Installation Manual: Generator Set

Installation Manual
Generator Set
QSK78 Engine with PowerCommand 3200 Control
DQLA (Spec A)
DQLB (Spec A)
English
Original Instructions 2-2015 908−0600 (Issue 4)
-
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Table of Contents
SECTION TITLE PAGE

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 INTRODUCTION
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 MOUNTING THE GENERATOR SET
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Access to Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Vibration Isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Check Generator To Engine Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
4 MECHANICAL CONNECTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Ventilation and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
5 DC CONTROL WIRING
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Remote Monitor/Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Run Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Alarm Relay (K10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
6 AC ELECTRICAL CONNECTIONS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Insulation Resistance (Megger) & Polarization Index (PI) Testing . . . . . . . 6-2
Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Control Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Generator Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
i
SECTION TITLE PAGE
7 PRESTART PREPARATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Control Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
8 INSTALLATION CHECKLIST
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Generator Set Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Cooling Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Diesel Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
AC and DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Generator Set Prestart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9 WIRING DIAGRAMS
Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1/9-2
Cooling System Installation (40 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3/9-5
Cooling System Installation (50 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6/9-8
ii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator and batter-  Provide an adequate exhaust system to properly
ies. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operator’s Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
 Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
 Engine exhaust and some of its constituents are
ator, service personnel, or the equipment. known to the state of California to cause cancer,
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
 Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un-
moving parts.
safe practice which can result in severe person-
al injury or death.  Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative (-) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage.  Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result  Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
 DO NOT fill fuel tanks while engine is running, un- caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential  If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
 DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
 Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
 Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
 Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.
LS-14M
iii
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH  Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
 Remove electric power before removing protective changer pressure cap while the engine is running.
shields or touching electrical equipment. Use rub- Allow the generator set to cool and bleed the system
ber insulative mats placed on dry wood platforms pressure first.
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing  Used engine oils have been identified by some state
(particularly wet shoes) or allow skin surface to be or federal agencies as causing cancer or reproduc-
damp when handling electrical equipment. Do not tive toxicity. When checking or changing engine oil,
wear jewelry. Jewelry can short out electrical con- take care not to ingest, breathe the fumes, or con-
tacts and cause shock or burning. tact used oil.
 Use extreme caution when working on electrical  Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
components. High voltages can cause injury or
such as wood and cloth; Class B fires, combustible
death. DO NOT tamper with interlocks.
and flammable liquid fuels and gaseous fuels; Class
 Follow all applicable state and local electrical C fires, live electrical equipment. (ref. NFPA No. 10).
codes. Have all electrical installations performed by  Make sure that rags are not left on or near the en-
a qualified licensed electrician. Tag and lock open gine.
switches to avoid accidental closure.
 Make sure generator set is mounted in a manner to
 DO NOT CONNECT GENERATOR SET DIRECT- prevent combustible materials from accumulating
LY TO ANY BUILDING ELECTRICAL SYSTEM. under the unit.
Hazardous voltages can flow from the generator set  Remove all unnecessary grease and oil from the
into the utility line. This creates a potential for elec- unit. Accumulated grease and oil can cause over-
trocution or property damage. Connect only heating and engine damage which present a poten-
through an approved isolation switch or an ap- tial fire hazard.
proved paralleling device.
 Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
MEDIUM VOLTAGE GENERATOR SETS
bris from the set and keep the floor clean and dry.
(601V to 15kV)  Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
 Medium voltage acts differently than low voltage. or drug that makes the operation of equipment un-
Special equipment and training is required to work safe.
on or around medium voltage equipment. Operation  Substances in exhaust gases have been identified
and maintenance must be done only by persons by some state or federal agencies as causing can-
trained and qualified to work on such devices. Im- cer or reproductive toxicity. Take care not to breath
proper use or procedures will result in severe per- or ingest or come into contact with exhaust gases.
sonal injury or death.
 Do not store any flammable liquids, such as fuel,
 Do not work on energized equipment. Unauthorized cleaners, oil, etc., near the generator set. A fire or
personnel must not be permitted near energized explosion could result.
equipment. Due to the nature of medium voltage
electrical equipment, induced voltage remains even
 Wear hearing protection when going near an oper-
after the equipment is disconnected from the power ating generator set.
source. Plan the time for maintenance with autho-  To prevent serious burns, avoid contact with hot
rized personnel so that the equipment can be de-en- metal parts such as radiator, turbo charger and ex-
ergized and safely grounded. haust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
1. Introduction
ABOUT THIS MANUAL mance, and safe operation. Refer to Operators
Manual for troubleshooting information.
This manual provides installation instructions for
the generator set models listed on the front cover. Installation Checklist − reference checks
This includes the following information: upon completion of installation.
Mounting Recommendations - for fastening
generator set to base and space requirements This manual DOES NOT provide application infor-
for normal operation and service. mation for selecting a generator set or designing the
complete installation. If it is necessary to design the
Mechanical and Electrical Connections - various integrated systems (fuel, exhaust, cooling,
covers most aspects of the generator set instal- etc.), additional information is required. Review
lation. standard installation practices. For engineering
Prestart − checklist of items or procedures data specific to the generator set, refer to the Speci-
needed to prepare generator set for operation. fication and Data Sheets. For application informa-
Initial Startup − test complete system to en- tion, refer to Application Manual T-030, “Liquid
sure proper installation, satisfactory perfor- Cooled Generator Sets”.
1-1
INSTALLATION OVERVIEW installed, maintained, and operated. However, the
overall safety and reliability of the complete system
These installation recommendations apply to typi- is dependent on many factors outside the control of
cal installations with standard model generator the generator set manufacturer. To avoid possible
sets. Whenever possible, these recommendations safety hazards, make all mechanical and electrical
also cover factory designed options or modifica- connections to the generator set exactly as speci-
tions. However, because of the many variables in fied in this manual. All systems external to the gen-
any installation, it is not possible to provide specific erator (fuel, exhaust, electrical, etc.) must comply
recommendations for every situation. If there are with all applicable codes. Make certain all required
any questions not answered by this manual, contact inspections and tests have been completed and all
your nearest Cummins Power Generation distribu- code requirements have been satisfied before certi-
tor for assistance. fying the installation is complete and ready for ser-
vice.
Application and Installation
A standby power system must be carefully planned Standby Heating Devices
and correctly installed for proper operation. This in-
volves two essential elements: application and In accordance with NFPA 110, Cummins Power
installation. Generation recommends installing diesel standby
generator sets (life safety systems) equipped with
Application (as it applies to generator set installa- engine jacket water coolant heaters in locations
tions) refers to the design of the complete standby where the minimum ambient temperature is above
power system that usually includes power distribu- 40F (4C). NFPA also requires that the engine
tion equipment, transfer switches, ventilation equip- jacket water coolant be maintained at a minimum of
ment, mounting pads, and cooling, exhaust, and 90F (32C) and, for most applications, accept the
fuel systems. Each component must be correctly emergency load in 10 seconds or less. Although
designed so the complete system will function as in- most Cummins Power Generation generator sets
tended. Application and design is an engineering will start in temperatures down to −25F (−32C)
function generally done by specifying engineers or when equipped with engine jacket water coolant
other trained specialists. Specifying engineers or heaters, it might take more than 10 seconds to
other trained specialists are responsible for the de- warm the engine up before a load can be applied
sign of the complete standby system and for select- when ambient temperatures are below 40F (4C).
ing the materials and products required.
The Engine Cold (Code 1435) message, in con-
Installation refers to the actual set-up and assem-
junction with illumination of the Warning LED, is pro-
bly of the standby power system. The installers set
vided to meet the requirements of NFPA 110. The
up and connect the various components of the sys-
engine cold sensing logic initiates a warning when
tem as specified in the system design plan. The
the engine jacket water coolant temperature falls
complexity of the standby system normally requires
below 70F (21C). In applications where the ambi-
the special skills of qualified electricians, plumbers,
sheetmetal workers, etc. to complete the various ent temperature falls below 40F (4C), a cold en-
segments of the installation. This is necessary so all gine may be indicated even though the coolant
components are assembled using standard meth- heaters are connected. Under these conditions, al-
ods and practices. though the generator set may start, it may not be
able to accept load within 10 seconds. When this
Safety Considerations condition occurs, check the coolant heaters for
proper operation. If the coolant heaters are operat-
The generator set has been carefully designed to ing properly, other precautions may be necessary to
provide safe and efficient service when properly warm the engine before applying a load.
Copyright 2004 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.
1-2
2. Specifications
MODEL DQLA DQLB

