2013 Copyright Cummins Power Generation

Publication A046V007 Owner’s Manual
Issue 3 - 02 - 2015 Model: DXP35 D5 TO DXP40 D5

5. Maintenance Schedule
SYSTEM A -C H ECK B-CHECK C -C H E C K D - C H EC K
Within 50 Hours/ One Every 475-500 hours Every 1450-1500 Every 4800- 5000 Hrs.
Month from Date of OR 12 months, hours OR 18 OR 24 months
GROUP Installation ( whichever whichever is earlier months,whichever is whichever is earlier
is earlier ) earlier
1: Check Lube oil 1: Change lubrication 1:Change lubrication 1:Change
2.Top-up Lube oil up Oil. Oil lubrication Oil
to ‘H’ mark on 2: Use only CH4- 2:Use only CH4- 2:Use only CH4-
LUBRICATION dipstick. 15W40 Lube Oil. 15W40 Lube Oil 15W40 LubeOil
SYSTEM 3: Use only CH4- 3:Change Spin-on 3: Change Spin-on 3: Change Spin-on
15W40 Lube oil Lube Oil Filter Lube Oil Filter. Lube Oil Filter.
4: Check visually for 4: Check visually
metal particles in used for metal particles
Lube Oil. in used Lube Oil.

1: Check for leaks. 1: Check for leaks. 1.Check Coolant level 1.Check Coolant
Rectify leak if found Rectify leak if found in tank, coolant. If level in tank,
any. any. required, fill Premix coolant. If required,
2: Check Coolant 2: Check Coolant level Coolant only in the fill Premix Coolant
level in radiator in radiator (Caution : Tank, coolant up to H only in the Tank,
(Caution : Do not Do not remove Cap mark. coolant up to H
remove Cap when when hot ) 2: Check condition of mark.
COOLING hot ) 3: Check Coolant level Hoses & clamps. 2: Check condition
SYSTEM 3: Check Coolant in tank, coolant. If Replace if necessary. of Hoses & clamps.
level in recovery required, fill Premix Check sealings around Replace if
bottle. T op up if Coolant only in the Radiator necessary.
necessary; fill Premix Tank, coolant up to H 3: If required, clean Check sealing’s
Coolant only in the mark. dust on Core of around radiator.
recovery bottle, *Check Belt Tension. Radiator by very low 3: If required, clean
coolant up to H mark. Tighten if required pressure of Air. ( 3.5 dust on Core of
Kg / cm2 ) Radiator by very
4: Check Cap, radiator low pressure of
for seal. Change the Air.( 3.5 Kg / cm2)
Cap if required. 4: Check Cap,
radiator for seal.
Change the Cap if
required.
1: Check for fuel 1: Check & rectify 1: Check & rectify leak 1: Check & rectify
leaks. leak if any. In case of if any. In case of leak leak ifany. In case
2: Rectify leak if any. leak at Banjo, change at Banjo, change the of leak at Banjo,
In case of leak at the Copper Washer. Copper Washer change the copper
Banjo, change the 2: Change Spin-on 2: Change Spin-on Washer
Copper Washer. Fuel Filter. Fuel Filter 2: Chang Spin-on
FUEL 3: Drain sediments 3: Clean Fuel tank 3: Clean Fuel tank inlet Fuel Filter
SYSTEM from Fuel Water inlet strainer. strainer 3: Clean Fuel tank
Separator 2: Check all joints in inlet strainer
Fuel Lines & tighten 2: Check all joints
in Fuel Lines &
tighten
2: ChangeFuel
Hosesif required
3: Calibrate
Nozzles &
FIP at BOSCH
service centre.

2013 Copyright Cummins Power Generation Page 6

Owner’s Manual Publication A046V007
Model: DXP35 D5 TO DXP40 D5 Issue 1 - 06 - 2013

SYSTEM A - CHECK B - CHECK C - CHECK D - CHECK

Every 475-500 hours Every 1450-1500 Every 4800-5000 Hrs.

