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PLAN MANTTO G.E +500KW - Unlocked PDF
PLAN MANTTO G.E +500KW - Unlocked PDF
Recommendations
Standby Diesel Generator Sets
(500 kW and up)
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
English
Original Instructions 01-2014 A035G976 (Issue 3)
Table of Contents
Subject Page Number
Important Safety Instructions 3
Background 9
Service Support 9
Warranty 10
Task List 10
Procedures 12
1
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.
NOTE: It is in the Operator’s interest to read and understand all Warnings and Cautions contained within the documentation
relevant to the generator set, its operation and daily maintenance.
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 b end or b reak, 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 (-) b attery
cab le at the b attery using an insulated wrench.
CAUTION: Make sure that rags are not left on or near the engine.
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 ob structions. Remove any deb ris 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.)
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.
WARNING: On an enclosed generator set, the canopy doors must be locked before repositioning and they must
remain locked during transportation and sitting.
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.
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 dow n slowly.
Loosen the slings; unhook and remove the shackles.
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.
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.
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.
1.5.2 Spillage
Any spillage that occurs during fueling or during oil top-off or oil change must be cleaned up before starting the generator set.
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.
WARNING: Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects,
and other reproductive harm.
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 generato r 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.
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.
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.
CAUTION: Exceeding the recommended speeds can cause severe damage to the g enerator set. Damage caused b y 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
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.
In general, when a field issue has been identified, a Distributor Service Technician is enga ged 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.
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 interes t and in need of return.
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.
5.2 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.
Technicians are to notify their site contact of the details given on the work order. The actual scheduling will be establishe d 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.
Read, understand, and comply with all Caution and Warning notes in this section, those contained within oth er 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 b ecome 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 b attery charger from its AC source b efore disconnecting the b attery cab les. 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.
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.
NOTE: Refer also to the Operator’s 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.
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.
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 b e kept clean and free of dirt
or water. Dirt or water in the system can cause severe damage to b oth 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.
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.
Compare the pre-exercise level against the post-exercise level. The difference should be appropriate for the leng th of the run
and dependent on tank size. The technician is to use judgment to determine if tank level was unreasonably lower.
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.
The fuel filters can be inspected for collected water by checking the clear bowl at the bottom of each filter.
The drained liquids must be disposed of in accordance with local environmental regulations.
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.
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. Install a new o-ring, filter element, (supplied with a sealing grommet inserted into the filter element), the filter
spring, and the clear cover.
2. Install the vent cap and the collar onto the clear cover.
3. Hand tighten. Do not use tools to tighten the collar.
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.
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.
Any other fluid containment area must also be checked and emptied as above.
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.
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.
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.
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™ o r 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.
NOTE: Use the M14 to ¼” 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 o f
the test.
1. Make sure the sampling area and connectors are clean and accessible before sampling.
2. Idle the engine at 1000 rpm for 5 minutes or until normal operating temperature is reached (minimum coolant
temperature of 60°C [140°F]).
3. Shut the engine down, and sample no later than 1 minute after shutdown.
4. Make sure the vacuum pump and other sampling tools are free of debris and any other potential contaminants.
5. Remove the rear metal cap from the pump.
6. Remove the rubber plug from the sampling needle.
7. Place a rubber plug in the rear breathing open area to achieve suction when sampling.
8. Remove the lid from the black plastic mailer and lay it on a clean area facing up.
9. Immediately take the ISO clean jar out of the mailer. Remove the lid of the ISO clean jar.
10. Place the ISO clean jar lid with the black plastic mailer lid to avoid contamination while sampling .
11. Securely screw the jar to the vacuum pump.
12. Remove the cap from the QuickDraw™ fitting.
13. Connect the pump to the QuickDraw™ fitting.
14. 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.
CAUTION: Do not operate the engine with the oil level b elow the low mark or ab ove the high mark. Overfilling can cause
foaming or aeration of the oil while operation b elow the low mark may cause loss of oil pressure.
CAUTION: Prolonged and repeated skin contact with used engine oils can cause ski n disorders or other b odily injury. Comply
with all local health and safety regulations/codes when handling or disposing of used engine oil.
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.