Cummins Diesel Series QSK78 (60 Hz) QSK78 (50 Hz)
Generator kW Rating See Genset Nameplate for rating information.
Oil Capacity, Maximum Qts (L)
Standby 312 (295)
Prime 492 (465)
*Oil Type
Engine Fuel Connection
Inlet/Outlet Thread Size Refer to Generator Outline Drawing
**Fuel Consumption gph (L/hr) gph (L/hr)
Standby/Full Load 172 (652) 174 (662)
Exhaust
Outlet Size Refer to Generator Outline Drawing
Maximum Allowable Back Pres.
H20 27 in (686 mm)
kPa 6.7
Electrical System
Starting Voltage 24 Volts DC
Battery Four, 12 Volt
Group number 8D
CCA (minimum)
Cold Soak @ 0 F (-18 C) 1800
* Refer to Cummins QSK78 Series Engine Operation and Maintenance Manual for lubricating oil
recommendations/specifications.
** Refer to Data Sheet for other applications.
2-1
THIS PAGE LEFT INTENTIONALLY BLANK
2-2
3. Mounting the Generator Set
GENERAL  Non-combustible mounting surface.
Generator set installations must be engineered so  Electrical connections
the generator set will function properly under the ex-  Accessibility for operation and servicing
pected load conditions. Use these instructions as a  Noise levels
general guide only. Follow the instructions of the
 Vibration isolation
consulting engineer when locating or installing any
components. The complete installation must com- LOCATION
ply with all local and state building codes, fire ordi-
nances, and other applicable regulations. Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and ex-
Requirements to be considered prior to installation: haust. The set should be located as near as pos-
sible to the main power service entrance. Exhaust
 Level mounting surface
must not be able to enter or accumulate around in-
 Adequate cooling air habited areas.
 Adequate fresh induction air
Provide a location away from extreme ambient tem-
 Discharge of generator set air peratures and protect the generator set from ad-
 Discharge of exhaust gases verse weather conditions.
WARNING
INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE

PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST
BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND MECHANICAL COM-
PONENT INSTALLATION.
IMPORTANT
DEPENDING ON YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS
AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT
BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL
POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR
CONSTRUCTION PLANS.
3-1
MOUNTING
SUBBASE OR
Generator sets are mounted on a steel skid that pro- VIBRATION
vides proper support. The engine-generator as- ISOLATOR
sembly is isolated from the skid frame by rubber FLANGE
mounts that provide adequate vibration isolation for
normal installations. Where required by building HEX NUT
codes or special isolation needs, generator sets
may be mounted on rubber pads or mechanical
FLAT OR BEVEL
spring isolators. The use of unapproved isolators WASHER
may result in harmful resonances and may void the
genset warranty.
Mount the generator set on a substantial and level Ç Ç
base such as a concrete pad. A non-combustible
material must be used for the pad.
Ç
Ç Ç
Ç 1-1/2 x 6 INCH
Use 3/4 inch anchored mounting bolts to secure the
vibration isolators to the base. Secure the vibration MOUNTING
Ç PIPE
12 IN.
isolators to the skid using flat or bevel washer and BASE (305 mm)
hexagonal nut for each bolt (see Figure 3-1). The CONCRETE
1-1/2 x 6 inch pipe inserted over the mounting bolts
allows minor adjustment of the bolts to align them to
the holes in the subbase or vibration isolator.
Locate the isolators as shown on the generator set
Outline Drawing referenced in the Data Sheet. MOUNTING
BOLT
FIGURE 3-1. BOLT DIAGRAM

