Maintenance

Planned Maintenance Recommendations
Standby Diesel Generator Sets (500 kW and up)
Models: C500x, C550x C600x, C650x C700x, C750x, C780x C800x, C825x C900x C1000x C1100x, C1160x C1200x, C1250x C1400x C1500x, C1540x C1675x C1750x, C1760x C2000x C2200x, C2250x C2750x C3000x DFHx DFLx DQFx DQCx DQGx DQKx DQLx
Date: July 24, 2012
Revision B Revision Date: 06/03/12
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Table of Contents Subject

Important Safety Instructions Background Service Support Warranty Task List Procedures
Page Number
3 9 9 10 10 12
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1.0 Important Safety Instructions

SAVE THESE INSTRUCTIONS - This document contains important instructions that should be followed during installation and maintenance of the generator set and batteries. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions.
1.1 Warning, Caution and Note Styles Used In This Manual

The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel or the equipment . DANGER: Warns of a hazard that will result in severe personal injury or death. WARNING: Warns of a hazard that may result in severe personal injury or death. CAUTION: Warns of a hazard or an unsafe practice that can result in product or property damage. NOTE: A short piece of text giving information that augments the current text.
1.2 General Information

This manual should form part of the documentation package supplied by Cummins Power Generation with specific generator sets. This manual should not be used in isolation. NOTE: It is in the Operators interest to read and understand all Warnings and Cautions contained within the documentation relevant to the generator set, its operation and daily maintenance. 1.2.1 General Safety Precautions WARNING: Coolants under pressure can cause severe scalding. Do not open a radiator or heat exchanger pressure cap while the engine is running. Let the engine cool down before removing the coolant pressure cap. Turn the cap slowly and do not open it fully until the pressure has been relieved. WARNING: Moving parts can cause severe personal injury or death and hot exhaust parts can cause severe burns. Make sure all protective guards are properly in place before starting the generator set. WARNING: Used engine oils have been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil. WARNING: Operation of equipment is unsafe when mentally or physically fatigued. Do not operate equipment in this condition, or after consuming any alcohol or drug. WARNING: Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not breathe in or come into contact with exhaust gases. WARNING: Flammable liquids can cause fire or explosion. Do not store fuel, cleaners, oil, etc. near the generator set. WARNING: Wear hearing protection when going near an operating generator set. WARNING: Hot metal parts can cause severe burns. Avoid contact with the radiator, turbo charger, and exhaust system. WARNING: Maintaining or installing a generator set can cause severe personal injury. Wear personal protective equipment such as safety glasses, protective gloves, hard hats, steel-toed boots, and protective clothing when working on equipment. WARNING: Ethylene glycol, used as engine coolant, is toxic to humans and animals. Clean up coolant spills and dispose of used antifreeze in accordance with local environmental regulations. WARNING: Starting fluids, such as ether, can cause explosion and generator set engine damage. Do not use. CAUTION: Stepping on the generator set can cause parts to bend or break, leading to electrical shorts, or to fuel, coolant, or exhaust leaks. Do not step on the generator set when entering or leaving the generator room. CAUTION: To prevent accidental or remote starting while working on the generator set, disconnect the negative (-) battery cable at the battery using an insulated wrench. CAUTION: Make sure that rags are not left on or near the engine.
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CAUTION: Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit. CAUTION: Accumulated grease and oil can cause overheating and engine damage presenting a potential fire hazard. Keep the generator set clean and repair any oil leaks promptly. CAUTION: Before performing maintenance and service procedures on enclosed generator sets, make sure the service access doors are secured open. CAUTION: Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. NOTE: Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in applicable region.)
1.3 Generator Set Safety Code

Before operating the generator set, read the manuals and become familiar with them and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. WARNING: Improper operation and maintenance can lead to severe personal injury or loss of life and property by fire, electrocution, mechanical breakdown, or exhaust gas asphyxiation. Read and follow all Safety Precautions, Warnings and Cautions throughout this manual and the documentation supplied with your generator set. WARNING: Lifting and repositioning of the generator set must only be carried out using suitable lifting equipment, shackles, and spreader bars, in accordance with local guidelines and legislation, by suitably trained and experienced personnel. Incorrect lifting can result in severe personal injury, death and/or equipment damage. For more information, contact your authorized distributor. 1.3.1 Moving Parts Can Cause Severe Personal Injury Or Death Keep your hands, clothing, and jewelry away from moving parts. Before starting work on the generator set, disconnect the battery charger from its AC source, then disconnect the starting batteries using an insulated wrench, negative () cable first. This will prevent accidental starting. Make sure that fasteners on the generator set are secure. Tighten supports and clamps; keep guards in position over fans, drive belts, etc. Do not wear loose clothing or jewelry in the vicinity of moving parts or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. If any adjustments must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc. 1.3.2 Positioning of Generator Set The area for positioning the set should be adequate and level and the area immediately around the set must be free of any flammable material. WARNING: On an enclosed generator set, the canopy doors must be locked before repositioning and they must remain locked during transportation and sitting. 1.3.3 Positioning of Generator Set - Open Sets The area for positioning the set should be adequate and level and the area immediately around the set must be free of any flammable material. 1.3.4 Moving the Generator Set WARNING: Transportation and handling of generator sets must only be undertaken by suitably trained and experienced personnel. It is essential that there are sufficient trained and experienced personnel in attendance to make sure the lifting and transportation of the generator set is undertaken in a safe and appropriate manner and in accordance to local guidelines and legislation. WARNING: Do not lift the generator set by attaching to the engine or alternator lifting points. Improper handling of the generator set may cause serious damage to the generator set and its components and can result in severe personal injury or death.
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Before lifting the generator set, lifting points, angle of slings, mass, access to intended site, and the distance of movement should all be taken into account when organizing a suitable crane/hoist. Consult the generator set information supplied with your generator set for details of dimensions and mass. Make certain that the crane operating area is able to support the mass of the crane and the generator set.
WARNING: Do not use the generator set as a means of access when attaching lifting shackles, chains etc. Use as access may damage the generator set and/or can result in severe personal injury or death. WARNING: On an enclosed generator set, the canopy doors must be locked before repositioning and they must remain locked during transportation and sitting. Make certain the equipment used for lifting is adequate to support the weight of the generator set. Attach the lifting device to the lifting points only, using suitable shackles, chains and spreader bars. Slowly tighten the slings. Inspect the lifting attachments before commencing a full lift to make sure they are attached correctly. Hoist the generator set slowly using the indicated lifting points only.
WARNING: Never stand underneath a lifted generator set. Contact with a lifted generator set can result in severe personal injury or death. Guide the generator set with ropes at a safe distance, to prevent uncontrolled rotation when positioning the generator set. Move the generator set to the desired location and place in position, bringing the set down slowly. Loosen the slings; unhook and remove the shackles.
1.3.4.1 Positioning a Generator Set Using a Forklift Truck WARNING: Transportation and handling of generator sets by forklift trucks must only be undertaken by suitably trained and experienced personnel who are familiar with the transport of these items. If using a forklift truck to transport/position the generator set, the dimensions, mass, and route must be taken into account when selecting an appropriate lifting truck. WARNING: Do not attempt to lift a generator set with an undersized forklift truck. Improper handling of the generator set may cause serious damage to the generator set and its components and can result in severe personal injury or death. It is essential that there are sufficient trained and experienced personnel in attendance to make certain the lifting and transportation of the generator set is undertaken in a safe and appropriate manner and in accordance to local guidelines and legislation. WARNING: A generator set must not be moved with a forklift truck if it is attached to the trailer. Improper handling of the generator set may cause serious damage to the generator set and its components and can result in severe personal injury or death. WARNING: On an enclosed generator set, the canopy doors must be locked before repositioning and they must remain locked during transportation and sitting. Fully insert the arms of the forklift into the forklift pockets, making sure the generator set completely rests on the forklift arms. Lift and handle the equipment slowly. Slowly set down the generator set in its final position.
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death
WARNING: Any work with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC, or higher poses a significant risk of electrical shock and electrical arc flash. These silent hazards can cause severe injuries or death. Refer to standard NFPA 70E or equivalent safety standards in corresponding regions for details of the dangers involved and for the safety requirements. Guidelines to follow when working on de-energized electrical systems: Use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards.
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De-energize and lockout/tagout electrical systems prior to working on them. Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment or the release of stored energy. Please refer to the lockout/tagout section for more information. De-energize and lockout/tagout all circuits and devices before removing any protective shields or making any measurements on electrical equipment. Follow all applicable regional electrical and safety codes.
Guidelines to follow when working on energized electrical systems: NOTE: It is the policy of Cummins Inc. to perform all electrical work in a deenergized state. However, employees or suppliers may be permitted to occasionally perform work on energized electrical equipment only when qualified and authorized to do so and when troubleshooting, or if deenergizing the equipment would create a greater risk or make the task impossible and all other alternatives have been exhausted. NOTE: Exposed energized electrical work is only allowed as per the relevant procedures and must be undertaken by a Cummins authorized person with any appropriate energized work permit for the work to be performed while using proper PPE, tools and equipment. In summary: Do not tamper with or bypass interlocks unless you are authorized to do so. Understand and assess the risks - use proper PPE. Do not wear jewelry and make sure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards. Make sure that an accompanying person who can undertake a rescue is nearby. 1.4.1 AC Supply and Isolation It is the sole responsibility of the customer to provide AC power conductors for connection to load devices and the means to isolate the AC input to the terminal box; these must comply to local electrical codes and regulations. Refer to the wiring diagram supplied with the generator set. NOTE: Local electrical codes and regulations (for example BS EN 12601:2001) may require the installation of a disconnect means for the generator set, either on the generator set or where the generator set conductors enter a facility. NOTE: The AC supply must have the correct over current and earth fault protection according to local electrical codes and regulations. This equipment must be earthed (grounded). The disconnecting device is not provided as part of the generator set, and Cummins Power Generation accepts no responsibility for providing the means of isolation. 1.4.2 AC Disconnect Sources WARNING: The equipment may have more than one source of electrical energy. Disconnecting one source without disconnecting the others presents a shock hazard that can result in severe personal injury or death. Before working on the equipment, disconnect and verify that all sources of electrical energy have been removed. 1.4.3 Medium Voltage Equipment (601 V to 15 kV) Medium voltage acts differently than low voltage. Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and experienced to work on such devices. Improper use or procedures will result in severe personal injury or death. Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with authorized personnel so that the equipment can be de-energized and safely grounded.
1.5 Fuel and Fumes Are Flammable

Fire, explosion, and personal injury or death can result from improper practices. DO NOT fill fuel tanks while the engine is running, unless the tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard. DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent. Be sure all fuel supplies have a positive shutoff valve. Be sure the battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.
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1.5.1 Gaseous Fuels Natural gas is lighter than air, and will tend to gather under hoods. Propane is heavier than air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling propane to be trained and qualified. 1.5.2 Spillage Any spillage that occurs during fueling or during oil top-off or oil change must be cleaned up before starting the generator set. 1.5.3 Fluid Containment If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals. Any liquid present should be drained out and disposed of in line with local health and safety regulations. Failure to perform this action may result in spillage of liquids which could contaminate the surrounding area. Any other fluid containment area must also be checked and emptied, as described above. NOTE: Where spillage containment is not part of a Cummins supply, it is the responsibility of the installer to provide the necessary containment to prevent contamination of the environment, especially water courses/sources. 1.5.4 Do Not Operate in Flammable and Explosive Environments Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a generator set where a flammable vapor environment can be created by fuel spill, leak, etc., unless the generator set is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the generator set are solely responsible for operating the generator set safely.
1.6 Exhaust Gases Are Deadly

Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. Be sure the unit is well ventilated.
WARNING: Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. 1.6.1 Exhaust Precautions WARNING: Exhaust pipes and charge air pipes are very hot and can cause severe personal injury or death from direct contact or from fire hazard. WARNING: Hot exhaust gas can cause burns resulting in severe personal injury. The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust. WARNING: Inhalation of exhaust gases can result in serious personal injury or death. Be sure deadly exhaust gas is piped outside and away from windows, doors, or other inlets to buildings. Do not allow to accumulate in habitable areas. WARNING: Contaminated insulation is a fire risk which can result in severe personal injury. The exhaust pipes may have some insulating covers fitted. If these covers become contaminated by fuel or oil, they must be replaced before the generator set is run. To minimize the risk of fire, make sure the following steps are observed: Make sure that the engine is allowed to cool thoroughly before topping off the oil or draining the fuel filters. Clean the exhaust pipe thoroughly.
1.7 Earth Ground Connection

The neutral of the generator set may be required to be bonded to earth ground at the generator location, or at a remote location depending on system design requirements. Consult the engineering drawings for the facility or a qualified electrical design engineer for proper installation. NOTE: The end user is responsible for ensuring that an earthing arrangement is established, that is compliant with local conditions and is tested before the equipment is used.
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1.8 Distribution Panel Door

CAUTION: Opening the distribution panel door while the generator set is running will trip the generator set circuit breaker and abruptly shut off power to all loads. Be sure that the generator set is not running and is in off mode before you open the distribution panel door.
1.9 Transport and Towing

The generator set is capable of being towed on the highway or off the highway. Consult state and local transportation codes before transporting the generator set. When there are differences between the instructions in this manual and the state and local traffic laws, the state and local traffic laws take precedence. Do the following to move or tow the generator set: Be sure the towing vehicle is adequate to tow and stop the generator set. Disconnect all wiring and cabling from the generator set. Disconnect the ground wire from the generator set. WARNING: Failure to properly secure the trailer to the towing vehicle can result in serious injury or death. Always use the proper trailer hitch and safety chains to attach the trailer to the towing vehicle. Always obey all local and state laws when towing a generator set. Use a proper size hitch Use the front leveling jack to raise the trailer hitch enough to secure the hitch to the vehicle. Be sure the hitch coupler is properly secured to the vehicle. Attach the safety chains to the vehicle. If included on the generator set, attach the breakaway chain on the surge brake and the electrical coupler to the vehicle. Fully retract the front leveling jack. Check the trailer tires for proper inflation. Be sure the wheel lug nuts are tight. If included on the generator set, connect the electrical connector for the towing lights to the vehicle.
CAUTION: Exceeding the recommended speeds can cause severe damage to the generator set. Damage caused by exceeding the recommend speeds will void the manufacturer's warranty. Tow at the posted speeds for trailers or the following, whichever is least: o 60 mph (96 kph) on paved roads o 10 mph (16 kph) on unpaved roads
1.10 Beware of Traffic Hazards

When the generator set is on or beside the road, be clear of traffic when starting, stopping, or checking the generator set. Be sure there are no oil or fuel leaks that can spill onto the road. Be sure that all fasteners and mounting brackets are tight. Be sure that fasteners and mounting brackets will not fall off during transit.
1.11 Tipping Hazard
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2.0
Background
The purpose of this document is to outline the Cummins Power Generation factory-recommended maintenance tasks to be used with standby diesel generator sets greater than 500 kW. This material is supplementary to the operator, installation, and service manuals and is not intended to replace any one of those manuals. This is an approved list of maintenance procedures that can be used for purposes of marketing, expanding, and implementing common maintenance practices for Cummins Distributors. This list provides an improved and more optimized list of planned maintenance procedures for the end user.
2.1 Product Inclusions

This document provides maintenance tasks for diesel standby generator sets, as listed on the front cover of this manual, and does not include the necessary maintenance for Tier 4 (i or f) product.
3.0 Service Support

CPG Service will provide technical service support to distribution in the event technical assistance is needed during or after a maintenance event. Technical Support Request (TSR) is the primary interface and documentation mechanism for CPG Service for field issues. CPG Service is tasked with the following responsibilities: Track all product-related issues Document and communicate issue resolution to the field Provide common database for tracking product issues Communicate important issues monthly through the DFSE-C conference call or as necessary Issue Product Support Bulletins (PSB) and Parts & Service Bulletins as required
3.1 Aftermarket Support Plan

The support structure consists of three main levels: 1) Distributor Service Technician; 2) Distributor Power Generation DFSE-C; and 3) factory service. This general process is governed globally by the CPG Parts and Service Support process and regionally by a Distributors Support and Escalation process. In general, when a field issue has been identified, a Distributor Service Technician is engaged to resolve the issue. The Cummins Power Generation DFSE-C supports the Service Technician with necessary information and resources. If the event requires factory support, the DFSE-C engages CPG Service. A TSR Issue is created and assigned to the CPG Service group, which will be tasked with supporting the DFSE-C to issue closure.
3.2 Service Tools

The following is a list of additional tools that are required to effectively perform the procedures listed in this document. It is assumed that the field personnel have standard hand tools, InPower, InSite, PPE, and necessary service harnesses. SAR-GEL water/alcohol indicating paste or equivalent Manometer or 0-32 inches of water column gauge Quick-Draw valve ( NPT), p/n CC2724 Sampling Pump Kit, p/n CC2723 M14 to NPT Fitting Oil filter wrench, p/n 3375049 Refractometer, p/n CC-2800 Coolant test kit, p/n CC2602 Infra-red non-contact thermometer DCA test strips Hydrometer Battery terminal pliers Battery terminal spreaders Autometer SB-5 or equivalent Fluke 871V digital multimeter or better
3.3 Parts Return Process

A Parts Return process has been established to make sure that failed components can be returned to the factory for failure analysis and product improvement. Process Steps: A TSR issue has been created to document the event and resolution. A CPG Service Engineer will determine whether the failed component(s) is of interest and in need of return.
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A CPG Service Engineer will create a Notes/Discussion entry within the issue, with subject title Shipping Instructions that details shipping information. As applicable, a Short Term Solution will be issued with title Failed Parts Return Request. The DFSE-C is required to follow the shipping instructions to make certain that the failed component(s) is received in a timely, efficient manner. NOTE: The TSR number is to be noted on the package prior to shipment. The DFSE-C will create a Notes/Discussion entry within the TSR, with the subject title Tracking Information, which details the method of shipping and provides the applicable Tracking Number. The CPG Service Engineer must make sure that the package is received and the analysis is conducted. The CPG Service Engineer must communicate all results to the DFSE-C by documenting such within the TSR
4.0 Warranty
Implementing this list of maintenance tasks will not void the warranty of the products listed in this document. Subsequently, if this list is not followed AND the maintenance tasks in the generator set operator manual are followed, the warranty will not be voided.
5.0 Task List

Below is the task list. It lists all the factory recommended tasks for generator maintenance on 500 kW and above standby diesel generator sets.
5.1 Using the Task List

The following is a brief description of the columns: Column A = major generator set subsystem Column B = specific maintenance task Column C = defines how often and at what point during the maintenance event (pre, during, or post the generator set exercise) to implement the procedure. The row above the C designee explains how often a procedure should be performed: monthly, quarterly, semi-annually, or annually.
Frequency, whichever comes sooner: M=Monthly or after 100 hrs, Q=Quarterly, S=Semi-annually or after 250 hrs, A=Annually or after 500 hrs || Assume genset is exercised monthly. Designees pre, post and during indicate when to inspect during monthly exercise Pre and Post, M
A
FUEL SYSTEM Check day tank level
B
Component Check main supply tank level Test day tank float switch Check and test supply/transfer pump operation Test solenoid valve operation Check and change as required fuel filter Check and clean strainer, water in system, dirt leg [contaminant] Inspect and change as required flexible hose and connectors Check tank vents and overflow piping unobstructed Inspect piping Test fuel quality test
Pre and Post, M Pre, M Pre, M Pre, M A, At oil change interval or high filter restriction Pre and Post, M Pre, During, and Post; M Pre, A Pre, A A Pre and Post, M Per engine manufacturer Per engine manufacturer Pre, M S Pre and Post, M S 2 yrs or per coolant vendor specification During, M During, M A Visually (Pre and Post, M); R (S)
LUBRICATION SYSTEM
Check oil level Change lube oil Change oil filter(s) Check lube oil heater Check crankcase breather
COOLING SYSTEM
Check coolant level Test coolant freeze protection level Change as required antifreeze Check for adequate cooling water to heat exchanger Inspect for adequate fresh air through radiator Inspect and clean as required exterior of radiator Inspect and change as required fan and alternator belt [drive belts]
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Component COOLING SYSTEM Check grease fan bearing Inspect water pumps Check and change as required flexible hoses, connections, and clamps Test DCA / SCA level Change coolant filters COOLING SYSTEM Check jacket water heater Check low coolant sensor Check thermostat Inspect duct work, clean louvers Inspect louver motors and controls EXHAUST SYSTEM Inspect for leakage Check drain condensate trap Inspect insulation and fire hazards Inspect exhaust system hangers and supports Inspect flexible exhaust section BATTERY SYSTEM Check electrolyte level Inspect terminals clean and tight Inspect and remove corrosion, case exterior clean/dry Test specific gravity or state of charge Test cranking load test Check charger and charge rate Test equalize charge ELECTRICAL SYSTEM General inspection Check for tight control and power wiring connections Inspect for wire chafing where subject to movement Inspect and clean boxes, panels, and cabinets Inspect, clean, and test circuit breakers and fuses. Change as required Check and test calibration of voltage-sensing relays/devices PRIME MOVER General inspection Check and change as required air cleaner Test EPS at minimum of 30% nameplate rating Performance testing per manufacturer Performance testing per AHJ Check starter motor Check valve clearance GENERATOR Inspect rotor and stator and associated equipment Check generator (alternator) air outlet Check and change as required bearing grease Inspect exciter Inspect winding heaters Inspect anchorage, alignment, grounding Measure and/or PI testing and record resistance readings of windings with insulation tester (Megger)
Frequency, whichever comes sooner: M=Monthly or after 100 hrs, Q=Quarterly, S=Semi-annually or after 250 hrs, A=Annually or after 500 hrs || Assume genset is exercised monthly. Designees pre, post and during indicate when to inspect during monthly exercise A Pre, During, and Post; M Visually (Pre and Post); R (S) S With oil change intervals or as needed for SCA, A Pre, M Recommended, not required Recommended, not required Pre and Post (M), Clean (A) Pre and Post, M Pre, During, and Post; M Pre and Post, M Pre, During, and Post; M Pre, During, and Post; M Pre and Post, M Pre, M Pre, A Pre, A Pre, M Recommended, not required Pre and Post, M A Pre, M A Pre, M Pre, S Pre, A A Pre and During, M Pre, M M A 4 hrs every 36 months (see NFPA 110 8.4.9) Recommended, not required Per engine manufacturer A Pre, M A, Per factory recommendation A Recommended, not required Recommended, not required A, Per factory recommendation high and medium volt
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Component GENERAL Inspect general condition of EPSS, any unusual condition of vibration, leakage, noise, temperature, or deterioration Inspect service room or housing housekeeping RESTORE Restore system to automatic operation condition
Frequency, whichever comes sooner: M=Monthly or after 100 hrs, Q=Quarterly, S=Semi-annually or after 250 hrs, A=Annually or after 500 hrs || Assume genset is exercised monthly. Designees pre, post and during indicate when to inspect during monthly exercise Pre, and Post, M Pre, During, and Post; M Post, M
5.2 Terminology
The following section explains the terminology and acronyms in the table above. Visually inspect visually evaluate the state of the system, subsystem or component Check examine or investigate as to determine accuracy, quality or condition DCA Diesel Coolant Additive SCA Supplemental Coolant Additive EPS Emergency Power System EPSS Emergency Power Supply System AHJ Authority Having Jurisdiction
6.0 Procedures
The following information is intended to provide qualified service technicians the procedures for the above maintenance items and to make certain all technicians provide the same level of quality maintenance for all customers.
6.1 Pre-Departure Practices

Technicians are to review parts list and work order instructions prior to leaving the shop. Review with advisor if any questions arise. Technicians are to notify their site contact of the details given on the work order. The actual scheduling will be established by the service manager, service writer, or project manager. It is expected that the technician will advise the appropriate parties regarding substantial delays from the intended arrival time indicated.
6.2 On-Site Practices