NOTE: The Eliminator™ Centrifuge and Bypass Centrifuge do not have to be service d 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. Use an oil filter wrench, Part Number 3375049, or equivalent, to remove the oil filters.
5. 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. Clean the oil filter head sealing surface with a lint-free cloth.
7. Use engine oil to lubricate the oil filter's rubber seal.
8. 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]
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 indica ted 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.
NOTE: The Eliminator™ Centrifuge and Bypass Centrifuge do not have to be service d 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.
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. Locate the oil filter wrench, near the top of the oil filter canister. This will reduce the possibility of damaging the oil
filter.
7. Install the oil filter, turning it until the seal contacts the filter head's sealing surface.
8. Turn the oil filter an additional 3/4 to 1 full turn.
9. Install and tighten the drain plug(s). Torque Value: 47 N-m [35 ft-lb]
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 t he
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 obje cts 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 pull ing 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.
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.
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 b locked coolant system and
inadequate coolant flow causing the engine to overheat.
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 b e damaged. Allow the engine to cool to b elow 50 °C
(122 °F) b efore adding coolant.
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 °C (122 °F) or lower.
NOTE: Some radiators have two fill necks, both of which must be filled. Refer to the generator set specific drawings
supplied with the set.
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°C (-34°F) freezing point and a 100°C (228°F) boiling point, which is adequate for locations .
Replace the antifreeze per the manufacturer’s recommendation or every two years.
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.
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.
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.
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.
CAUTION: Do not mix old and new V-b elts 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.
CAUTION: V-Belts should never ride in the b ottom of the groove. Damaged or worn grooves should not b e used.
NOTE: Keep foreign materials away from sheaves and belts as this may cause belt slip.
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.
Re-lubricate the fan bearings. A grease fitting is provided for each bearing to allow use of a grease gu n. Make sure that the
grease gun is calibrated before use. Please refer to the specific generator set operator’s manual for the recommended
lubricant and quantity.
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.
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 32º to
54º C (90º to 130º F) or as outlined in the generator specific service manual.
6.6.15. Thermostat
Inspect the thermostat for cracks, corrosion, or damage. If thermostat is suspected of malfunctioning, test the thermostat for
proper operation.
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.
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.
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.
Record battery installation date. Recommend replacement per battery manufacturer replacement schedule.
CAUTION: Keep b atteries upright to prevent spillage. Electrolyte is a dilute sulphuric acid that is harmful to the skin
and eyes.
WARNING: Before disconnecting the battery, always remove power from the mains powered battery charger
(where fitted).
CAUTION: During the charging of a b attery, explosive gases are given off. Keep the b attery well ventilated and away
from naked flames and sparks. NO SMOKING.
CAUTION: When putting a b attery into service on a generator set, connect the earth lead LAST; when removing the
b attery, disconnect the earth lead FIRST.
CAUTION: Take care when filling b atteries with electrolyte and always wear personal protective equipment.
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 b attery charger from its AC source b efore disconnecting the b attery 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 ob jects across the top of the b attery. This can cause arcing that may ignite b attery g ases
causing explosions resulting in personal injury.
CAUTION: Keep b atteries upright to prevent spillage. Electrolyte is a dilute sulphuric acid that is harmful to the skin and e yes.
CAUTION: Use tools with insulated handles to prevent the risk of electric shock.
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.
Electrolyte Electrolyte
Bench Bench
Level Level
Battery Charging Battery Charging
Above Above
Type Rate Type Rate
Plates Plates
(A/hour) (A/hour)
(m m ) (m m )
1 8 3 325 8 20
7 8 3.5 327 8 11
15 8 4 328 8 20
16 8 4 329 8 20
17 8 9 332 8 25
35 8 3.5 333 8 11
36 8 3.5 386 8 6
37 8 4 404 8 7
38 8 4 414 8 20
46 8 6 415 8 20
47 8 3 471 8 15
48 8 4 484 8 25
49 8 4 501 8 9
63 8 4 511 8 10
65 8 5 521 8 12
67 8 7 531 8 13
68 8 7 541 8 15
69 8 7 543 8 15
70 8 7 591 8 14
71 8 6 602 8 8
72 8 8 612 8 9
73 8 6 635 16 12
74 8 7 643 16 9
75 8 7 644 16 12
77 8 4 645 16 9
78 12 5 646 16 8
83 8 3.5 647 16 12
84 8 4 648 16 12
85 8 5 649 16 9
90 12 7 655 16 12
91 8 6 656 16 12
92 12 5 663 16 9
93 8 6 664 16 9
97 8 6 665 16 9
154 4 3.5 678 8 6
175 8 7 679 16 9
191 6 6 701 8 16
221 8 8 702 8 20
222 8 12 703 8 25
279 8 6 711 8 16
312 8 14 712 8 20
313 8 14 713 8 25
315 8 14 721 8 15
319 8 14 722 8 20
320 8 14 732 8 15
321 8 14 733 8 20
322 8 14 769 8 45
324 8 20
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.