ACCESS TO SET
Generally, at least 1 meter (3 feet) of clearance
should be provided on all sides of the generator set
for maintenance and service access. A raised
foundation or slab of 150 mm (6 inches) or more
above floor level will make servicing easier.
Lighting should be adequate for operation, mainte-
nance and service operations and should be con-
nected on the load side of the transfer switch so that
it is available at all times.
3-2
SWEEPING
MUFFLER
ELBOW
THIMBLE DC CONTROL
WIRING
CONDENSATION AC POWER
DRAIN TRAP WIRING
FLEXIBLE
SECTION
AIR
IN
AIR OUTLET
DUCT
CONCRETE VIBRATION
BASE ISOLATORS
FIGURE 3-2. TYPICAL INSTALLATION
3-3
VIBRATION ISOLATORS The isolators are adjusted by inserting the lev-
eling bolt through the skid and into the isolator
Installation and Adjustment Procedure (the leveling bolt’s locking nut should be
(Optional Spring Type) threaded up towards the bolt head).
1. Place the vibration isolators (Figure 3-3) on the The leveling bolt will adjust the clearance be-
genset support structure. The isolators should tween the top plate and the isolator base. A
be shimmed or grouted to ensure that all of the nominal clearance of 0.25 inch (6 mm) or great-
isolator bases are within 0.25 inch (6 mm) er is desired. This will provide sufficient clear-
elevation of each other. The surface that the ance for the rocking that occurs during startup
isolator bases rest on must also be flat and lev- and shutdown. If the 0.25 inch (6 mm) clear-
el. ance is not present, turn the leveling bolt until
2. Loosen the side snubber lock nuts so that the the desired clearance is achieved.
top plate of the isolator is free to move vertically
and horizontally. Be sure that the top plate is 5. The genset may not be level yet; therefore, ad-
correctly aligned with the base and springs. just the leveling bolts until the set is level and
sufficient clearance still remains. (Clearance
3. Place the genset onto the isolators while align-
ing the skid’s mounting with the threaded isola- on all isolators should be roughly equal). Once
tor hole. The top plates will move down and ap- all isolators have been set, lock the leveling bolt
proach the base of the isolator as load is ap- in place with the lock nut.
plied. 6. The snubber nuts must remain loose and
4. Once the genset is in position, the isolators therefore provide better isolation between the
may require adjusting so that the set is level. genset and support structure.
GENSET SKID
LEVELING BOLT
LOCK NUT
SNUBBER CLEARANCE
BASE
FIGURE 3-3. VIBRATION ISOLATOR (SPRING TYPE)
3-4
Installation and Adjustment Procedure bases are within 0.25 inch (6 mm) elevation of
(Rubber Type) each other. The surface that the isolator bases
rest on must also be flat and level.
1. Place the vibration isolators (Figure 3-4) on the 2. Place the genset onto the isolators while align-
genset support structure. The isolators should ing the skid’s mounting with the threaded isola-
be shimmed to ensure that all of the isolator tor hole.
GENSET SKID
SCREW (M24X3X60)
WASHER, PLAIN
WASHER, SPRING
RUBBER
ISOLATOR
SHIM(S)
FIGURE 3-4. VIBRATION ISOLATOR (RUBBER TYPE)
3-5
CHECK GENERATOR TO ENGINE
ALIGNMENT
Proper alignment of the generator and engine as-
semblies is necessary to avoid premature wear and
excessive vibration. Checking the alignment of the
generator set must be performed before initial
start-up.
Complete the following alignment procedure after
the generator set skid is leveled and secured to the
mounting base.
1. Loosen the 23 M12x45 bolts used on the en-
gine/alternator coupling housing (Figure 3-5).
2. Using a feeler gauge, check the mating face to
the engine crankcase flywheel housing. The
gap must be the same at all locations. FIGURE 3-5. ENGINE/ALTERNATOR COUPLING
If the gap is even, the alternator is correctly HOUSING
shimmed and aligned. Tighten all 23 bolts on
the alternator housing using a tightening se-
quence pattern. Torque to 72 ft−lbs (98 Nm).
If gap varies, the generator to engine is misa-
ligned (realign the alternator to the engine us-
ing the following steps).
CHECK FOR
EVEN GAP
FIGURE 3-6. GENERATOR TO ENGINE ALIGNMENT
3-6
3. Loosen the four alternator mounting bolts (Fig- 5. Lift the alternator to allow the alternator cou-
ure 3-7). pling housing to butt up squarely to the engine
flywheel housing. Perform this operation slowly
WARNING To prevent personal injury, use
and carefully.
adequate lifting devices to support heavy
components. Keep hands and feet clear 6. With alternator positioned squarely to the en-
while lifting. gine flywheel housing, tighten all 23 bolts on
the alternator housing using a tightening se-
CAUTION Improper generator assembly
quence pattern.
rigging and handling can result in damage
to stator and rotor assemblies. Lift the gen- 7. The alternator housing is now flush to the en-
erator by hoisting at lifting eyes only. In- gine housing. Measure the distance between
spect the sling and attachments for ob- all four alternator mounting feet and the skid
vious defects. Make sure the generator is mounting pads using feeler gauges. Shim as
adequately hooked/strapped to maintain needed (add or remove shims) beneath the al-
level control of assembly while lifting and ternator mounting feet to align the alternator
moving. with the engine and eliminate gaps.
4. Attach shackles to the two alternator lifting 8. Lower hoist and hand tighten the four alternator
points (front and back) as shown in Figure 3-7. mounting bolts. Repeat steps 1 and 2. When
Only these points should be used to lift the al- proper alignment is achieved, torque the four
ternator to make sure it is balanced and stable alternator mounting bolts to 522 ft-lbs (710
during lift. Nm).
3-7
ALTERNATOR
MOUNTING BOLTS (4)
SHIM(S)
ALTERNATOR LIFTING
EYES (4)
FIGURE 3-7. ALTERNATOR COMPONENTS
3-8
4. Mechanical Connections
GENERAL will occur if the engine is run with the return fuel lines
The generator set mechanical system installation blocked or restricted.
includes connecting the fuel, exhaust, ventilation CAUTION Never install shutoff device in fuel
and cooling systems. Before starting any type of return line(s). If fuel return line(s) is blocked or
fuel installation, all pertinent state and local codes exceeds fuel restriction limit, engine damage
must be complied with and the installation must be will occur.
inspected before the unit is put in service.
Fuel Return Restriction (or Pressure) Limit: Fuel
FUEL SYSTEM return drain restriction (consisting of friction head
Cummins engines normally use ASTM No. 2 Diesel and static head) between the engine injector return
fuel. They will, however, operate on alternate diesel line connection and the fuel tank must not exceed
fuels within the specifications shown in the Cum- the limit stated in the Generator Set Data Sheet.
mins QSK78 Series Engine Operation and Mainte-
nance Manual. Fuel Lines − Routing
In all fuel system installations, cleanliness is of the A flexible fuel hose(s) or section of flexible fuel
upmost importance. Make every effort to prevent hose(s) must be used between the engine’s fuel
entrance of moisture, dirt or contaminants of any system and fuel supply and return line(s) to protect
kind into the fuel system. Clean all fuel system com- the fuel system from damage caused by vibration,
ponents before installing. expansion and contraction. Flexible lines for con-
necting between the engine and the stationary fuel
A fuel filter/strainer/water separator of 100-120 mesh lines are supplied as standard equipment.
or equivalent (approximately 150 microns nominal)
must be fitted between either the main tank and day WARNING Fuel leaks create fire and explosion
tank or between the main tank and the engine. hazards which can result in severe personal in-
jury or death. Always use flexible tubing be-
Use only compatible metal fuel lines to avoid elec- tween engine and fuel supply and return to
trolysis when fuel lines must be buried. Buried fuel avoid line failure and leaks due to vibration. The
lines must be protected from corrosion. fuel system must meet applicable codes.
CAUTION Never use galvanized or copper fuel Installation of the fuel hose must be done according
lines, fittings or fuel tanks. Condensation in the to all applicable codes and standards, and installa-
tank and lines combines with the sulfur in diesel tion recommendations provided by the manufactur-
fuel to produce sulfuric acid. The molecular er. The supplied flexible hose is approved by the
structure of the copper or galvanized lines or hose manufacture for use with the genset fuel type
tanks reacts with the acid and contaminates the and product application.
fuel.
Support fuel lines to restrain movement and prevent
An electric solenoid valve in the supply line is rec- chaffing or contact with sharp edges, electrical wir-
ommended for all installations and required for in- ing and hot exhaust parts.
door automatic or remote starting installations.
Connect the solenoid wires to the genset “Switched WARNING Sparks and hot surfaces can ignite
B+” circuit to open the valve during generator set fuel, leading to severe personal injury or death.
operation. Do not route fuel lines near electrical wiring or
hot exhaust parts.
Separate fuel return lines to the day tank or supply
tank must be provided for each generator set in a Fuel lines must be routed and secured to maintain a
multiple-set installation to prevent the return lines of 1/2 inch (12.7 mm) minimum clearance from electri-
idle sets from being pressurized. Fuel return lines cal wiring and a 2 inch (51 mm) minimum clearance
must not contain a shutoff device. Engine damage from hot exhaust parts.
4-1
ENGINE VENTED INJECTOR FUEL
RETURN LINE All models require a fuel return
FUEL FILL CAP line from injectors to tank.
PUMP
CONNECT TO
AC OUTPUT
SHUTOFF
VALVE
VENT LINE
DAY TANK
1 INCH
BAFFLE FILL PIPE
FLOAT
SWITCH
SUPPLY
LINE
FUEL TRANSFER
PUMP ELECTRIC
MOTOR DRIVEN
120 MESH FUEL