All maintenance tasks must be assessed for health and safety risks. All preventative measures identified must be actioned. Accompaniment is required for tasks where the presence of someone else will add significantly to the safety of the task. Read, understand, and comply with all Caution and Warning notes in this section, those contained within other chapters of this document, and those contained with the documentation supplied with the generator set. Make certain adequate lighting and staging (where required) are installed. CAUTION: Only authorized and qualified maintenance technicians, who are familiar with the equipment and its operation, should carry out maintenance. CAUTION: Before carrying out any maintenance work, the technician should become familiar with all the caution and warning notes in this document, together with all the documentation supplied with the generator set. CAUTION: Always disconnect a battery charger from its AC source before disconnecting the battery cables. Failure to do so can result in voltage spikes high enough to damage the DC control circuits of the generator set. WARNING: Accidental starting of the generator set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnecting the starting battery cables (negative [] first) using an insulated wrench. Make certain battery area has been well-ventilated before servicing the battery. Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury. Arcing can occur when cables are removed or replaced, or when the negative () battery cable is connected and a tool used to connect or disconnect the positive (+) battery cable touches the frame or other grounded metal part of the generator set. Insulated tools must be used when working in the vicinity of the batteries. Always remove the negative () cable first and reconnect last. Make sure hydrogen from the battery, engine fuel and other explosive fumes are fully dissipated. This is especially important if the battery has been connected to a battery charger.
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WARNING: To complete maintenance tasks at height, refer to local legislative requirements. Suitable equipment for performing these tasks must be used in accordance with the local guidelines and legislation. Failure to follow these instructions can result in severe personal injury or death. WARNING: Do not use the skid (bedframe) or any part of the generator set as a means of access. This could result in severe personal injury or death and/or property and equipment damage. WARNING: Some internal components in the panel may have live exposed terminations even if the generator set is not running. Isolate all external electrical supplies prior to access of the control panel. Voltages are present which can cause electrical shock, resulting in personal injury. Even with the power removed, improper handling of components can cause electrostatic discharge and damage circuit board components.
6.3 Locking the Generator Set Out of Service

Before any work is carried out for maintenance, etc., the generator set must be immobilized, as detailed in the following procedure (section 6.3.1). NOTE: Refer also to the Operators engine specific manual. This manual contains specific equipment instructions that may differ from the standard generator set. WARNING: Before carrying out any maintenance, isolate all supplies to the generator set and any control panels. Render the set inoperative by disconnecting the plant battery. WARNING: If the engine has been running recently, explosive gases (given off during battery charging) may be present in the vicinity of the batteries. Ignition of battery gases can cause severe personal injury. Make sure the area is well ventilated before disconnecting batteries. 6.3.1 Immobilizing for Safe Working NOTE: Shut down the engine first. To immobilize the engine: 1. Press the Off mode switch on the Operator Panel. 2. Press the Emergency Stop button. This will prevent the starting of the generator set regardless of the Start signal source and will therefore provide an additional safety step for immobilizing the generator set. NOTE: When this Stop button is pressed, the Operator Panel will indicate the Shutdown condition by illuminating the red Shutdown status LED and displaying a message on the graphical LCD display. NOTE: This fault will affect the Fault History memory bank. 3. As an additional precaution, thoroughly ventilate the plant room before disconnecting any leads. 4. Isolate and lock off the supply to the heater, where fitted. 5. Isolate and lock off the supply to the battery charger, where fitted. 6. Isolate the fuel supply to the engine. 7. Disconnect the starting batteries and control system batteries, (if separate). Disconnect the negative () cable first, using an insulated wrench. 8. Fit warning notices at each of the above points to indicate Maintenance in Progress Plant Immobilized for Safe Working.
6.4 Fuel System

WARNING: Ignition of fuel can cause serious personal injury or death by fire or explosion. DO NOT permit any flame, cigarette, or other igniter near the fuel system, or in areas sharing ventilation. WARNING: Engine fuel actuators can operate at voltages up to 140 Volts DC. WARNING: Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion which may result in severe personal injury or death. CAUTION: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and the injection nozzles. Use ASTM No. 2D fuel with a minimum Cetane number of 40. No. 2 diesel fuel gives the best economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 are often needed in high altitudes, or extremely low ambient temperatures, to prevent misfires and excessive smoke. Contact your authorized distributor for your operating conditions. NOTE: A diesel fuel to BS 2869:2010; (Fuel oils for agricultural, domestic and industrial engine and boilers), conforming to the requirements and test methods of that specification would be an acceptable alternative to ASTM No. 2D. Revision B Revision Date: 06/03/12 13 of 38
Refer to Cummins Inc. Required Diesel Fuel Specifications Bulletin 3379001 for further information. 6.4.1. Main supply tank level Check the main tank fuel level prior to and after the monthly exercise. Check generator sets with sub-base, base, belly, or above ground tanks; or other fuel vessels with reasonable access. Record the fuel level. Compare the pre-exercise level against the post-exercise level. The difference should be appropriate for the length of the run and dependent on tank size. The technician is to use judgment to determine if tank level was unreasonably lower. 6.4.2. Day tank level Check the day tank fuel level prior to and after the monthly exercise. Record the level. Check the day tank controls and pumps by operating the day tank controls where available. Inspect for leaks at all components. Inspect the wiring to and from the controls. Check the alarms and other status indicators. On open-top secondary tanks visually inspect for debris and fluids in the rupture basin (also known as interstitial or containment basin). Check for obstructions at locally-mounted vents. Compare the pre-exercise level against the post-exercise level. The difference should be appropriate for the length of the run and dependent on tank size. The technician is to use judgment to determine if tank level was unreasonably lower. 6.4.3. Day tank float switch In applications where a day tank is used, the fuel level float switch will control day tank pumps. Test the day tank float switch by manually moving the switch and simulating lower fuel level than required. This should signal the transfer pumps to come on and fuel level in the day tank to rise. Inspect for leaks at all components. Inspect the wiring to and from the controls and level switch. 6.4.4. Supply / transfer pump operation In applications where a day tank is used, there should be a priming / test control for day tank pumps. Test the day tank supply/transfer pump by manually actuating the priming / test button. This should signal the transfer pumps to come on and fuel level in the day tank to rise. Check the lubrication instructions on the motor. Lubricate as required per specifications. Visually inspect for leaks at the components. Inspect the wiring to and from the transfer pump(s). Inspect the supply line for leaks. Retighten the fuel line connections if required. 6.4.5. Solenoid valve operation In applications where a day tank is used, these valves should become active when the transfer pump is commanded to run. Test the day tank fuel supply solenoid valves prior to the monthly exercise, by manually actuating the priming / test button. This should signal the transfer pumps to come on and fuel supply valves to open. The level in the day tank should rise. Inspect for leaks at all components. Inspect the wiring to and from the solenoid(s). 6.4.6. Fuel filter Refer to the engine specific manual for a more detailed procedure for draining the fuel filters. The fuel filters can be inspected for collected water by checking the clear bowl at the bottom of each filter. To drain the water: 1. Shut off the engine. 2. Disconnect the batteries. 3. Close the fuel supply valve. 4. Place a suitable container under the fuel filter. 5. With the fuel supply valve closed, open the vent cap to break the airlock in the filter. 6. Open the drain valve counterclockwise until the valve drops down about one inch (25 mm). Accumulated water will drain first. Drain the filter sump of water until clear fuel is visible. 7. When fuel begins to flow out of the drain, push the valve up and turn the valve clockwise to close the drain valve. The drained liquids must be disposed of in accordance with local environmental regulations.
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FIGURE 1. DRAINING THE FILTER/SEPARATORS
6.4.6.1 Fuel filters removal
FIGURE 2. 1 Vent Cap, 2 Drain Valve, 3 Collar, 4 Clear Cover
WARNING: Fuel is flammable depending on the circumstances. To reduce the possibility of fire resulting in severe personal injury, death, or property damage never smoke or allow sparks or flames (such as pilot lights, electrical switches, or welding equipment) in the work area, when inspecting or performing service or repairs on the fuel system. NOTE: The fuel must be drained from the filter head prior to removing the element. Do not allow fuel to drain onto the ground. Drained fuel must be collected and disposed of in accordance with local environmental regulations. 1. 2. 3. 4. 5. 6. 7. 8. 9. Revision B Revision Date: 06/03/12 Shut off the engine. Disconnect the batteries. Close the fuel supply shutoff valve. Place a suitable container under the fuel filter to be replaced. With the fuel supply valve closed, use the collar/vent cap wrench to open the vent cap to break the airlock in the filter. Open the drain valve counterclockwise until the valve drops down about one inch (25 mm). Accumulated water will drain first. Drain the filter sump of water until clear fuel is visible. When fuel begins to flow out of the drain, push the valve up and turn the valve clockwise to close the drain valve. Loosen the collar with the collar/vent cap wrench. Remove the clear cover, filter spring, fuel filter element, and o-ring. 15 of 38
10. Remove the sealing grommet. 11. Discard the o-ring and grommet. 6.4.6.2 Fuel filters - element replacement
FIGURE 3. 1 Filter Spring, 2 Filter Element, 3 Sealing Grommet, 4 O-Ring WARNING: Fuel is flammable depending on the circumstances. To reduce the possibility of fire resulting in severe personal injury, death, or property damage never smoke or allow sparks or flames (such as pilot lights, electrical switches, or welding equipment) in the work area, when inspecting or performing service or repairs on the fuel system. NOTE: Fuel filter replacement includes the appropriate o-ring and sealing grommet. The o-ring and grommet must be replaced with the filter element to make sure of proper operation. 1. 2. 3. Install a new o-ring, filter element, (supplied with a sealing grommet inserted into the filter element), the filter spring, and the clear cover. Install the vent cap and the collar onto the clear cover. Hand tighten. Do not use tools to tighten the collar.
6.4.7. Strainer, water in system, dirt leg [contaminant] Using a water-indicating paste, check for presence of water in the fuel tank prior to and after the monthly exercise. Unitmounted tanks are to be tested for water. If water is found, it should then be recommended that a fuel sample is drawn for laboratory analysis. See the fuel sampling procedure for further details in 6.4.11. Inspect the fuel strainer in the supply line prior to and after the monthly exercise. Clean the strainer of debris. The fuel filters can be inspected for collected water by checking the clear bowl at the bottom of each filter prior to and after the monthly exercise. To drain the water: 1. Shut off the engine. 2. Disconnect the batteries. 3. Close the fuel supply shutoff valve. 4. Place a suitable container under the fuel filter to be replaced. 5. With the fuel supply valve closed, use the collar/vent cap wrench to open the vent cap to break the airlock in the filter. 6. Open the drain valve counterclockwise until the valve drops down about one inch (25 mm). Accumulated water will drain first. Drain the filter sump of water until clear fuel is visible. 7. When fuel begins to flow out of the drain, push the valve up and turn the valve clockwise to close the drain valve. 8. Before starting the engine, be sure to open the fuel supply valve. 9. If more than 2 oz (60 ml) is drained, refilling of the filter is required to prevent hard starting. CAUTION: Do not over-tighten the valve. Over-tightening can damage the threads. NOTE: If more than 2 oz (60 ml) is drained, refilling of the filter is required to prevent hard starting. Revision B Revision Date: 06/03/12 16 of 38
The drained liquids must be disposed of in accordance with local environmental regulations.
FIGURE 4. DRAINING THE FUEL/WATER SEPARATOR
Prior to and after the monthly exercise, inspect the bedframe fluid containment area if applicable. Any liquid should be drained off and disposed of in line with local health and safety regulations. Failure to perform this action may result in spillage of liquids likely to contaminate the surrounding area.
1 Oil Filler, 2 Dip Stick, 3 Containment Area FIGURE 5. FLUID CONTAINMENT INSPECTION
Any other fluid containment area must also be checked and emptied as above. 6.4.8. Flexible hoses and connectors WARNING: Moving parts can cause severe personal injury or death. Use extreme caution around hot manifolds, moving parts, etc. To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbocharger and exhaust system.
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FIGURE 6. HOSES AND FUEL LINE INSPECTION
With the generator set operating, inspect the supply lines, return lines, filters, and fittings for leaks. Check any flexible sections for cuts, cracks, abrasions, and rubbing that could cause breakage. If any leaks are detected, shut down the generator set. Inspect all diesel fuel hoses for deterioration, leaks, cracks, abrasion, or other damages prior to and after the monthly exercise. Inspect all hose clamps for correct type and appropriate tension. If loose or over-torqued clamps are suspected, see addendum pertaining to hose clamp torque. Make sure flexible hoses are not rubbing against anything. It may be necessary to note suspect areas (e.g. areas where there may be high vibration) and return to inspect those locations when the unit is operating. 6.4.9. Tank vents and overflow piping unobstructed Visually inspect secondary containment storage on day tank(s) and sub-base-tank for the presence of fuel or other fluids and debris, prior to the monthly exercise. Do not utilize drain ports for this inspection unless there is no fluid in the vessel. If fluids are found, determine the source of contamination and fluid type. If tank failure is suspected, it may be necessary to pressure test the vessel in accordance with the manufacturer test procedures. Make note if any fluids are found in the secondary containment vessel and address the issue per the service issue process. Notify the supervisor and the site contact of the findings. Some fuel vessels also have a catch basin to trap any engine-based lost fluids. If the catch basins are found to contain fluids, the source must be located for correction. Also note that the catch basin sections may also catch rainwater from outside sources which poses a risk of tank loss if allowed to remain and then exposed to freezing temperatures. Any fluid source in the catch basin must be evacuated from the tank quickly to prevent overflow and/or freezing. Notify the supervisor per the service issue process. It may be necessary to note suspect areas (e.g. areas where there may be high vibration) and return to inspect those locations when the unit is operating. 6.4.10. Piping Inspect all diesel fuel piping for leaks, cracks, abrasion, or other damage prior to the monthly exercise. Inspect all threaded fitting connections for leaks or looseness. If loose or over torqued fittings are suspected, follow the applicable service instructions for proper tightening or replacement due to over-tightening. Make sure flexible hoses are not rubbing against anything. Inspect the fuel pump low-pressure supply lines for cracks, chafing, leaks, and loose or broken clamps. Inspect the injector high-pressure supply lines for cracks, chafing, leaks, and loose or broken clamps. It may be necessary to note suspect areas (e.g. areas where there may be high vibration) and return to inspect those locations when the unit is operating. 6.4.11. Fuel quality test Fuel tanks must be inspected and maintained to avoid contamination of the fuel by either water or debris. Long-term storage (in excess of six months) is not recommended unless the fuel has been stabilized by the fuel supplier and there is a monitoring program in place. This procedure covers fuel sampling for Cummins high horsepower (HHP) engines using either Industrial Pro or Sea Pro Stage-1 filtration systems. This sampling procedure was designed to obtain the minimum fuel sample quantity required for a contaminant particle count analysis.
TABLE 1. FUEL SAMPLE KIT PARTS
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Part Number CC2724 CC2723 Varies
Description QuickDraw Valve (1/4" NPT) Sampling Pump Kit M14 to 1/4" NPT Fitting
NOTE: Use the M14 to NPT fitting to install the QuickDraw oil sampler in one of the available inlet ports on the Stage-1 fuel filter (Industrial Pro or Sea Pro) as specified. The QuickDraw fitting itself cannot be directly installed into the Stage-1 fuel filter housing. NOTE: If more than one filter housing is available, samples can be taken from any of them. This will not affect the results of the test. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Make sure the sampling area and connectors are clean and accessible before sampling. Idle the engine at 1000 rpm for 5 minutes or until normal operating temperature is reached (minimum coolant temperature of 60 [140 C F]). Shut the engine down, and sample no later than 1 minute after shutdown. Make sure the vacuum pump and other sampling tools are free of debris and any other potential contaminants. Remove the rear metal cap from the pump. Remove the rubber plug from the sampling needle. Place a rubber plug in the rear breathing open area to achieve suction when sampling. Remove the lid from the black plastic mailer and lay it on a clean area facing up. Immediately take the ISO clean jar out of the mailer. Remove the lid of the ISO clean jar. Place the ISO clean jar lid with the black plastic mailer lid to avoid contamination while sampling. Securely screw the jar to the vacuum pump. Remove the cap from the QuickDraw fitting. Connect the pump to the QuickDraw fitting. Actuate the vacuum pump, and fill the sampling jar.
NOTE: Discard the first jar of sampled fuel, in accordance with local environmental regulations, to prevent contamination of the sample. If this is not the first sample taken, in one sampling event, go to step 16. 15. Do not reuse the jar used for the first sample. 16. Immediately connect a new, ISO (C) sampling jar to the pump. Connect the pump to the QuickDraw valve if the pump was removed in the previous step. Actuate the pump, and fill the jar 3/4 full. Particle count testing usually requires 80 ml [3 oz] sample or more. 17. Remove the jar from the vacuum pump, and immediately install the lid firmly onto the sample jar to prevent contamination. The lid must be tight so the sample does not leak. 18. Consult the fluid analysis lab for shipping and handling.
6.5 Lubrication System