Keep the battery case clean and dry. An accumulation of moisture will lead to a more rapid discharge and battery failure.
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.
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 (0.9 6 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.
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 80º F (27º C). A fully charged battery will have a corrected specific gravity of 1.260
at 25º C (77º F). Charge the battery if the reading is below 1.215.
Table 3 shows the specific gravity (SG) of electrolyte, corrected to 25º C (77º F). Correct the SG reading for other
temperatures by adding or subtracting seven gravity points (0.007) for every 10º C (18º F). Apply the correction
formula as follows:
1. For every 10º C (18º F) above 25º C (77º F), subtract 0.007 (7 points)
2. For every 10º C (18º F) below 25º C (77º F), add 0.007 (7 points)
For example: if the specific gravity at 25º C (77º F) is 1.260, then the specific gravity at 15º C (59º F) is 1.267.
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.
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.
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 regulator s, 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, overh eating,
abrasion, etc.
Use a vacuum to remove all dust and debris from the cabinets, panels, electrical boxes, etc. Never use compressed air to
blow out dust.
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.
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)
CT’s (B)
Use a calibrated RMS multimeter for accurate measurements. Fluke models 87 or better.
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.
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.
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
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. Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner.
2. Loosen the wing bolt (2) and remove the band clamp securing the dust pan (1).
3. Remove the dust shield (3) from the dust pan (1).
4. Clean the dust pan and shield.
5. Remove the wing nut (5) that secures the air cleaner element (4) in the air cleaner
housing.
6. Inspect the rubber sealing washer on the wing nut.
7. 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 Elem ent, 5 Wing Nut
FIGURE 16. NORMAL DUTY AIR CLEANER
1. Install the air cleaner element (4) in the air cleaner housing.
2. Inspect the rubber sealing washer, and make sure it is in place under the wing nut (5).
3. Tighten the wing nut (5) that secures the element (4) in the ai r cleaner housing.
4. Assemble the dust shield (3) and the dust pan (1).
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. Before disassembly, wipe dirt from the cover and the upper portion of the air cleaner.
2. Loosen the wing bolt (1) and remove the band clamp securing the dust pan (2).
3. Remove the dust shield (4) from the dust pan (2).
4. Clean the dust pan and shield.
5. Loosen the wing bolt (3).
6. Remove the wing nut (5) that secures the air cleaner primary element (6) in the air cleaner housing.
7. Inspect the rubber sealing washer on the wing nut.
8. 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 Prim ary Elem ent, 7 Wing Nut,
8 Air Cleaner Inner Safety Elem ent
FIGURE 17. HEAVY DUTY AIR CLEANER
Each filter canister includes a primary and safety element that is checked periodically to make sure they
are clean.
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
Due to the varying types of generator sets, controls, and building system layouts, the site’s 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.
This test should be performed on a generator set that is fully warmed with a coolant temperature of at least 71º C (160º F). If
the engine is not warmed, s tart 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.
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 CT’s, 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.
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 flexib le 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.
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.
The initial m easurement 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 ar e
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. Disconnect all electronic components, AVR’s, electronic protection equipment, etc... Ground the RTD’s (Resistance
Temperature Detection Devices) if outfitted.
2. 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.
3. Carry out the insulation test in accordance with the megger testing equipment instructions provided by the
manufacturer.
4. The measured value of the insulation resistance for all wi ndings 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 th e methods for drying the windings should be carried out per the
alternator service manual.
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.
6.13 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.
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 .