STRAINER
FUEL TANK
LARGER OVER-
FLOW LINE
FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION
Engine Fuel Connections pump will also be required. If an overhead main fuel
tank is installed, a transfer tank and float valve will
Identification tags are attached to the fuel supply be required to prevent fuel head pressures from be-
line and fuel return line connections. ing placed on the fuel system components.
Supply Tank For critical start applications, where generator sets
are paralleled or must satisfy emergency start-time
Locate the fuel tank as close as possible to the gen- requirements, it is recommended that a fuel tank or
erator set and within the restriction limitations of the reservoir be located such that the lowest possible
fuel pump. fuel level is not less than 6 inches (150 mm) above
the fuel pump inlet. This will prevent air from accu-
Install a fuel tank that has sufficient capacity to sup- mulating in the fuel line while the set is in standby,
ply the genset operating continuously at full rated eliminating the period during startup when it has to
load for the planned period of operation or power be purged.
outage. Refer to Data Sheet for fuel consumption
data. Fuel Inlet Pressure/Restriction Limit: Engine
performance and fuel system durability will be com-
If the fuel inlet restriction exceeds the defined limit promised if the fuel inlet pressure or restriction limits
due to the distance/customer-supplied plumbing are not adhered to. Fuel inlet pressure or restriction
between the genset and the main fuel tank, a trans- must not exceed the limits stated in the Generator
fer tank (referred to as a day tank) and auxiliary Set Data Sheet.
4-2
Day Tank (If Used) turn line to the bottom of day tank as shown in Fig-
ure 4-1. Provide a day tank overflow line to the sup-
Fuel day tanks are used when fuel inlet restriction ply tank in case the float switch fails to shut off the
limits can not be met, or the supply tank is overhead fuel transfer pump.
and presents problems of high fuel head pressure
for the fuel inlet and return lines.
WARNING Spilled fuel presents the hazard of
Supply Tank Lower Than Engine: With this instal- fire or explosion which can result in severe per-
lation, the day tank is installed near the generator sonal injury or death. Provide an overflow line
set, below the fuel injection system and within the to the supply tank from the day tank.
fuel inlet restriction limit. Install an auxiliary fuel
pump, to pump fuel from the supply tank to the day Supply Tank Higher Than Engine: Install the day
tank. A float switch in the day tank controls opera- tank near the generator set, but below the fuel injec-
tion of the auxiliary fuel pump. tion system. Use fuel line at least as large as the fuel
pump inlet. The engine fuel return line must enter
The supply tank top must be below the day tank top the day tank.
to prevent siphoning from the fuel supply to the day
tank.
Include a shutoff valve in the fuel line between the
Provide a return line from the engine injection sys- fuel supply tank and the day tank to stop fuel flow
tem return connection to the day tank. Plumb the re- when the generator set is off.
WARNING Spilled fuel can create environmental hazards. Check local requirements for containment
and prevention of draining to sewer and ground water.
4-3
EXHAUST SYSTEM Combustion Engines and Gas Turbines, NFPA 37
or applicable local standards, Section 6-3. Build ac-
Pipe exhaust gases to the outside of any enclosure. cording to the code requirements in effect at the
Locate the exhaust outlets away from any air inlets installation site.
to avoid gases re-entering the enclosure. Exhaust
installations are subject to various detrimental con- WARNING Hot exhaust pipes can start a fire
ditions such as extreme heat, infrequent operation and cause severe injury or death if improperly
and light loads. Regularly inspect the exhaust sys- routed through walls. Use an approved thimble
tem both visually and audibly to see that the entire where exhaust pipes pass through walls or
system remains fume tight and safe for operation. partitions.
WARNING Inhalation of exhaust gases can re- WARNING Inhalation of exhaust gases can re-
sult in severe personal injury or death. Use ex- sult in severe personal injury or death. Do not
treme care during installation to provide a tight use exhaust heat to warm a room, compartment
exhaust system. Terminate exhaust pipe away or storage area.
from enclosed or sheltered areas, windows,
doors and vents. Rain caps are available for the discharge end of ver-
tical exhaust pipes. The rain cap clamps onto the
For indoor installation, the exhaust system must end of the pipe and opens due to exhaust discharge
use sealed joint type fittings, (for example NPT fit- force from the generator set. When the generator
tings) to provide a tighter exhaust system. Use of set is stopped, the rain cap automatically closes,
slip type fittings (secured with a muffler clamp) may protecting the exhaust system from rain, snow, etc.
allow leakage of exhaust gases into the building.
Use a section of flexible exhaust pipe between the
WARNING Inhalation of exhaust gases can re- engine and remainder of exhaust system. Support
sult in severe personal injury or death. Use ex- exhaust system to prevent weight from being ap-
treme care during installation to provide a tight plied to engine exhaust outlet elbow/turbocharger
exhaust system. Use NPT or equivalent type fit- connection.
tings for all indoor installations.
CAUTION Weight applied to the engine man-
Use an approved thimble (Figure 4-2) where ex- ifold can result in turbocharger damage. Sup-
haust pipes pass through wall or partitions. Insu- port the muffler and exhaust piping so no
lated wall/roof thimbles are used where exhaust weight or stress is applied to engine exhaust el-
pipes pass through a combustible roof or wall. This bow.
includes structures, such as wood framing or insu-
lated steel decking, etc. Uninsulated wall/roof The exhaust system design should meet local code
thimbles are used where exhaust pipes pass requirements.
through a non-combustible wall or roof, such as
Liability for injury, death, damage, and warranty ex-
concrete. When a unit is provided with a partially pense due to use of unapproved mufflers or modifi-
installed or incomplete exhaust system, exhaust cations becomes the responsibility of the person
piping and chimneys shall be designed, installing the unapproved muffler or performing the
constructed, and installed in accordance with the modification. Contact a Cummins Power Generation
Standard for the Installation and Use of Stationary distributor for approved exhaust system parts.
4-4
Avoid sharp bends by using sweeping, long radius
elbows and provide adequate support for muffler
and tailpipe. Pitch a horizontal run of exhaust pipe
DOWNWARD (away from engine) to allow any RAIN CAP DRIP CAP
moisture condensation to drain away from the en- HOLES IN
gine. If an exhaust pipe must be turned upward, END OF INNER
install a condensation trap at the point where the SLEEVE
rise begins (Figure 4-3).
9 INCH
Shield or insulate exhaust lines if there is danger of (230 mm)
personal contact. Allow at least 12 inches (305 mm) VERTICAL
ROOF
of clearance if the pipes pass close to a combustible
wall or partition. Before installing insulation on ex-
haust system components, check the exhaust sys- 9 INCH
tem for leaks while operating the genset under full (230 mm)
load and correct all leaks.
WARNING Exhaust pipes are very hot and they
can cause severe personal injury or death from
direct contact or from fire hazard. Shield or in-
sulate exhaust pipes if there is danger of per- HORIZONTAL
sonal contact or when routed through walls or
near other combustible materials.
WALL OR PARTITION
FIGURE 4-2. MOUNTING EXHAUST THIMBLE
IF EXHAUST LINE MUST BE

PITCHED UPWARD, CONSTRUCT
A TRAP AT POINT OF RISE
AVOID
SHARP
BENDS
DRAIN CONDENSATION
TRAP PERIODICALLY
FIGURE 4-3. CONDENSATION TRAP
4-5
VENTILATION AND COOLING
Generator sets create considerable heat that must

be removed by proper ventilation. Outdoor installa-
tions normally rely on natural air circulation but in-
door installations need properly sized and posi-
tioned vents for required airflow. PREVAILING WINDS PREVAILING WINDS
Vents and Ducts
For indoor installations, locate vents so incoming air

passes through the immediate area of the installa-
tion before exhausting. Install the air outlet higher
than the air inlet to allow for convection air move-
ment.
Size the vents and ducts so they are large enough to

allow the required flow rate of air. The ”free area” of
ducts must be as large as the exposed area of the
radiator. Refer to the genset Data Sheet for the air-
flow requirements and allowed airflow restriction.
Wind will restrict free airflow if it blows directly into

the air outlet vent. Locate the outlet vent so the ef- FIGURE 4-4. WIND BARRIER
fects of wind are eliminated. See Figure 4-4.
4-6
Dampers equipment room to be heated while the genset en-
gine is still cold, increasing the engine efficiency.
Dampers or louvres protect the genset and equip-
ment room from the outside environment. Their op- Engine Coolant Heater (Optional)
eration of opening and closing should be controlled
by operation of the genset. An optional jacket water coolant heater is available
to keep the engine warm for improved starting and
In cooler climates movable or discharge dampers code compliance. Connect the heater to a power
are used. These dampers allow the air to be recircu- source that will be energized when the engine is
lated back to the equipment room. This enables the NOT running.
4-7
Radiator Cooling vanes. The effective open area specified by the lou-
ver or screen manufacturer should be used.
Radiator Set Requirements: Radiator set cooling Locate the cooling air outlet directly in front of the ra-
air is drawn past the control end of the set by pusher diator and as close as possible. The outlet opening
fans that blow air through the radiator (Figure 4-5). must be at least as large as the radiator area.
Locate the air inlet to the rear of the set. Make the Length and shape of the air outlet duct should offer
inlet vent opening 1-1/2 to 2 times larger than the ra- minimum restriction to airflow.
diator area.
Attach a canvas or sheet metal duct to the flange
Louvers and screens over air inlet and outlet open- and the air outlet opening using screws and nuts so
ings restrict air flow and vary widely in performance. duct can be removed for maintenance purposes.
A louver assembly with narrow vanes, for example, The duct prevents circulation of heated air. Before
tends to be more restrictive than one with wide installing the duct, remove the radiator core guard.
THERMOSTATIC AIR
RECIRCULATING DAMPER *
WIND/NOISE
BARRIER
INLET AIR
DAMPER
HOT AIR
COOL AIR
D
RADIATOR FLEXIBLE DUCT DISTANCE SHOULD NOT

* Louvers should close when room CONNECTOR BE LESS THAN HEIGHT
ambient is above 60 F (16 C) OF RADIATOR
FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION
4-8
Remote Radiator Cooling (Optional) Heat Exchanger (Optional)
Remote radiator cooling substitutes a remote
mounted radiator and an electrically driven fan in The optional heat exchanger (Figure 4-6) uses a
place of the set mounted components. Removal of shell and tube type heat exchanger instead of the
the radiator and the fan from the set reduces noise standard radiator and fan. Engine jacket coolant cir-
levels without forcing dependence on a continuous culates through the shell side of the heat exchanger
cooling water supply (necessary with heat ex- while the cooling water is pumped through the
changer cooling). The remote radiator installation tubes. Engine coolant and raw water do not mix.
must be completely protected against freezing.
This system may reduce set enclosure airflow re-
Remote radiator plumbing will vary with installation. quirements and noise levels. Proper operation de-
Follow recommendations given in Application pends on a constant supply of raw water for heat re-
Manual T-030. See product Data Sheet for friction moval. Adjust the flow to maintain engine coolant
head and static head limits. temperature between165 F and 195 F (74 C and
Before filling cooling system, check all hardware for 91 C) while viewing the water temperature gauge.
security. This includes hose clamps, capscrews, fit- The engine coolant side of the system can be pro-
tings and connections. Use flexible coolant lines tected from freezing; the raw water side cannot be
with heat exchanger or remote mounted radiator. protected.
VENTILATING
FAN
WATER WARM FLEXIBLE