6.5.1. Lubricating oil level WARNING: Crankcase pressure can blow out hot oil and cause severe burns. Do NOT check the oil while the generator set is operating. CAUTION: Do not operate the engine with the oil level below the low mark or above the high mark. Overfilling can cause foaming or aeration of the oil while operation below the low mark may cause loss of oil pressure. CAUTION: Prolonged and repeated skin contact with used engine oils can cause skin disorders or other bodily injury. Comply with all local health and safety regulations/codes when handling or disposing of used engine oil.
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FIGURE 7. ENGINE OIL LEVEL CHECK
NOTE: Use high-quality 15W-40 multi-viscosity lubricating oil such as Cummins Premium Blue or its equivalent. Consult your authorized distributor for the correct lubricating oil for your operating conditions. Check the oil level prior to and after the monthly exercise. The oil level should not be checked until the oil has settled into the oil pan after the engine has been shut down for at least 15 minutes. Check the oil level with the dipstick oil gauge located on the engine. The dipstick is stamped with high and low marks to indicate the level of oil in the crankcase. Keep the dipstick with the engine and oil pan with which it was originally furnished. Keep the oil level as near the H (high) mark as possible, but never above it. When filled to the high level, oil will just start to flow from the weep hole near the center of the oil pan. Check and record the oil level prior to and after the monthly exercise. 6.5.2. Lubricating oil and filter change 1. Operate the engine until the water temperature reaches 60 [140 C F]. 2. Shut off the engine. 3. Remove the oil drain plugs, and drain the oil immediately to make sure all contaminants are removed from the engine. NOTE: The Eliminator Centrifuge and Bypass Centrifuge do not have to be serviced until the 1,000-hr service interval. NOTE: The QST30 engine has either four combination or full-flow oil filters. When equipped with full-flow oil filters, two bypass filters will be located at the rear of the engine. 4. 5. Use an oil filter wrench, Part Number 3375049, or equivalent, to remove the oil filters. Discard the filter if it is not required for failure analysis.
NOTE: The oil filter O-ring can stick on the filter head. Make sure it is removed. 6. 7. 8. Clean the oil filter head sealing surface with a lint-free cloth. Use engine oil to lubricate the oil filter's rubber seal. Fill the oil filters with clean engine oil.
NOTE: Mechanical over-tightening can distort the threads or damage the filter element seal. If the threads appear damaged, replace the oil filter head adapter. 9. Locate the oil filter wrench, near the top of the oil filter canister. This will reduce the possibility of damaging the oil filter. 10. Install the oil filter, turning it until the seal contacts the filter head's sealing surface. 11. Turn the oil filter an additional 3/4 to 1 full turn. 12. Install and tighten the drain plug(s). Torque Value: 47 N-m [35 ft-lb]
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Use a high quality 15W-40 multi-viscosity engine oil that meets the American Petroleum Institute (API) performance classification CE or CF4 or better. Choose the correct oil for the operating climate. Refer to the appropriate service manual for oil viscosity recommendation. 13. Fill the engine to the correct level with clean engine oil. 14. Check the oil level on the dipstick. The level must be to the high (H) mark on the dipstick. Do not overfill. Drain off excess oil in a pan. Before starting engines not equipped with a PRELUB system, complete the following steps. Engine damage will occur, because of inadequate lubrication at startup, if these steps are not followed. NOTE: This procedure will cause fault codes to be logged for unplugged sensors. They will go inactive and have no effect on engine operation after the sensors are connected. The following steps must be completed after each oil change or after the engine has been shut down for more than five days to make sure the engine receives the correct oil flow through the lubricating system. 1a. On engines using mechanically-actuated injectors, disconnect the engine position sensor. 1b. On engines using electronically-actuated injectors, the following two sensors need to be disconnected for priming: i. Engine speed sensor located in the flywheel housing ii. Camshaft position sensor located above the fuel pump on the left bank side. 2. Use the starter motor to rotate the engine crankshaft until oil pressure is indicated on the gauge or the warning light goes out. 3. Connect the engine position sensor on engines with mechanically-actuated injectors. 4. Connect the engine speed and camshaft position sensors on engines with electronically-actuated injectors. 5. Operate the engine at idle speed to inspect for leaks at the filters and drain plug(s). 6. Shut the engine off. 7. Wait 15 minutes to allow the oil to drain from the upper parts of the engine. 8. Check the oil level. 9. Add oil as necessary to bring the oil level to the high (H) mark on the dipstick. 6.5.3. Lubricating oil filter(s) Change the oil filter per the manufacturers recommendation or at the time of a full oil change. NOTE: The Eliminator Centrifuge and Bypass Centrifuge do not have to be serviced until the 1,000-hr service interval. NOTE: The QST30 engine has either four combinations or full-flow oil filters. When equipped with full-flow oil filters, two bypass filters will be located at the rear of the engine. To replace the oil filter: 1. Use an oil filter wrench, to remove the oil filters. 2. Discard the filter if it is not required for failure analysis. NOTE: The oil filter O-ring can stick on the filter head. Make sure it is removed. 3. Clean the oil filter head sealing surface with a lint-free cloth. 4. Use engine oil to lubricate the oil filter's rubber seal. 5. Fill the oil filters with clean engine oil. NOTE: Mechanical over-tightening can distort the threads or damage the filter element seal. If the threads appear damaged, replace the oil filter head adapter. 6. 7. 8. 9. Locate the oil filter wrench, near the top of the oil filter canister. This will reduce the possibility of damaging the oil filter. Install the oil filter, turning it until the seal contacts the filter head's sealing surface. Turn the oil filter an additional 3/4 to 1 full turn. Install and tighten the drain plug(s). Torque Value: 47 N-m [35 ft-lb]
6.5.4. Lubricating oil heater Inspect all oil heater hoses for deterioration, leaks, cracks, checking, abrasion or other damage. Inspect all hose clamps for correct type and appropriate tension. If loose or over-torqued clamps are suspected, re-torque the hose clamps to proper torque. Make sure flexible hoses are not rubbing against anything.
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Inspect the electrical element for signs of overheating or shorting such as discoloration of the material used in the components and/or melting. Inspect the heater element wiring to make sure that all wiring connections are tight and that none of the wires show fraying and/or chaffing. 6.5.5. Crankcase breather Inspect the breather tube for sludge, debris, or ice in the tube prior to the monthly exercise. Inspect the tube more frequently in icy conditions. If sludge, debris, or ice is found, clean the tube with detergent and warm water or a solvent. Dry the tube with compressed air. Visually inspect the tube for cracks or damage. If damage is found, replace the crankcase breather tube. If there is soot inside the tube, check for leaks in the engine exhaust system and exhaust blow back into the air intake. Also inspect for the possibility of exhaust from other equipment soiling the cartridge. Inspect the breather cleaner/cartridge for excessive oil mist. If the cartridge appears oily, check for fumes escaping from the crankcase breather. Inspect the cartridge for soot or oil. Inspect the clamps and flexible hose or tubing to make sure all the fittings are air-tight on cleaners with exhaust aspirators. The precleaner dust bin is self-cleaning. Clean the precleaner openings. Remove all soot, oil film, and any other objects that can become lodged in the opening. Remove debris in the lower portion of the precleaner and aspirator tubing. Remove all foreign materials from the inside of the air cleaner housing. Cummins does not recommend cleaning and reusing the cartridge. To remove the cartridge, begin by loosening the wing nuts on the air cleaner housing. Remove the precleaner panel with the dust bin. If the precleaner panel is equipped with an exhaust aspirator, loosen the u-bolt clamp securing the precleaner to the aspirator tubing. Remove the dirty cartridge by inserting fingers into the cartridge opening (loosen all four corners of the cartridge one at a time) and pulling it straight out. With the larger cartridge, break the seal along the edges. After the seal has been broken, pull the cartridge straight out and slightly up so the cartridge will clear the sealing frame and edges of the air cleaner housing Install a new cartridge by inserting fingers in the cartridge opening and pushing the cartridge straight into the housing. Do not hit the cartridge tubes against the sealing flange on the edges of the air cleaner housing. Firmly press all edges and corners of the cartridge with fingers to create a positive air seal against the sealing flange of the housing. The cartridge must not be pounded or pressed in the center to seal the cartridge. Care must be taken to keep the cleaner's face unobstructed. Replace the precleaner panel, and tighten the wing nut by hand. Turn the wing nuts 1 to 1-1/2 turns with a small adjustable wrench. Do not over-tighten. For a precleaner equipped with an exhaust aspirator, attach the aspirator tube to the precleaner panel, and tighten the U-bolt.
6.6 Cooling System