Within 50 Hours/One OR 12 months, hours OR18 OR 24 months
GROUP Month from Date of whichever is earlier months, whichever whichever is earlier
Installation is earlier
( whichever
1: Check Indicator 1: Check Indicator
Service for Air Service for Air
Restriction (Red Band Restriction (Red
indication). Band indication).
1: Check Indicator 1: Check Indicator 2: Clean Element, Air 2: Clean Element,
Service for Air Service for Air Cleaner in reverse Air Cleaner in
Restriction (Red Restriction (Red Band direction of Air flow, reverse direction of
Band indication). indication). using dry air with max Air flow, using dry
2: Clean Element, 2: Clean Element, Air 3.5 kg / cm2 pressure. air with max 3.5 kg
Air Cleaner in Cleaner in reverse 3: Check sealing & / cm2 pressure.
AIR reverse direction of direction of Air flow, condition of Air 3: Check sealing &
SYSTEM Air flow, using dry using dry air with max Cleaner condition of Air
air with max 3.5 kg / 3.5 kg / cm2 pressure. 4: Clean Element, Air Cleaner
cm2 pressure. 3: Check sealing & Cleaner, if required. 4: Clean Element,
3: Check sealing & condition of Air Change Element, Air Cleaner, if
condition of Air Cleaner Air Filter required.2: Change
Cleaner 4: Clean Element, Air 5: Check Hose & Element,
Cleaner, if required. Clamps. Air Filter
6: Check indicator 5: Check Hose &
Service, for its proper Clamps.
function. 6: Check indicator
Service, for its
proper functioning.
7: Measure
exhausts back
pressure. Should
not exceed 3 mm of
Hg. Take corrective
action as required.
Check / Adjust valve
Other lashes.

Note: All the B, C and D checks MUST be carried out by skilled technician only.

Page 7 2013 Copyright Cummins Power Generation

 Publication A046V007 Owner’s Manual
Issue 1 - 07 - 2014 Model:DXP35 D5 TO DXP40 D5

Compleat EG 50:50 Premix Engine Coolant corrosion inhibitor test:

Purpose: To confirm the corrosion inhibitor concentration level
in EG50:50 premix coolant:
Compleat EG 50:50 Premix Engine Coolant’s corrosion inhibitor level needs to be inspected
atleast every 6months or every 500Hrs of operation whichever is earlierusing 3-Way Test
Strip analysis.
And DCA4 is a Supplemental coolant additive (SCA) wich is to be added in the cooling
system in as is condition to maintain the required concentration level of corrosion inhibitors
(Molybdate & Nitrite) in Compleat EG 50:50 Premix Engine Coolant based on 3 way test strip
analysis result.

3 way strip analysis chart: Test procedure:

1.Stop the genset and ensure the coolant temperature reduces to less than 40°C confirmed
from monitoring controller / gauge.
2. Collect the coolant sample in beaker from the radiator with the help of dropper provided
in the kit.Dip 3-Way Test Strip into the coolant for one second and take out the strip outside
area. And shake the strip well to remove the excess coolant on the strip.
3. Wait for 45seconds and verify the strip colour with the below mentioned chart within
30seconds and add DCA4 dosing as per the result.

2013 Copyright Cummins Power Generation Page 8

 Publication A046V007
Owner’s Manual
Issue 3 - 02 - 2015
Model:DXP35 D5 TO DXP40 D5

Follow detailed procedure given along with 3-Way Test Kit.

Dosing required details with respect to the engine model mentioned

below.
DCA4 dosing instructions: (Cummins part no for DCA4 (1 ltr pack)
is 4104802 )
Engine premix DCA 4 to be added(in ml)
coolant if found SCA units
Genset capacity Engine model (EG 50:50) less than 0.3 as per strip
Capacity in (Ltrs) analysis

35 to 40 kVA X3.6TAA-G1 /G2 13 409.5

Note: No need to add DCA4 concentration if SCA units found more than 0.3 from 3-Way
strip analysis test. (If the readings are in green zone as per test kit chart).

Maintenance Kits / Parts Availability

Compleat EG 50:50 Premixed Coolant
S/N Part description in CIL Fleetguard Quantity in
CIL Sysrem Part No. Part No. Litres

1 Inhibitor Corrosion 3816986 CC2769 5 Litre

2 Inhibitor Corrosion 4926654 CC2505 10 Litre

3 Inhibitor Corrosion 3816981 CC2774 205 Litre

Compleat EG Coolant Test Kit

S/N Part description in CIL Fleetguard Quantity
CIL Sysrem Part No. Part No.

1 Kit Coolant Testing 3816985 CC02602CM 1 No.

2 ----- ----- CC2602M 50 Strips

Page 9 2013 Copyright Cummins Power Generation

 Call nearest Cummins Dealer for assistance

When a product requires servicing, contact your area nearest Cummins authorized service
dealer To locate your local Cummins authorized service dealer or area office, refer to website
www.cumminsindia.com/DBU/service_locator.html

If you have difficulty arranging service or resolving an issue, please contact the
Service Manager at the nearest Cummins India Limited distributor for assistance or
call our 24 hours service CAC.

E-mail: powermaster-india@cummins.com

Registered Office:-
Cummins India Office Campus Tower A,6th
Floor
Survey no.21, Balewadi,Pune
Maharashtra-411045
Authorised Representative

©2013 Cummins Power Generation Inc. All rights reserved.

Cummins Power Generation and Cummins are registered trademarks of Cummins Inc.
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Specifications are subject to change without notice.
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