SOLENOID AIR WATER
VALVE CONNECTIONS
MOUNTED HEAT
COOL AIR EXCHANGER
RAW WATER
SUPPLY
RAW WATER
DISCHARGE
FIGURE 4-6. TYPICAL HEAT EXCHANGER INSTALLATION
4-9
COOLANT
The cooling system of radiator type gensets can be COOLANT FILTER
SHUTOFF VALVE
shipped installed or as a separate item. If shipped
with the cooling system installed, both radiators are
filled with the proper fluids at the factory. Make sure
that the coolant levels of both radiators are correct
before starting.
The procedure for checking and filling the cooling

system of a set mounted radiator is provided in Sec-
tion 9 of this manual.
Coolant Filters
Two spin-on type corrosion filters (Figure 4-7) are
standard equipment. To prevent coolant loss during
filter replacement, a coolant shut off valve is pro-
vided (Figure 4-7). Make sure shutoff valve is in the
ON position before operating the generator set.
FILTERS
NOTE:
OPEN
COOLANTF
L
ITE
RSHUT
O F
FVAL
V E
BE
FORE
OPE
RATN
IGGENE
R A
TORSET
.
FIGURE 4-7. TYPICAL COOLANT FILTER
4-10
5. DC Control Wiring
CONTROL WIRING CAUTION When removing terminal block con-
nectors (TB4, TB5, or TB8) from cards in card
The generator set electronics box, which is located cage, note orientation of connector. These ter-
on the backside of the control housing, contains minal block connectors are not keyed and can
connection points for remote control and monitor be installed incorrectly, which will cause con-
options. These connection points are located in two
trol failures.
different locations within the electronics box as
shown in Figure 5-1.
Terminal Block Wiring
CAUTION Do not attach conduit to the elec-
tronics box for any reason. All conduit must be CAUTION Always run control circuit wiring in
attached to the control housing. Attaching con- a separate metal conduit from AC power cables
duit to the electronics box will compress the to avoid inducing currents that could cause
electronics box vibration isolators, causing the problems within the control.
box to vibrate and damage the electronic cir-
cuitry. Digital Connections: Connection points, other
then relayed outputs, network, switched B+ and B+
Use flexible conduit for all wiring connections to the are considered digital connections to the terminal
generator set. All conduit used for control wiring blocks. The type/gauge wire to use for these con-
must be attached to the control housing, not to the nections are:
electronics box. Route the control wiring through
the control housing and into the access hole on the  Less than 1000 feet (305m), use 20 gauge
back panel of the electronics box. Use cable ties to stranded copper wire.
keep control wiring away from sharp edges and AC  1000 to 2000 feet (305 to 610m), use 18 gauge
power cables within control housing. stranded copper wire.
CAUTION Stranded copper wire must be used Relay Connections: Due to the wide variety of de-
for all customer connections to the electronics vices that can be attached to the relay outputs of ter-
box. Solid copper wire may break due to genset minal blocks, the electrical contractor must deter-
vibration. mine the gauge of the stranded copper wire that is
used at this installation site. Refer to Customer
REMOTE MONITOR/CONTROL Connections diagram in Section 10 for the relay
CONNECTIONS specifications.
Customer monitor/control connections are at- Switched B+: (Fused at 20 amps.) Same as Relay
tached to terminal blocks TB3, TB4 TB5 and TB8. Connection description.
Optional equipment such as a remote annunciator
panel, sensing devices used to monitor genset op- B+: (Fused at 20 amps.) Same as Relay Connec-
eration, remote start/stop switches, control box tion description.
heater, and etc. are attached to these terminal
blocks. Driver signals for customer supplied relays Network Connections: Refer to 900-0366 Power-
are also provided for several alarm and shut down Command Network Installation and Operation
conditions. Refer to Customer Connections dia- manual for the type/gauge wire to use for these con-
gram in Section 10. nections.
5-1
ELECTRONICS
OPTIONAL BOX
TB1-3 COMMON ALARM
RELAY K10
OPTIONAL RUN
RELAYS K11, K12 &
K13
TB5
TB4
CARD
CAGE
TB8
FIGURE 5-1. ELECTRONICS BOX
5-2
RUN RELAYS (K11, K12, K13) fans, pumps and motorized air dampers. The run
relays are energized when the generator set reach-
The optional run relays are rail mounted inside the es operating speed.
electronics box (Figure 5-1). The rail mount allows
you to easily remove and replace the snap-on re- The contacts are rated:
lays. The generator set can be equipped with one,
two or three run relays.  10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw run relays (Figure  6 amps at 240 VAC, 80%PF
5-2) are used to control auxiliary equipment such as  3 amps at 480/600 VAC, 80%PF
K11, K12, K13
CUSTOMER
K11, K12, K13
CONNECTIONS
K11, K12, K13
K11 K12 K13