WARNING: Contact with hot coolant can result in serious scalding. Allow the cooling system to cool to 50 C (122 F) before releasing pressure and removing the water jacket radiator cap. CAUTION: Loss of coolant can allow engine to overheat without protection of shutdown device, and cause severe damage to the engine. Maintain coolant level for proper operation of high engine temperature shutdown system. 6.6.1. Coolant level WARNING: Do not remove the radiator cap from a hot engine; wait until the temperature is below 50 (122 before C F) removing the pressure cap. Failure to do so can result in personal injury from heated coolant spray or steam. Remove pressure cap slowly to release coolant system pressure. CAUTION: Avoid prolonged or repeated skin contact with antifreeze. Comply with all local health and safety regulations/codes when handling or disposing of antifreeze. CAUTION: Never use a sealing additive to stop leaks in the coolant system. This can result in a blocked coolant system and inadequate coolant flow causing the engine to overheat.
FIGURE 8. COOLANT LEVEL PROCEDURE
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Check the coolant level prior to and after the monthly exercise. A sight glass is provided. The coolant level should be approximately in the middle of the sight glass, with the coolant temperature at 120 F (50 C) or lower. Clean the sight glass to aid in ease of level inspection. The standard coolant concentration is 50% Ethylene Glycol and water, this concentration must be maintained. Warranty claims for damage will be rejected if the incorrect mix of antifreeze has been used. The recommended antifreeze is Fleetguard Compleat ES, which is a low-silicate antifreeze, or its equivalent. CAUTION: Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool to below 50 C (122 before adding coolant. F) NOTE: On applications that use a coolant recovery system, check to make sure the coolant is at the appropriate level on the coolant recovery tank dependent on engine temperature. Fill the cooling system with coolant to the bottom of the fill neck in the radiator or expansion tank with the coolant temperature at 50 (122 or lower. C F) NOTE: Some radiators have two fill necks, both of which must be filled. Refer to the generator set specific drawings supplied with the set. 6.6.2. Coolant freeze protection level Using a clean sample jar, draw an antifreeze sample directly from the radiator or from the radiator drain valve on a cool system. If a sample must be drawn from the bottom tank of the radiator, it is advised that a reasonable amount of coolant be drained first if sampling from the bottom tank to eliminate sediment.) Using a refractometer measure and record the freeze point of the antifreeze. 6.6.3. Antifreeze Fully-formulated antifreeze must be mixed with quality water at a 50/50 ratio (40-60% working range). A 50/50 mixture of antifreeze and water gives a -36 (-34 freezing point and a 100 (228 boiling point, which is adequate for locations. C F) C F) Replace the antifreeze per the manufacturers recommendation or every two years. 6.6.4. Adequate cooling water to heat exchanger Verify proper operation of the cooling system heat transfer. Check the control for evidence of recent High Coolant Temperature alarms. Inspect the cooling system for correct pressure and possible air trapped in the system. If system pressures are out of specification, test the radiator cap for proper operation. Test the coolant for proper antifreeze and SCA (Supplemental Coolant Additive) concentration levels. Test the cooling system for proper water flow. Inspect the cooling lines for restrictions or leaks. Check the water pump for leaks or damage. Test the thermostat for proper operation. 6.6.5. Adequate fresh air through radiator Inspect ducting for leaks and restrictions. Verify the intake ducting is drawing in fresh air, free from exhaust or other harmful fumes and debris. Test louvers for proper operation, see Section 6.6.16. Inspect the cooling fan for proper operation, cracks, bent or loose blades. Check the radiator for damage or restrictions. See Section 6.6.6. If the control indicates a history of high engine temperature alarms, verify the intake manifold air temperatures are within specification. 6.6.6. Radiator Regularly inspect the radiator for signs of corrosion, restriction, and damage.
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FIGURE 9. RADIATOR CHECK
Check for damaged hoses and loose and damaged hose clamps. Inspect the exterior of the radiator (through the guarding) for obstructions. During the service life of a radiator, a build-up of foreign matter can obstruct the flow of air through the radiator cores, reducing the cooling capability. To maintain the efficiency of the radiator, the core will require cleaning. 6.6.6.1 Clean exterior of radiator Remove all dirt and foreign material with a soft brush or cloth. Use care to avoid damage to the fins. If available, use low pressure compressed air or stream of water (maximum of 35 psi/242 kPa) in the opposite direction of normal air flow. When using compressed air or a pressure washer, maintain an angle of 90 to core to prevent damage to radiator fins. With the pressures involved it is important that the distance between the core face and the nozzle is a minimum of 18 in (450 mm); any closer may cause damage. In dust-laden environments, the radiator should not be wet cleaned. This is due to the tendency of this type of contamination to coalesce and become extremely difficult to remove. If using water, protect the engine and the generator from the overspray. Allow the radiator to dry prior to unit start up. 6.6.7. Fan and alternator belt [drive belts]
FIGURE 10. DRIVE BELT INSPECTION
Visually inspect the belt through the guarding. Check for: Intersecting cracks. Small transverse (across the belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with transverse cracks are NOT acceptable. Frays or pieces of material missing. Glazed or cracked side walls. Uneven wear on sidewalls of belt. CAUTION: Do not mix old and new V-belts on the same drive. Inspect drive belts for missing cogs, severe weathering and other visual defects prior to and after the monthly exercise. Inspect the belt alignment and deflection. When applicable, inspect slack adjustment or tension device travel. To remove the fan belt: 1. Move the O/Manual/Auto switch on the control panel to O (off) position. 2. Turn off or remove the AC power from the battery charger. 3. Press the Emergency Stop button, and wait at least 30 seconds. Revision B Revision Date: 06/03/12 24 of 38
4. 5. 6.
Remove the negative (-) battery cable from the generator set starting battery. Remove the fan belt guard (between the engine and radiator) to gain access to the fan belt. Use an 8-point socket and breaker bar or a large wrench to hold the idler in position against the spring tension. Slowly turn the wrench until the spring tension is relieved.
To replace the fan belt: 1. Slip the new fan belt onto the crankshaft and fan hub pulley. WARNING: The fan belt idler is under tension. Do not allow your hands to get between the idler and the belt or the fan hub. Personal injury will result. 2. A. Not using locking bar: Use an 8-point socket and breaker bar or a large wrench to hold the idler in position against the spring tension. Turn the wrench until the idler pulley position is sufficient to position the belt in front of the idler pulley. Align the grooves of the belt on the ribs of the pulley and shaft, and then slowly release spring tension onto the belt. B. Using a locking bar: Use an 8-point socket and breaker bar or a large wrench to hold the idler at a 6 oclock position against the spring tension and install the locking bar (1 [25.4 mm] x 12 [305 mm]) to lock the tensioner at the 6 oclock position. Align the grooves of the belt on the ribs of the pulley and shaft. Remove the locking bar and then slowly release spring tension onto the belt. 3. Install the fan belt guards. 4. Reconnect the starting batteries (negative cables last). 5. Visually check the belt for proper alignment while engine is running. Visually inspect sheaves through the guarding. Check for: Damaged or worn grooves. Breaks on flanges of grooves Frays or pieces of material missing. Glazed or cracked side walls. Uneven wear on sidewalls of belt. CAUTION: V-Belts should never ride in the bottom of the groove. Damaged or worn grooves should not be used. NOTE: Keep foreign materials away from sheaves and belts as this may cause belt slip. 6.6.8. Cooling Fan WARNING: Personal injury can result from a fan blade failure. Never pull on or pry the fan, this can damage the fan blade(s) and cause fan failure. Prior to and after the monthly exercise, visually inspect the cooling fan for loose rivets or retaining bolts, broken welds, cracks, and bent or loose blades.
FIGURE 11. COOLING FAN INSPECTION
Re-lubricate the fan bearings. A grease fitting is provided for each bearing to allow use of a grease gun. Make sure that the grease gun is calibrated before use. Please refer to the specific generator set operators manual for the recommended lubricant and quantity.
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6.6.9. Water pumps Inspect the water pump and bypass for coolant or oil leakage. Check the water pump weep hole for excessive leakage. Listen for pump noise, indicating possible internal damage. Repair or replace as needed. 6.6.10. Condition of flexible hoses, connections, and clamps Inspect the hoses for deterioration, leaks, cracks, checking, abrasions or other visible damage prior to and after the monthly exercise. Inspect the hose clamps for correct sizing and tension. Repair loose or over-torqued clamps and hoses if necessary. Inspect radiator cap and filler neck. Inspect for brass or rubber sealing-ring damage. Inspect for evidence of compromised solder, braze or weld joints. 6.6.11. DCA / SCA level Using a clean sample jar, draw an antifreeze sample directly from the radiator or from the radiator drain valve on a cool system. If a sample must be drawn from the bottom tank of the radiator, it is advised that a reasonable amount of coolant be drained first if sampling from the bottom tank to eliminate sediment. Utilizing a DCA test strip, measure the Molybdate and Nitrate levels. Record the DCA concentration per gallon or unit. Utilize a Quick-Check strip to measure ph, sulfate and chloride levels of the antifreeze. Record the data. 6.6.12. Coolant filters Replacing the coolant filters, 1. Remove the pressure cap from the radiator. 2. Turn valve on the coolant filter head to the OFF position to prevent water loss. 3. Remove the coolant filters. 4. Clean the area around the coolant filter head and gasket surface, to prevent contamination. a. The O-ring can stick on the coolant filter head. Make sure the O-ring is removed. 5. Discard the used coolant filters. 6. Lubricate the seal on the coolant filter with clean engine oil. 7. Install the new coolant filters. a. Turn the coolant filter clockwise until the seal touches the coolant filter head. b. Turn the coolant filter an additional to of a turn after contact. 8. Turn the valve on the coolant filter head to the ON position. 6.6.13. Coolant Heater Cummins recommends an inspection for all coolant heater hoses for deterioration, leaks, cracks, checking, abrasion or other damages prior to the monthly exercise. Inspect all hose clamps for the correct type and appropriate tension. If loose or overtorqued clamps are suspected, re-torque the hose clamps to the proper torque. Make sure flexible hoses are not rubbing against anything. Check the operation of the coolant heater by verifying that hot coolant is being discharged from the outlet hose. Do Not Touch the Outlet Hose. If the heater is operational, radiant heat should be felt with a hand held close to the outlet hose. Inspect the electrical element for signs of overheating or shorting such as discoloration of the components and/or melting prior to the monthly exercise. Inspect the heater element wiring to make sure that all wiring connections are tight and that none of the wires show signs of fraying and/or chafing. Make certain the heater is cycling between the temperature ranges of 32 to 54 C (90 to 130 F) or as outlined in the generator specific service manual. 6.6.14. Low coolant sensor Verify the low coolant sensor is properly reading the coolant level. Inspect the sensor harness for corrosion. connections for loose connections and for evidence of fluids. Inspect
6.6.15. Thermostat Inspect the thermostat for cracks, corrosion, or damage. If thermostat is suspected of malfunctioning, test the thermostat for proper operation. 6.6.16. Inspect duct work, clean louvers Inspect louvers for proper operation, damage, debris and possible restrictions prior to and after the monthly exercise. Make certain duct work is properly mounted and is clear of any leaks or restrictions. Repair and clean per the manufacturers recommendations. 6.6.12. Louver motor and control Check for proper louver motor and control operation prior to and after the monthly exercise. Louvers should open immediately upon generator set startup for emergency/standby installations. In cold climates, louvers may open partially for combustion air only and may be controlled to regulate the temperature in the room. Consult with the customer and/or building engineering group to verify installation design parameters.
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6.7 Exhaust System