RUN RELAY RUN RELAY RUN RELAY
NO NO NO
NC NC NC
COIL TB3-7
TB3-5
(SWITCHED B+) COM (B-)
FIGURE 5-2. OPTIONAL RUN RELAYS (K11, K12, K13)
5-3
ALARM RELAY (K10) as audible alarms. Any generator set warning or
shutdown will energize the alarm relay.
The optional alarm relay is rail mounted inside the
electronics box (Figure 5-1). The rail mount allows The contacts are rated:
you to easily remove and replace the snap-on relay.  10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw alarm relay (Figure  6 amps at 240 VAC, 80%PF
5-3) is often used to energize warning devices such  3 amps at 480/600 VAC, 80%PF
K10
CUSTOMER
K10
CONNECTIONS
K10
K10
COMMON ALARM
NO
NC
COIL TB3-10
TB3-32
(COM ALARM) COM (B-)
FIGURE 5-3. OPTIONAL ALARM RELAY (K10)
5-4
6. AC Electrical Connections
GENERAL WARNING Each of the operations described in
this section should be done only by persons
This section provides the procedure that is used to trained and experienced in electrical mainte-
connect the AC electrical system of the genset. nance. Improper procedures may result in prop-
erty damage, bodily injury or death.
Before making any AC electrical connections, make Connecting the genset AC electrical system in-
certain the generator set cannot be accidentally volves:
started. Move the O/Manual/Auto switch on the
control panel to the O (off) position. Turn off or re-  Generator insulation check
move AC power from the battery charger and then  Installation of transfer switch
remove the negative (−) battery cable from the set  Generator output voltage selection
starting battery.
 Load cable connection
WARNING Ignition of explosive battery gases  Standard and optional AC equipment connec-
can cause severe personal injury or death. Arc- tions (e.g., control box heater, coolant heater,
ing at battery terminals, light switch or other etc.
equipment, flame, pilot lights and sparks can ig- Local regulations often require that wiring connec-
nite battery gas. Do not smoke, or switch tions be made by a licensed electrician, and that the
trouble light ON or OFF near battery. Discharge installation be inspected and approved before op-
static electricity from body before touching bat- eration. All connections, wire sizes, materials used,
teries by first touching a grounded metal sur- etc. must conform to the requirements of electrical
face. codes in effect at the installation site.
Ventilate battery area before working on or near WARNING Improper wiring can cause a fire or
battery—Wear goggles—Stop genset and dis- electrocution, resulting in severe personal inju-
connect charger before disconnecting battery ry or death and/or property and equipment dam-
cables—Disconnect negative (−) cable first and age.
reconnect last.
Before starting the genset, check to make sure that
all electrical connections are secure, and that all
CAUTION Disconnect battery charger from AC
wiring is complete. Replace and secure any access
source before disconnecting battery cables. panels that have been removed during installation.
Otherwise, disconnecting cables can result in Check that the load cables from the genset are
voltage spikes damaging to DC control circuits properly connected.
of the set.
WARNING Backfeed to utility system can
WARNING Accidental starting of the generator cause electrocution or property damage. Do
set can cause severe personal injury or death. not connect to any building electrical system
Prevent accidental starting by disconnecting except through an approved device and after
the negative (−) cable from the battery terminal. building main switch is opened.
6-1
INSULATION RESISTANCE (MEGGER) & 3. Put on high voltage gloves with leather protec-
POLARIZATION INDEX (PI) TESTING tors.
4. Using two pre-tested voltage detection devices
Megger and PI testing must be performed on all (of the proper rating), verify de-energized con-
medium voltage (601 through 15,000 volts) genera- dition in the work area. (Retest voltage detec-
tor sets before initial start-up. PI testing for low volt- tion devices immediately after verification of
age (less than 600 volts) generator sets is recom- de-energized condition.)
mended by Cummins Power Generation.
5, Remove the metal cover from the generator
These tests are used to verify that the windings are output box to gain access to generator load ter-
dry before the generator set is operated and devel- minals.
op a base line for future test comparisons. 6. Securely install the Grounding Cluster ground
clamp to a verified “grounded” conductor.
Before these tests can be performed on medium
voltage generator sets, you must first perform the WARNING Hazardous voltage. Can cause
generator grounding procedure. severe personal injury or death. After DC
voltage from the test equipment has been
Generator Set Grounding Procedure applied to the windings and ground, there
will be a definite static charge on the wind-
Prior to performing service or inspection proce- ings. Reconnect Grounding Cluster to re-
dures that may expose personnel to conductors move static charge from the winding after
normally energized with voltages greater than 600 each generator test.
volts, the following generator set grounding proce-
dure must be followed. 7. With the Grounding Cluster in place, you are
protected from all static and/or induced
Do not perform these procedures charges that may have been present in the
unless fully trained in medium voltage ground- generator stator.
ing procedures and have necessary safety Leave grounds connected for one minute to in-
equipment. Severe injury or death due to high sure static charge dissipation. Remove ground
voltage electrical shock may result. cluster and perform PI and/or any other tests
1. Open, lock-out and tag-out all sources of power required on the stator winding. Reconnect
to the immediate work area. grounds if additional generator service is nec-
essary.
2. Disable the starting system of the generator
set: 8. When work on the generator set is complete,
remove the Grounding Cluster in the reverse
a. Disconnect the battery charger from its AC order of installation.
source.
9. After getting clearance from all personnel in-
b. Remove the negative battery cable from volved in the lock-out/tag-out procedure, re-
the battery. move all lock-out devices in reverse order of
c. Install a lockout device on the battery installation.
cable end. (For engines equipped with an
air-powered starting system, close air
valve and install valve locking device.)
6-2
Megger and PI Test 2. Disconnect connector 10 from the voltage reg-
ulator output stage module and the AC control
Medium-voltage, 601 to 15,000 input leads from the generator output termi-
volts, present special hazards of severe person- nals. The AC control leads are marked 5, 6, 7
al injury or death. Even after genset shutdown, and 8. Refer to the reconnection diagram,
an electrical shock hazard may still exist, which is located on the upper side cover of the
caused by induced voltage within the generator
control housing.
or cables. Service personnel must be well-
trained/qualified to work with distribution volt- 3. If the RTD (resistive thermal device) option is
ages. (See Generator Set Grounding Proce- installed, ground all six resistive thermal device
dures, Page 6-2.) temperature leads. Each RTD has three leads,
one red and two white leads. Total of 18 leads
WARNING Windings of medium voltage (601
must be grounded.
through 15,000 volts) generator sets must be
dry before the generator is operated. Failure to
Main Stator:
ensure dry windings before start-up may result
in catastrophic failure, severe personal injury
and death. 4. Disconnect the main rotor and voltage sup-
pressor leads from terminals F1+ and F2− on
Megger Test: The megger test consists of applying the rotating rectifier assemblies and isolate
voltage for up to one minute. The highest resistance them from ground. Tag and mark each lead
values shown in Table 6-1 should be obtained for a with its terminal number (F1+ or F2−).
new generator with dry windings. For a set that has
been in service, the resistance reading should not 5. Remove and separate the neutral leads of the
be less than the lower value shown. generator from the generator load terminal
marked “N”.
PI Test: The PI test consists of applying a voltage
between the winding and ground for ten minutes 6. Connect the megger between one phase of the
and recording resistance values at one minute and stator and ground while grounding the other
at ten minutes. The PI is the ratio of a ten minute two phases and conduct the test. Refer to Table
reading in megohms divided by a one minute read- 6-1 for megger voltage selection and required
ing in megohms. A ratio of two or greater is consid- resistance values.
ered good for new and in-service sets.
Repeat this step in turn for the other two
If low readings are obtained, investigate the cause phases.
and correct before the generator set is returned to
service. If moisture is determined to be the cause of Main Rotor:
low test readings, a winding drying process will be
required (refer to genset Service manual for drying 7. Disconnect the main rotor and voltage sup-
procedure). pressor leads from terminals F1+ and F2− on
1. Perform the Generator Set Grounding Proce- the rotating rectifier assemblies and isolate
dure in this section. them from ground. Tag and mark each lead
with its terminal number (F1+ or F2−).
CAUTION When megger testing a genera-
tor, failure to protect the voltage regulator, 8. Connect the megger between one of the rotor
control and diodes could result in perma- leads and ground and conduct the test. Refer to
nent damage to one or more of the electron- Table 6-1 for megger voltage selection and re-
ic components. quired resistance values.
6-3
TABLE 6-1. GENERATOR INSULATION RESISTANCE
MINIMUM RESISTANCE (MEG)

GENERATOR VOLTAGE MEGGER VDC
SETTING MAIN STATOR MAIN ROTOR
600 VAC or less 500 5.0 − 1.0 5.0 − 1.0
601 thru 5000 VAC 2500 400 − 50
1000 5.0 − 1.0
5001 thru 15000 VAC 5000 1000 − 200
1000 5.0 − 1.0
TRANSFER SWITCH
If the installation is for standby service, a transfer LOAD
switch must be used for switching the load from the
normal power source to the genset (see Figure 6-1).
NORMAL
Either a manual or automatic transfer switch may be SOURCE GENSET
used. Follow the installation instructions provided
with the transfer switch when connecting the load
and control wiring.
FIGURE 6-1. TYPICAL LOAD TRANSFER

FUNCTION
6-4
AC WIRING All loads are connected to the generator by bolting
the stranded load wires to the appropriate termi-
Generator Voltage Connections nals on the generator reconnection terminal block.
The terminals are stamped U, V, W and N to indicate
The generator output voltage and maximum current
the line and neutral connections. (Reference: U, V,
rating are specified on the generator set nameplate.
and W correspond with L1, L2 and L3; and N with L0
Line-to-neutral voltage is always the lower voltage
respectively).
shown and line-to-line voltage is the higher rating.
The generators are available at the voltages shown Load Balancing

in the Wiring Diagram located on the upper side
cover of the control housing. The generator is con-
When connecting loads to the generator set, bal-
nected at the factory to produce a specified voltage
ance the loads so the current flow from each line ter-
per customer order (they cannot be reconfigured for
minal (L1, L2 and L3) is about the same. This is es-
different voltages in the field). Before shipping, the
pecially important if both single phase and three
factory tests the generator set at the specified volt-
phase loads are connected. Any combination of
age.
single phase and three phase loading can be used
Load Connections as long as each line current is about the same, with-
in 10 percent of median value and no line current ex-
Flexible conduit and stranded conductors must be ceeds the nameplate rating of the generator. Check
used for connections to take up movement of the the current flow from each line after connections by
generator set. observing the control panel ammeter.
6-5
Grounding Make sure the genset is grounded to earth in one
location only. On generators without a circuit break-
The following is a brief description of system and er, ground to the point indicated on the top of the
equipment grounding of permanently installed AC generator. On gensets with circuit breakers, use the
generators within a facility wiring system. It is impor- ground lug provided in the circuit breaker box.
tant to follow the requirements of the local electrical
WARNING Electric current can cause severe
code.
personal injury or death. Bonding and ground-
ing must be done properly. All metallic parts
Figure 6-2 illustrates typical system grounding for a that could become energized under abnormal
3-pole and a 4-pole automatic transfer switch conditions must be properly grounded.
(ATS). In the 3-pole ATS, note that the generator
neutral is connected to the ATS and is NOT bonded Typical requirements for bonding and grounding
to ground at the generator. In the 4-pole ATS sys- are given in the National Electrical Code, Article
tem, a grounding electrode conductor and a bond- 250. All connections, wire sizes, etc. must conform
ing jumper are used to connect the generator neu- to the requirements of the electrical codes in effect
tral to ground. at the installation site.
SERVICE ENTRANCE GENERATOR SET