WARNING: Exhaust components become very hot when the generator set is in use and remain hot for a period of time after the generator set has been shut down. These components can cause severe personal injury or death from contact. Allow these components to cool completely before performing any maintenance tasks. WARNING: Inhalation of exhaust gases can result in serious personal injury or death. Be sure deadly exhaust gas is piped outside and away from windows, doors or other inlets to buildings. Do not allow exhaust gases to accumulate in habitable areas. WARNING: Moving parts can cause severe personal injury or death. Use extreme caution around hot manifolds, moving parts, etc. 6.7.1. Leakage Visually inspect all connections and flex sections of the exhaust system prior to and after the monthly exercise. Look for signs of carbon or soot on the outside of the pipe. Inspect for excessive rust or corrosion that may lead to holes in the exhaust system piping. If any signs of leakage are present, have these components service promptly. While the generator set is operating, inspect the entire exhaust system visually and audibly including the exhaust manifold, muffler, and exhaust pipe. Check for leaks at all connections, welds, gaskets, and joints and also make sure that exhaust pipes are not heating surrounding areas excessively. If any leaks are detected, shut down the generator set and have leaks corrected immediately. 6.7.2. Drain condensate trap Locate the condensation traps at the exhaust silencers or any low points in the exhaust system prior to and after the monthly exercise. Open the traps and catch any water that may run out of them. Once empty, thread the plugs back in and tighten to the manufacturers specification. 6.7.3. Insulation and fire hazards If equipped with thermal insulation on the exhaust piping, inspect the insulation prior to and after the monthly exercise. Check for any severe burn marks and soot marks that would indicate leaks in the exhaust piping. While the generator set is running, review the equipment, looking for any loose or hanging insulation, and secure promptly. Inspect enclosure or room insulation at or near where it passes through roofs, walls, or bulkheads for signs of heat or sooting. If any of these signs are present, have them repaired immediately. 6.7.4. Exhaust system hangers and supports Inspect all exhaust system hanger and/or supports prior to and after the monthly exercise. Make certain the fasteners are tight and that the banding material is not deformed or damaged. Make certain the exhaust system tubing is either level or at the appropriate gradient for condensation drainage per the original site plans. If any damage or deformity is present, repair immediately. It may be necessary to note suspect areas (e.g. areas where there may be high vibration) and return to inspect those locations when the unit is operating. 6.7.5. Flexible exhaust section Visually inspect all bellows or braiding in the flex sections of the exhaust system prior to and after the monthly exercise. Look for signs of carbon or soot on the outside of the pipe. Inspect for excessive rust or corrosion that may lead to holes in the exhaust system piping. Look for stress cracks in the low sections of the bellows or the peaks that can occur after vibration and thermal cycling. If any signs of leakage are present, have these components serviced promptly.
6.8 Battery System

Maintenance-free batteries are sealed and do not require the addition of electrolyte. Some manufacturers of maintenance-free batteries provide an eye or some visible means of telling when the battery is discharged or approaching the end of its useful life. Record battery installation date. Recommend replacement per battery manufacturer replacement schedule. 6.8.1 Safety Precautions The handling and proper use of lead-acid batteries is not hazardous providing the correct precautions are observed and personnel are trained in their use. 6.8.1.1 General Precautions CAUTION: Never lay tools or metal objects across the top of the battery. This can cause arcing that may ignite battery gases causing explosions resulting in personal injury. CAUTION: Keep batteries upright to prevent spillage. Electrolyte is a dilute sulphuric acid that is harmful to the skin and eyes. Revision B Revision Date: 06/03/12 27 of 38
CAUTION: Use tools with insulated handles to prevent the risk of electric shock. 6.8.1.2 Fire Hazard WARNING: Make sure that batteries are charged in a well ventilated area, away from naked flames and sparks. WARNING: Before disconnecting the battery, always remove power from the mains powered battery charger (where fitted). CAUTION: During the charging of a battery, explosive gases are given off. Keep the battery well ventilated and away from naked flames and sparks. NO SMOKING. CAUTION: When putting a battery into service on a generator set, connect the earth lead LAST; when removing the battery, disconnect the earth lead FIRST. 6.8.1.3 Fluid Hazard CAUTION: Take care when filling batteries with electrolyte and always wear personal protective equipment. WARNING: Never add undiluted sulfuric acid to a battery. WARNING: Always wear an acid-proof protective apron, goggles and gloves when handling electrolyte. If electrolyte is splashed on the skin or in the eyes, flush the affected areas immediately with water and seek medical attention. WARNING: Thoroughly ventilate battery area before working on the battery. Ignition of explosive battery gases can cause severe personal injury. Do not smoke while servicing batteries, or cause sparks or arcing that may ignite battery gases. CAUTION: Always disconnect a battery charger from its AC source before disconnecting the battery leads. Failure to do so can result in voltage spikes high enough to damage the DC control circuits of the generator set. WARNING: To prevent dangerous arcing, always disconnect the negative (-) ground cable from the battery using an insulated wrench, before working on any parts of the electrical system or the engine. Discharge static electricity from body before touching batteries, by first touching a grounded metal surface. CAUTION: Never lay tools or metal objects across the top of the battery. This can cause arcing that may ignite battery gases causing explosions resulting in personal injury. CAUTION: Keep batteries upright to prevent spillage. Electrolyte is a dilute sulphuric acid that is harmful to the skin and eyes. CAUTION: Use tools with insulated handles to prevent the risk of electric shock. 6.8.1. Electrolyte level CAUTION: Never add tap or well water, and never allow the battery electrolyte to drop below the top of the plates; otherwise, damage will occur. CAUTION: Do not add water in freezing weather unless the engine will run long enough (two to three hours) to assure a thorough mixing of water and electrolyte. Check the level of the electrolyte (acid and water solution) in the batteries prior to the monthly exercise. Maintain the electrolyte to the levels indicated in the table below by the addition of distilled water only, and recharge. Replace the vent plugs once filling is completed.
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TABLE 2. ELECTROLYTE LEVELS Electrolyte Level Above Plates (mm) 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 12 8 8 8 12 8 12 8 8 4 8 6 8 8 8 8 8 8 8 8 8 8 8 Bench Charging Rate (A/hour) 3 3.5 4 4 9 3.5 3.5 4 4 6 3 4 4 4 5 7 7 7 7 6 8 6 7 7 4 5 3.5 4 5 7 6 5 6 6 3.5 7 6 8 12 6 14 14 14 14 14 14 14 20 Electrolyte Level Above Plates (mm) 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 16 16 16 16 16 16 16 16 16 16 16 16 16 8 16 8 8 8 8 8 8 8 8 8 8 8 Bench Charging Rate (A/hour) 20 11 20 20 25 11 6 7 20 20 15 25 9 10 12 13 15 15 14 8 9 12 9 12 9 8 12 12 9 12 12 9 9 9 6 9 16 20 25 16 20 25 15 20 15 20 45
Battery Type 1 7 15 16 17 35 36 37 38 46 47 48 49 63 65 67 68 69 70 71 72 73 74 75 77 78 83 84 85 90 91 92 93 97 154 175 191 221 222 279 312 313 315 319 320 321 322 324
Battery Type 325 327 328 329 332 333 386 404 414 415 471 484 501 511 521 531 541 543 591 602 612 635 643 644 645 646 647 648 649 655 656 663 664 665 678 679 701 702 703 711 712 713 721 722 732 733 769
NOTE: If not listed in the above table, use the bench rate given in the catalog, or charge at a current equal to 10% of the nominal capacity at the twenty-hour rate (Amperes/hour), or 5% of the reserve capacity in minutes. NOTE: Batteries of the 800 series should be prepared in accordance with the instructions supplied with each battery. If the cell is low, check the case for leaks. Keep the battery case clean and dry. An accumulation of moisture will lead to a more rapid discharge and battery failure. 6.8.2. Terminals clean and tight Do not remove the battery cables from the batteries with any battery charger operational in the system. Check the battery cable terminals at the battery studs or posts, at the starter motor, starter solenoid, and engine block prior to the monthly Revision B Revision Date: 06/03/12 29 of 38
exercise. Inspect the connections for corrosion. Inspect the connections for loose connections. Inspect the connections for evidence of fluids. Tighten and clean as required. If corrosion is present around the terminal connections, remove the battery cables and wash the terminals with a solution consisting of pound of baking soda added to 1 quart of water. Be sure the vent plugs are tight to prevent cleaning solutions from entering the cells. After cleaning, flush the outside of the battery and surrounding areas with clean water. Reconnect one end of the cable to the negative battery terminal and the other end to ground. This will make sure that any arcing will be away from the battery and least likely to ignite explosive battery gases. After making the connections, coat the terminals with a light application of non-conductive grease to impede corrosion. 6.8.3. Remove corrosion, case exterior clean and dry WARNING: Electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. Do not get the substance in your eyes or in contact with skin. Wear goggles, protective rubber gloves, and apron when servicing batteries. WARNING: In case of skin contact, immediately wash the affected area with soap and water. In case of eye contact, immediately flood eyes with large amounts of water for a minimum of fifteen minutes. Immediately call a physician. Prevent a buildup of dirt or corrosion by wiping the batteries with a damp cloth prior to the monthly exercise. Use a solution consisting of 1/4 lb (0.11 kg) of baking soda added to 1 quart (0.96 liters) of water to neutralize any possible acid. Be sure the vent plugs are tight to prevent any cleaning solution from entering the cells. After cleaning, make sure the battery and surrounding areas are dry. After making connections, coat the terminals with a light application of petroleum jelly to retard corrosion. Keep the battery terminals clean and tight. A loose connection can reduce battery standby time and cause battery fires. Check the battery case on every battery prior to the monthly exercise. Inspect for evidence of corrosion. Inspect for moisture or evidence of moisture. Inspect for cracks in the battery case or indication the battery case is strained / deformed. Check the vent caps for blockage or restrictions. Inspect for discoloration or evidence of heating. Replace the battery case as required. 6.8.4. Specific gravity or state of charge 6.8.4.1 Checking Specific Gravity Using a Hydrometer Use a hydrometer to check the specific gravity (SG) of the electrolyte in each battery cell prior to the monthly exercise. Remove the vent caps. Do not add water at this time. Fill and drain the hydrometer 3 times before sampling. Sample the electrolyte, accumulating enough to support the float in the hydrometer. Hold the hydrometer vertical, and take a reading. Record it. Return the electrolyte back to the cell. Repeat the procedure for every cell. Replace the vent caps. Wipe off any spilled electrolyte. Compare the electrolyte readings. The readings should be at or above factory specification. If any readings register low, recommend battery replacement, or charge battery and repeat test. Correct the specific gravity reading for temperature, by adding four gravity points (0.004) for every ten degrees the electrolyte temperature is above 80 F (27 C). A fully charged battery will have a corrected specific gravity of 1.260 at 25 C (77 F). Charge the battery if the reading is below 1.215.
FIGURE 12. CHECKING SPECIFIC GRAVITY
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6.8.4.2 Checking Specific Gravity Using a Refractometer Follow the instructions included with the refractometer. Obtain a small drop of liquid and place it under the clear plastic cover to check the specific gravity (SG) of the electrolyte in each battery cell.
FIGURE 13. TYPICAL BATTERY ACID REFRACTOMETER
6.8.4.3 Specific Gravity Values for Batteries Hold the hydrometer vertical and take the reading. A fully charged battery will have a corrected specific gravity of 1.260 at 25 C (77 F). Charge the battery if the reading is below 1.215. TABLE 3. SPECIFIC GRAVITY Specific Gravity Temperature For Filling New Cells Ambient temperature normally below 32 C 1.270 Ambient temperature frequently above 32 C 1.240 Maximum permissible temperature of 113 F (45 C) electrolyte during charge
At End of Charge 1.270 1.290 1.240 1.260 113 F (45 C)
Table 3 shows the specific gravity (SG) of electrolyte, corrected to 25 C (77 F). Correct the SG reading for other temperatures by adding or subtracting seven gravity points (0.007) for every 10 C (18 F). Apply the correction formula as follows: 1. 2. For every 10 C (18 F) above 25 C (77 F), subtract 0.007 (7 points) For every 10 C (18 F) below 25 C (77 F), add 0.007 (7 points)
For example: if the specific gravity at 25 C (77 F) is 1.260, then the specific gravity at 15 C (59 F) is 1.267. 6.8.5. Cranking load test Cummins recommends performing a battery load test. Connect the digital multimeter and load tester to the battery. Apply load to the battery to the rated cold-cranking amps (CCA) of the battery for 15 seconds. Record the battery voltage, while the load is still engaged. Repeat for all batteries in the system. 6.8.6. Charger and charge rate Inspect the AC and DC battery chargers prior to and after the monthly exercise. For the DC battery charger, make certain the battery charger output wiring is securely connected to the primary side of the starter solenoid (positive) and the generator set frame (negative) or other grounding location. Inspect the DC battery charger set-up for proper settings. Refer to the applicable Battery Charger service manual for further set-up information. Inspect the condition of the wiring on the AC and DC chargers. Inspect the terminals for loose, broken, corroded, missing, or other damage. Inspect for proper gauge wire from the charger to the battery, with respect to distance. 6.8.7. Equalize charge Water the batteries before performing procedure. Turn battery charger on. Place charger in equalize state. Equalize batteries for 1-2 hours, while maintaining a temperature of less than 125 F. When two consistent specific gravity readings are taken half an hour apart, the batteries are equalized.
6.9 Electrical System

6.9.1. General inspection Verify proper operation of all meters and controls prior to the monthly exercise. Inspect for overheating, moisture, or excess contact corrosion. Carefully inspect insulating materials or standoff insulators for signs of contamination. Clean contaminated surfaces with an approved solvent. Revision B Revision Date: 06/03/12 31 of 38
Replace and secure all terminal caps, pole covers, and chutes. Check the following while the generator set is operating: Frequency: The generator set frequency should be stable and the reading should be the same as the generator set nameplate rating (50 Hz / 1500 RPM or 60 Hz / 1800 RPM). AC Voltage: At no load, the line-to-line voltage(s) should be the same as the generator set nameplate rating. AC Ammeter: At no load, the current readings should be zero. With a load applied, each line current should be similar. Panel Lamps: When the Operating Panel is first connected to the DC supply, the system runs a check by illuminating each of the indicator lamps in turn. 6.9.2. Tighten control and power wiring connections Check all engine-mounted wiring, senders, and electrical devices. Visually inspect all wiring termination points on the engine, including screw, push-on and plug connections. Correct loose wiring as required. Check all generator set control panel wiring connections and related components. Physically verify wiring point integrity at all screw and pressure block terminal strips. Verify all relay to socket connections. Inspect all wiring terminations to plugs. Inspect terminations to components and modules such as governing controls, field voltage regulators, control relays, etc. Check all accessory components and wiring. All unit-mounted connection boxes, coolant heaters, battery chargers, distribution panels, etc. should be inspected. Wiring between devices should be inspected for signs of strain, overheating, abrasion, etc.
FIGURE 14. CHECK HARNESS CONNECTIONS
6.9.3. Wire chafing where subject to movement Prior to the monthly exercise, check all wiring channels, grommets, zip ties, tie downs, etc (where wire and cabling is subject to movement and vibration). Inspect for abrasion, proper bend radius, strain relief, and pinched insulation. Replace or reroute and refasten where appropriate. 6.9.4. Boxes, panels, and cabinets Prior to the monthly exercise, inspect the cabinets for proper sealing. Open conduit knock-outs or other penetrations should be properly sealed to prevent the introduction of dust, moisture, or other foreign matter prior to the monthly exercise. Enclosures installed outside should be inspected for proper seals and appropriate gasketing. Make certain that the enclosure door securing devices are intact and properly secured. Use a vacuum to remove all dust and debris from the cabinets, panels, electrical boxes, etc. Never use compressed air to blow out dust. 6.9.5. Circuit breakers, fuses Inspect all fuses in the system for integrity prior to the monthly exercise. Replace fuses as required. Inspect all circuit breakers, and test them by simulating an overload condition. Make note to recommend replacement of breakers if they are outside the supplier-recommended useful life. 7.9.6. Calibration of voltage-sensing and current-sensing relays / devices Measure and record the following data and setpoints: (a) Normal source voltage: phase-to-phase, phase-to-ground, and phase-to-neutral (b) Engine start time (from crank start to source available light or relay pickup) (c) Emergency source: voltage phase-to-phase, phase-to-ground, and phase-to-neutral (d) Load current for each phase (e) Momentary override normal deviation where provided Revision B Revision Date: 06/03/12 32 of 38
(f) Transfer time delay where provided (g) Return to normal source time delay where provided (h) Engine cooldown where provided Note that the type of calibration to perform varies for each card. The letters A, B and C are used to designate which of the following three calibration procedures are required for each card/module. Generator set/Parallel board (A, B & C) PT/CT board (A & B) Bus PT (C) CTs (B) Use a calibrated RMS multimeter for accurate measurements. Fluke models 87 or better. (A) Generator set Voltage Display Calibration 1. With the generator set OFF, attach a calibrated voltmeter to the AC output from L1 to L2. (Use L1 to Neutral for single phase alternators.) 2. Start the generator set and allow it to reach normal operating speed. 3. Calibrate the voltage reading for L1 so that the reading on the display agrees with the calibrated voltmeter. 4. Shut the generator set off. 5. Repeat steps 2 through 5 for L2 and L3. (In step 2, attach the meter to the AC output from L2 to L3 to calibrate L2 and from L3 to L1 to calibrate L3.) 6. Exit menu to save changes. (B) Generator set Ammeter Display Calibration 1. With the generator set OFF, attach a calibrated ammeter to L1. 2. Start the generator set, and allow it to reach normal operating speed. 3. Load the generator set to maximum rated kVA at rated voltage. 4. Calibrate the reading for L1 current so that the reading on the display agrees with calibrated ammeter. 5. Repeat steps 2 through 5 for L2 and L3. (In step 2, attach meter to L2 to calibrate L2 current and to L3 to calibrate L3 current.) 6. Exit menu to save changes. (C) Bus Voltage Calibration 1. With all generator sets OFF, attach a calibrated voltmeter to TB1-A (L1) and TB1-B (L2) of the bus PT module. 2. Start another generator set and allow it to reach normal operating speed and voltage. Connect operating generator set to the bus. 3. Calibrate the voltage reading for Bus Volts L1 so that the reading on the display matches the reading on the calibrated meter. 4. Shut the generator set OFF. 5. Repeat steps 2 through 5 for Bus Volts L2 and L3. (In step 2 attach meter to the AC output from L2 to L3 to calibrate L2; L3 to L1 to calibrate L3.) 6. Exit menu to save changes.
6.10 Prime Mover