3-POLE ATS
LOAD
THREE-PHASE, FOUR-WIRE UTILITY, THREE-POLE ATS
SERVICE ENTRANCE GENERATOR SET

4-POLE ATS
LOAD
THREE-PHASE, FOUR-WIRE UTILITY, FOUR-POLE ATS
FIGURE 6-2. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS
6-6
CONTROL HEATER (OPTIONAL) terior. It protects the components when the genera-
A control heater (Figure 6-3) provides a means of tor set is subjected to varying ambient air conditions
humidity /temperature control of the control box in- during extended periods of non-use.
TO ACCESSORY BOX
TB3-19 & TB3-20
HEATER
BOTTOM VIEW OF
CONTROL BOX
FIGURE 6-3. OPTIONAL CONTROL HEATER
6-7
COOLANT HEATER the time the engine is not running. Be sure the sup-
ply voltage and circuit amperage is correct for the
Coolant heaters keep the engine coolant warm heater element rating.
when the engine is shut down. It heats and circu-
lates the coolant within the engine. This reduces
startup time and lessens engine wear caused by A battery charger is required to prevent battery dis-
cold starts. It is electrically operated and thermo- charge. The heater control relay draws 83 mA of cur-
statically controlled. rent when the heater(s) is off. The heater is off when
the engine has reached the proper temperature or
CAUTION The coolant heater must not be op- the engine is running.
erated while the cooling system is empty or
when the engine is running or damage to the
CAUTION Do not connect AC power to the
heater will occur.
heater before connecting battery cables. Heater
Figure 6-4 shows a typical coolant heater. Connect will run continuously without DC power and can
the heater to a source of power that will be on during overheat and damage heater.
THERMOSTAT
COOLANT
FLOW
ARROWS
DC SUPPLY
LINE
DC CONTROL
LINE
DRAIN
AC ELECTRICAL CONNECTION
BOX (ELECTRICAL DIAGRAM
INSIDE COVER)
AC POWER
LINE
FIGURE 6-4. TYPICAL COOLANT HEATER
6-8
GENERATOR HEATER Figure 6-5 illustrates the installation of two heater
A generator heater(s) is used to help keep the gen- elements. Connect the heater(s) terminals to a
erator free of condensation when the generator set source of power that will be on during the time the
is not running. During cool and humid conditions, engine is not running. Be sure the supply voltage
condensation can form within a generator, creating and circuit amperage is correct for the heater ele-
flashing and a shock hazard. ment rating.
WARNING Water or moisture inside a genera-
tor increases the possibility of flashing and
electrical shock, which can cause equipment
damage and severe personal injury or death. Do
not use a generator which is not dry inside and
out.
HEATER LEADS
HEATER LEADS
HEATERS
HEATER
TERMINAL BOX
HEATER
VOLT/WATTS
LABEL
TERMINAL
BLOCK
FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION
6-9
THIS PAGE LEFT INTENTIONALLY BLANK
6-10
7. Prestart Preparation
GENERAL Necessary battery cables are on the unit. Service
batteries as necessary. Infrequent use (as in emer-
Before attempting the initial start of the generator gency standby service), may allow battery to self-
set, be sure to complete the Installation Checklist in discharge to the point where it cannot start the unit.
Section 8. If installing an automatic transfer switch that has no
ELECTRICAL SYSTEM built-in charge circuit, connect a separate trickle
charger. Cummins Power Generation automatic
Make sure all electrical connections are secure and transfer switches include such a battery charging
all wiring is complete and inspected. Replace and
circuit.
secure any access panels that may have been re-
moved during installation.
WARNING Ignition of explosive battery gases
Battery Connections can cause severe personal injury or death. Al-
WARNING Accidental starting of the generator ways connect negative (−) battery cable last to
set can cause severe personal injury or death. prevent arcing.
Make sure that the Run/Off/Auto switch on the
control panel is set to the Off position before WARNING Ventilate battery area before work-
connecting the battery cables. ing on or near battery. Arcing at battery termi-
nals, light switch or other equipment, flame, pi-
Starting the unit requires 24 volt battery current, us- lot lights and sparks can ignite battery gas. Do
ing four, 12 volt batteries (see Specification sec- not smoke, or switch trouble light ON or OFF
tion). Connect the batteries in series (negative post near battery. Discharge static electricity from
of first battery to the positive post of the second bat- body before touching batteries by first touching
tery) as shown in Figure 7-1. a grounded metal surface.
BATTERY
NEGATIVE (−)
CONNECTION
BATTERY POSITIVE
(+) CONNECTION
+ +
USE TWO, 12
− − VOLT BATTERIES
FOR EACH
STARTER
FIGURE 7-1. GENSET BATTERY CONNECTIONS
7-1
CONTROL PRESTART CHECKS For this reason, a separate password is required to
modify the Setup submenus. The Adjust submenu
All generator set configuration options are set at the may or may not require a password (site depen-
factory except for site related options, (e.g., Start/ dent).
Stop Delays, Cycle Crank, Customer Fault names,
etc.). The following procedure describes how to modify
Adjustments of these options are divided into two the Adjust submenu options that are required to
categories within the menu driven system. These complete the genset installation.
two categories are Setup and Adjust.
The Adjust submenu allows you to calibrate the
The Setup submenus are intended for qualified ser- generator set voltage/frequency and start/stop time
vice personnel only. The Adjust submenu is in- delays. For the prestart checks, adjustment of only
tended for qualified service and site personnel only. the start/stop delays is required.
7-2
ADJUST Submenu Changes are automatically saved when you exit
this menu.
Figure 7-2 shows the main menus (Menu A and
Menu B) of the system control and the Adjust sub- Use the + and − buttons to increase or decrease the
menu. values in the following fields. Use the arrow () but-
To display the Adjust submenu, press the MORE>> ton to move the cursor within a field or to the next
field. Selected field is highlighted.
button in Menu A and then the ADJUST button in
Menu B.
START DELAY: This delay applies only to remote
The Adjust procedure is intended for qualified ser- starting in the Auto mode. The Start Delay adjust-
vice personnel and site personnel only and may re- ment range is 0 to 300 seconds.
quire a USER password. If a password is required,
the USER password menu will appear when you try STOP DELAY: This delay applies only to remote
to modify the Adjust submenu. (Refer to PASS- stopping in the Auto mode. The Stop Delay adjust-
WORD Menu in this section to enter password. ment range is 0 to 600 seconds.
MENU A
MENU
ENGINE MORE>> B
ALTERNATOR _\_
CONTROL HISTORY/ABOUT
MENU B
ADJUST
BUS DATA
MENU
SETUP BACK<<
A
ADJUST:
+ VOLTAGE 208 1.2 % B
FREQ 60.0 HZ -0.0 HZ
− START DELAY 5 SEC Y
 STOP DELAY 11 SEC
FIGURE 7-2. ADJUST SUBMENU
7-3
PASSWORD Menu
When viewing the Adjust submenu, pressing either + OR − BUTTON
the + or − button will display the Password menu
(Figure 7-3) if a User password is assigned to this
field. After entering the correct password, the sys-
tem will allow you to modify the submenu. To pre-
vent unauthorized adjustment, the entered pass- ENTER USER PASSWORD
+ ENTER
word is valid for only 10 minutes after the last button
is pressed. −
 XXXXXXXX
To enter the password:
1. Display Adjust submenu.
2. Press either the + or − button within the dis-
played submenu. The Password menu ap- FIGURE 7-3. PASSWORD MENU
pears. (Adjustment is allowed if Password
menu does not appear.)
3. Press the + and − button to select the first char-
acter of the User password.
4. Press the  button to select the next character
field.
5. Repeat steps 3 and 4 to enter remaining pass-
word characters.
6. Press the Enter button after entering the pass-
word. The Adjust submenu will reappear.
7. Exit Adjust submenu to save changes.
STARTING
Refer to the generator set Operator’s manual for im-
portant safety precautions and recommended pro-
cedures for starting the genset and verifying proper
operation. Start the generator set and verify all en-
gine and generator gauges are displaying the cor-
rect values.
7-4
8. Installation Checklist
GENERAL
j Generator set wattage capacity is sufficient to handle maximum anticipated load.
j At least 3 feet of clearance (or greater for housing door) is provided around entire generator set for servic-
ing and ventilation.
j Generator set is located in an area not subject to flooding.
j All operating personnel have read and are familiar with Operator’s Manual.
j All operators have been thoroughly briefed on preventive maintenance procedures.
j All operators have read and understand all Important Safety Instructions in Operator’s Manual.
GENERATOR SET SUPPORT
j Floor, roof or earth on which the generator set rests is strong enough and will not allow shifting or move-
ment. Observe local codes on soil bearing capacity due to freezing and thawing.
j Generator set is properly supported and retained to approved base.
j Supporting base is large enough and is of non-combustible material − extends 6-inches all around set.
COOLING AIR FLOW
j Generator set air inlet is faced into direction of strongest, prevailing winds.
j Air inlet openings are unrestricted and at least 1−1/2 times larger than air outlet area.
j Cooling air outlet is on downwind side of building (if not, wind barrier is constructed).
j Proper ducting material (sheet metal, canvas) is used between radiator and air outlet.
DIESEL FUEL SYSTEM