6.10.1. General inspection Prior to the monthly exercise, walk around the entire unit, noting areas of concern or suspect points. When inspecting the prime mover as a whole, you should keep a log of items that are in question such as possible or potential leaks, noises, or visual markings. This way, a detailed observation can be referenced for seeing if or how an issue is progressing prior to repair. Look and listen for changes in engine performance, sound, or appearance that can indicate service or repair is needed. Some engine changes to look for and report on are: Unusual engine noise Excessive smoke (black or white) Misfire Vibration Review the suspect areas during the monthly exercise to eliminate any concerns. 6.10.2. Service air cleaner The air cleaner service indicator is located either on the air cleaner assembly or between the assembly and the inlet side of the turbocharger. Check the air cleaner service indicator. If the gauge has crossed the band (1), replace the filter. Revision B Revision Date: 06/03/12 33 of 38
Inspect the air cleaner prior to the monthly exercise. The filter element (standard or heavy duty) should be replaced yearly or sooner if the service indicator button pops up indicating air restriction. Inspect all components of the air filtering system including all ducts and hoses. Verify that all connections and clamps are tight and inspect each component for cracks, dents, or other damage. Repair or service as necessary.
1 Red Mark FIGURE 15. AIR CLEANER SERVICE INDICATOR
6.10.2.1 Normal Duty Air Cleaner 6.10.2.1.1 Air Cleaner Element Removal Normal duty air cleaners combine centrifuge cleaning with element filtering before air enters the engine. CAUTION: Holes, loose-end seals, dented sealing surfaces, corrosion of pipes, and other forms of damage render the air cleaner inoperative and require immediate element replacement, or engine damage can occur. NOTE: Cummins Inc. does not recommend cleaning paper-type air cleaner elements. Elements that have been cleaned will clog, and airflow to the engine will be restricted. 1. 2. 3. 4. 5. 6. 7. Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner. Loosen the wing bolt (2) and remove the band clamp securing the dust pan (1). Remove the dust shield (3) from the dust pan (1). Clean the dust pan and shield. Remove the wing nut (5) that secures the air cleaner element (4) in the air cleaner housing. Inspect the rubber sealing washer on the wing nut. Remove the dirty cleaner element (4). Dispose of the dirty element in accordance with local environmental agency requirements.
1 Dust Pan, 2 Wing Bolt, 3 Dust Shield, 4 Air Cleaner Element, 5 Wing Nut FIGURE 16. NORMAL DUTY AIR CLEANER
6.10.2.1.2 Air Cleaner Element Installation 1. 2. 3. 4. Install the air cleaner element (4) in the air cleaner housing. Inspect the rubber sealing washer, and make sure it is in place under the wing nut (5). Tighten the wing nut (5) that secures the element (4) in the air cleaner housing. Assemble the dust shield (3) and the dust pan (1).
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5.
Position the dust shield (3) and dust pan (1) on the air cleaner housing, and secure them with the band clamp wing bolt (2).
6.10.2.2 Heavy Duty Air Cleaner 6.10.2.2.1 Air Cleaner Element Removal Heavy duty air cleaners combine centrifuge cleaning with element filtering before air enters the engine. NOTE: Cummins Inc. does not recommend cleaning paper-type air cleaner elements. Elements that have been cleaned will clog, and airflow to the engine will be restricted. 1. 2. 3. 4. 5. 6. 7. 8. Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner. Loosen the wing bolt (1) and remove the band clamp securing the dust pan (2). Remove the dust shield (4) from the dust pan (2). Clean the dust pan and shield. Loosen the wing bolt (3). Remove the wing nut (5) that secures the air cleaner primary element (6) in the air cleaner housing. Inspect the rubber sealing washer on the wing nut. Remove the dirty cleaner element (6). If the inner safety element (8) is being replaced based upon high intake restriction, remove the wing nut (7), and replace the inner safety element. Dispose of the dirty elements in accordance with local environmental agency requirements.
1 Wing Bolt, 2 Dust Pan, 3 Wing Nut, 4 Dust Shield, 5 Wing Nut, 6 Air Cleaner Primary Element, 7 Wing Nut, 8 Air Cleaner Inner Safety Element FIGURE 17. HEAVY DUTY AIR CLEANER
6.10.2.2.2 Air Cleaner Element Installation 1. If the inner safety element (8) is being replaced, install the safety element, and secure it with the wing nut (7). 2. Check the seals. 3. Install the air cleaner primary element (6) in the air cleaner housing. 4. Inspect the rubber sealing washer on the wing nut (5). 5. Tighten the wing nut to secure the primary element in the air cleaner housing. 6. Install the dust shield (4) in the dust pan (2). 7. Install the dust shield and dust pan assembly, and secure it using the band clamp, and tighten the wing bolt (1). 8. Tighten the other wing bolt (3). 6.10.2.2.3 Heavy Duty Air Cleaner Maintenance There is a rubber breather tube on the bottom of each filter canister that should be checked periodically to make sure it is free of dust and dirt. Each filter canister includes a primary and safety element that is checked periodically to make sure they are clean. 6.10.3. EPS at minimum of 30% nameplate rating Once a month the standby power system should be tested at 30% of its name plate rating for 30 minutes to make sure that the engine bearings and seals stay lubricated and that all electrical contacts are energized, which will help remove condensation and oxidation. The option to either perform testing on the building loads or a separate load bank is up to the choice of the customer and/or building engineering group. Make sure that loads can be loaded onto the generator in such a manner as to meet or exceed
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the 30% minimum loading target. The benefit of testing on building loads is that the entire system can be tested and verified to function properly before the need arises. Due to the varying types of generator sets, controls, and building system layouts, the sites standby power transfer protocol and procedures should be followed when applying load to the generator set as to not cause damage to the generator set and switchgear. Remember the engine must undergo a cool down period after testing has been completed. Run the engine at rated speed and zero load for four minutes prior to engine shutdown. 6.10.4. Performance testing per manufacturer The standby power system should be tested at 100% of its nameplate rating for one hour annually to make sure that the full performance is attainable when needed. Due to the requirement of loading to nameplate rating, a load bank of suitable size should be connected either solely or in conjunction with the building loads so that a complete test can be performed. This test should be performed on a generator set that is fully warmed with a coolant temperature of at least 71 C (160 F). If the engine is not warmed, start the generator set and run at low idle speed for one minute, then increase to rated speed and 25% load for four minutes, increase to 50% load for five minutes, and then begin full load testing. Remember the engine must undergo a cool down period after testing has been completed. Run the engine at rated speed and no load for four minutes prior to engine shutdown. 6.10.5. Performance testing per Authority Having Jurisdiction (AHJ) Certain applications require a standby power system test every 36 months at 80% or greater of its nameplate rating for 4 hours or more. This is per NFPA110 8.4.9. If the site is under additional or other statutes set forth by another (AHJ) other than NFPA, those ruling and requirements should be followed in order to maintain certification and compliance. Please see the AHJ requirements for further details. Remember the engine must undergo a cool-down period after testing has been completed. Run the engine at rated speed and no load for four minutes prior to engine shutdown. 6.10.6. Starter motor Visually inspect the starter(s), pilot relay(s), harness, and cabling in the starting system. Look for loose or frayed wires, areas of discoloring, melted or deformed terminals / components or blown fuses. Repair or service any of these components as necessary. 6.10.7. Valve clearance Valve clearance should be checked. Based on the number of hours, most of the time, valve clearance should only be performed at time of injector and/or cylinder head/valve replacement, per the Cummins recommendation. The following engine platforms should follow this guideline. QSK19 QSK23 QSK38 QSK45 QSK50 QSK60 QSK78 The QST30 engine is a mechanically-controlled engine that requires the valve lash be set correctly per Cummins guidelines for proper operation and performance every 2000 hours. Refer to the engine service manual for further information on setting the valve clearance.
6.11 Generator
6.11.1. Rotor and stator and associated equipment Visually inspect around the rotor and stator components looking for signs of discoloring, melted or deformed terminals/components, moisture, and chaffing of insulation where the output leads come into contact with another surface such as CTs, terminal blocks, top hat housing, or breaker cabinet. Inspect around the rotor shaft looking for signs of grease seeping from bearing and shaft seals. Remove endbell dust cover to visually access the non-drive end (NDE) bearing assembly and the exciter rotor/stator group. Repair or service as necessary. 6.11.2. Check generator (alternator) air outlet Check the condition of the stator cooling air outlet. Make certain that the outlet is free and clear of all obstructions. If equipped with an air filtration or handling system as used in flammable or severely dusty environments, make sure the filters are cleaned or replaced.
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6.11.3. Bearing(s) grease Re-lubricate the generator bearing(s). A grease fitting is provided for each bearing to allow use of a grease gun. Make certain that the grease gun is calibrated before use, for proper operation. Please refer to the specific alternator manual for the recommended lubricant and quantity. It is important that the correct quantity of grease is used for periodic re-lubrication with a grease gun during planned maintenance. Refer to the label located at the bearing end of the generator (if provided) or the alternator-manual which specifies the grease fill quantity. To determine how much grease is supplied with each pump (stroke) of the device, weigh the quantity required, against the number of pump strokes taken to inject the prescribed amount onto a small weighing scale. Also note in practice: If the pump hits an airlock (i.e. no pressure when pumping) these strokes cannot be counted. For greater accuracy, the grease fitting can be unscrewed, and a flexible grease-pipe screwed directly to the fitting adaptor. This will make sure that no grease is expelled outside the fitting. If too much grease is applied, any excess will be exhausted out of the bearing cartridge via the grease escape. (Any exhausted grease should be cleaned out of the PMG cover.) Always extend the grease gun pump arm out to its full extent with each pump. Failure to do this could mean little or no grease is going into the bearing. To re-lubricate the bearing(s), use the following procedure: 1. Make sure the grease gun nozzle and re-lubricating fittings are free from contaminants or abrasive materials. 2. With the generator running, apply the specified re-lubrication grease fill quantity through the grease fitting. 3. Run the generator for a minimum of 10 minutes to allow excess grease to exhaust. 4. Check inside the PMG cover for expelled grease. Clean as necessary. 6.11.4. Exciter Remove endbell dust cover to visually access the non-drive end (NDE) bearing assembly and the exciter rotor/stator group. Visually inspect around the exciter rotor/stator group components looking for signs of discoloring, melted or deformed terminals/components, moisture, and chaffing of insulation where the field output leads come into contact with another surface such as endbell, terminal blocks, top hat housing, or stator housing. Repair or service as necessary. 6.11.5. Winding heaters Remove endbell dust cover to visually access the non-drive end (NDE) bearing assembly and the end of the stator. Visually inspect around the stator winding heater(s) looking for signs of discoloring, melted or deformed terminals/components, moisture, and chaffing of insulation where the heater input leads come into contact with another surface such as the endbell, terminal blocks, top hat housing, or stator. Repair or service as necessary. 6.11.6. Anchorage, alignment, grounding Visually inspect all mounting feet, hardware, flywheel adaptors, and grounding straps to make sure that they are tight and corrosion-free. If any witness marks such as scratches, metal gouges, scuffing marks, or loose hardware is identified, have the equipment serviced and realigned by a trained, certified technician before operating the unit again. 6.11.7. Measure winding resistance and/or PI testing (Megger) The condition of the windings can be determined by measurement of the insulation resistance (IR) between each phase and earth. Care should be taken when dealing with windings that are suspected of being excessively damp or dirty. The initial measurement of the IR should be established using a low-voltage 500V megger type instrument. If manually powered, the handle should initially be turned slowly as to not deliver full test voltage inadvertently. If low IR values are suspected or immediately indicated during testing, only proceed long enough to verify the situation. Full megger test should not be applied until the windings have been dried out, and if necessary cleaned per the alternator service manual. 1. 2. 3. 4. Disconnect all electronic components, AVRs, electronic protection equipment, etc... Ground the RTDs (Resistance Temperature Detection Devices) if outfitted. Short out the diodes on the rotating diode assembly. Please keep in mind all of the components connected to the system under test that could cause false readings or become damaged due to the testing voltage. Carry out the insulation test in accordance with the megger testing equipment instructions provided by the manufacturer. The measured value of the insulation resistance for all windings to earth, and phase to phase should be compared with the guidance given from the alternator service manual Life Stages Curve. The minimum acceptable value is 1.0 Megaohm on a 500V megger.
If low winding insulation is confirmed, one or more of the methods for drying the windings should be carried out per the alternator service manual. Revision B Revision Date: 06/03/12 37 of 38
6.12 General
6.12.1. General condition of EPS Inspect the EPS, keep a log of items that are in question such as possible or potential leaks, noises, or visual markings prior to and after the monthly exercise. A detailed observation can be referenced for determining if an issue is progressing prior to repair. Keep an eye out for unusual discoloration of components, odors, and or noises. If excessive temperatures exist, have the equipment shut down and a trained, certified technician inspect and repair as necessary. It may be necessary to note suspect areas (e.g. areas where there may be high vibration) and return to inspect those locations when the unit is operating. 6.12.2. Service room or housing housekeeping Inspect the equipment room prior to and after the monthly exercise. The generator set room should be clean and clear of hazards and free from objects that could restrict airflow.
6.13 Restore
6.13.1. Restore system to automatic operation condition Make certain all trash, waste, debris, oil, filters, etc have been cleaned and the area has been secured after the monthly exercise and maintenance event has concluded. Brief the customer on the status of the equipment and answer any questions. Make sure all energy source lock-out provisions applied to the battery connections, battery disconnect switches, fuel delivery sources, service disconnect breakers, etc have been removed and that all tag-out devices are removed. Verify all loads are restored to normal power, all equipment is automated, and the engine cooldown timer has expired. Verify all equipment is in remote/auto. Verify all unit-mounted circuit breakers are in the correct position. Verify the battery charger is operational or on. Verify all breakers and switches are on. Verify all component heaters are on and operational. Clean any hand, figure, or boot prints left from oil, sludge, or dirt from the equipment and equipment housing. Dispose of shop towels, rags, and absorbent pads per local environmental regulations.
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Maintenance

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Maintenance

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Planned Maintenance Recommendations

Standby Diesel Generator Sets (500 kW and up)

Revision B Revision Date: 06/03/12

Table of Contents Subject

Revision B Revision Date: 06/03/12

1.0 Important Safety Instructions

1.1 Warning, Caution and Note Styles Used In This Manual

1.2 General Information

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1.3 Generator Set Safety Code

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1.5 Fuel and Fumes Are Flammable

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1.6 Exhaust Gases Are Deadly

1.7 Earth Ground Connection

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1.8 Distribution Panel Door

1.9 Transport and Towing

1.10 Beware of Traffic Hazards

1.11 Tipping Hazard

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2.1 Product Inclusions

3.0 Service Support

3.1 Aftermarket Support Plan

3.2 Service Tools

3.3 Parts Return Process

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5.0 Task List

5.1 Using the Task List

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6.1 Pre-Departure Practices

6.2 On-Site Practices

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6.3 Locking the Generator Set Out of Service

6.4 Fuel System

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FIGURE 1. DRAINING THE FILTER/SEPARATORS

6.4.6.1 Fuel filters removal

FIGURE 2. 1 Vent Cap, 2 Drain Valve, 3 Collar, 4 Clear Cover

FIGURE 4. DRAINING THE FUEL/WATER SEPARATOR

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FIGURE 6. HOSES AND FUEL LINE INSPECTION

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Part Number CC2724 CC2723 Varies

6.5 Lubrication System

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FIGURE 7. ENGINE OIL LEVEL CHECK

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6.6 Cooling System

FIGURE 8. COOLANT LEVEL PROCEDURE

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FIGURE 9. RADIATOR CHECK

FIGURE 10. DRIVE BELT INSPECTION

FIGURE 11. COOLING FAN INSPECTION

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6.7 Exhaust System

6.8 Battery System

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