j Fuel tanks meet or exceed all Local, State or National codes.
j Fuel lines are properly installed, supported and protected against damage.
j Approved flexible fuel line is installed between main fuel supply line and generator set’s fuel system, near
the generator set, to protect the fuel system from damage caused by vibration, expansion and contrac-
tion.
j Strainer or fuel screen (100 to 120 mesh) is installed in the fuel supply line to protect the fuel lift pump, day
tank transfer pump or float valve seat from fuel supply tank debris.
j Fuel supply line shutoff valves are installed to prevent fuel flow in case of leaks.
j No shutoff valves are installed on engine fuel return line.
j External fuel pumps are connected and operational at all times (generator set started or shut down).
j Fuel system is properly primed.
j No fuel leaks are found in supply line or engine fuel system.
8-1
EXHAUST SYSTEM
j Operators are thoroughly briefed on the dangers of carbon monoxide gas.
j Areas around set are well ventilated. No possibility of exhaust fumes entering building doors, windows, or
intake fans.
j Exhaust gases are piped safely outside and away from building.
j The correct length of approved rigid pipe is connected to the generator set flexible pipe using approved
securing methods with no weight resting on engine exhaust components. There are no bends in flex sec-
tion.
j Condensation drain is provided in lowest section of exhaust piping.
j Exhaust piping is insulated to guard against burns to personnel.
j Exhaust piping passing through walls or ceilings have approved fire-proof materials and are in com-
pliance with all codes.
j Exhaust piping is large enough in diameter to prevent excessive back pressure on engine.
AC AND DC WIRING
j Wire sizes, insulation, conduits and connection methods all meet applicable codes.
j AC and DC wires are separated in their own conduit to prevent electrical induction.
j All load, line and generator connections are proper and correct.
j Flexible conduit between generator set and building or surrounding structure.
GENERATOR SET PRESTART

j Generator set engine is properly serviced with oil and coolant.
j Batteries are properly installed, serviced and charged.
j Battery charger and engine coolant heater are connected and operational.
j All generator set covers and safety shields are installed properly.
j All fuel and coolant shutoff valves are operational.
8-2
No.
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CUSTOMER CONNECTIONS (PAGE 1 OF 2)
9-1
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No.
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9-5
No.
61 2-
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No.
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No.
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9-8
THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 179-3301 sh 1 of 20
Rev. E
Modified 4−2014
COOLING SYSTEM INSTALLATION (405 C HIGH AMBIENT)
9-9
No. 179-3301 sh 2 of 20
Rev. E
Modified 4−2014
9-10
No. 179-3301 sh 3 of 20
Rev. E
Modified 4−2014
9-11
No. 179-3301 sh 4 of 20
Rev. E
Modified 4−2014
9-12
No. 179-3301 sh 5 of 20
Rev. E
Modified 4−2014
9-13
No. 179-3301 sh 6 of 20
Rev. E
Modified 4−2014
9-14
No. 179-3301 sh 7 of 20
Rev. E
Modified 4−2014
9-15
No. 179-3301 sh 8 of 20
Rev. E
Modified 4−2014
9-16
No. 179-3301 sh 9 of 20
Rev. E
Modified 4−2014
9-17
No. 179-3301 sh 10 of 20
Rev. E
Modified 4−2014
9-18
No. 179-3301 sh 11 of 20
Rev. E
Modified 4−2014
9-19
No. 179-3301 sh 12 of 20
Rev. E
Modified 4−2014
9-20
No. 179-3301 sh 13 of 20
Rev. E
Modified 4−2014
9-21
No. 179-3301 sh 14 of 20
Rev. E
Modified 4−2014
9-22
No. 179-3301 sh 15 of 20
Rev. E
Modified 4−2014
9-23
No. 179-3301 sh 16 of 20
Rev. E
Modified 4−2014
9-24
No. 179-3301 sh 17 of 20
Rev. E
Modified 4−2014
COOLING SYSTEM INSTALLATION (405 C HIGH AMBIENTt)
9-25
No. 179-3301 sh 18 of 20
Rev. E
Modified 4−2014
9-26
No. 179-3301 sh 19 of 22
Rev. E
Modified 4−2014
9-27
No. 179-3301 sh 20 of 22
Rev. E
Modified 4−2014
COOLING SYSTEM INSTALLATION (405 C HiGH AMBIENT)
9-28
No. 179-3301 sh 21 of 22
Rev. E
Modified 4−2014
9-29
ITEM QTY PART NO. DESCRIPTION

1 1 0130−5997−01 RADIATOR (50C)
2 1 0130−5997−02 RADIATOR (50C)
3 1 0130−5997−03 RADIATOR (50C)
4 1 0130−5997−04 RADIATOR (50C)
5 1 0130−5997−05 RADIATOR (50C)
6 1 0319−5235−02 FRAME−CABINET
7 1 0300−5819 CONTROL ASSY (RADIATOR)
8 1 0338−4402 HARNESS−POWER
9 1 0338−4407 HARNESS−CONTROL
10 1 0501−0811 HOSE ASSY (1”BSPTX1−1/2”BSP 90DEG FM/FM/)
11 1 0505−2161−02 ADAPTER−PIPE (1” BSPTX1−1/2”NPT M/M)
12 4 0800−3017−20 SCREW−HEX HD M8 X 25 LONG
13 4 0862−0026−55 NUT−HEX (REG STL)
14 8 0526−0399−60 WASHER−FL
15 4 0850−0114−54 WASHER−LOCK SPRING M8 716370
16 0.1 0524−0826 SEALANT−THREAD
17 4 0098−8094 LABEL−WARNING (PRESS LIQUID)
18 4 0098−8095 LABEL−WARNING (HOT SURFACE)
19 2 0098−8104−01 LABEL−WARNING (VARIOUS VOLTAGES)
20 4 0098−8104−04 LABEL−WARNING (VARIOUS VOLTAGES)
21 2 0098−8104−05 LABEL−WARNING
22 2 0098−8106 LABEL−INFORMATION (TAG−WATER FILL)
23 2 0098−8130 LABEL−CAUTION (ROTATING PARTS)
24 1 0338−3832 HARNESS−LCL
No. 179-3301 sh 22 of 22
Rev. E
Modified 4−2014
COOLING SYSTEM INSTALLATION (405 C HiGH AMBIENT)
9-30
No. 179-3302 sh 1 of 19
Rev. E
Modified 1−2015
COOLING SYSTEM INSTALLATION (505 C Enhanced High Ambient)
9-31
No. 179-3302 sh 2 of 19
Rev. E
Modified 1−2015
9-32
No. 179-3302 sh 3 of 19
Rev. E
Modified 1−2015
9-33
No. 179-3302 sh 4 of 19
Rev. E
Modified 1−2015
9-34
No. 179-3302 sh 5 of 19
Rev. E
Modified 1−2015
9-35
No. 179-3302 sh 6 of 19
Rev. E
Modified 1−2015
9-36
No. 179-3302 sh 7of 19

Rev. E
Modified 1−2015
9-37
No. 179-3302 sh 8 of 19
Rev. E
Modified 1−2015
9-38
No. 179-3302 sh 9 of 19
Rev. E
Modified 1−2015
9-39
No. 179-3302 sh 10 of 19
Rev. E
Modified 1−2015
9-40
No. 179-3302 sh 11 of 19
Rev. E
Modified 1−2015
9-41
No. 179-3302 sh 12 of 20
Rev. E
Modified 1−2015
9-42
No. 179-3302 sh 13 of 20
Rev. E
Modified 1−2015
9-43
No. 179-3302 sh 14 of 19
Rev. E
Modified 1−2015
9-44
No. 179-3302 sh 15 of 19
Rev. E
Modified 1−2015
9-45
No. 179-3302 sh 16 of 19
Rev. E
Modified 1−2015
9-46
No. 179-3302 sh 17 of 19
Rev. E
Modified 1−2015
9-47
1 1
2 1 0130−5997−01 RADIATOR (50C)
3 1 0130−5997−02 RADIATOR (50C)
4 1 0130−5997−03 RADIATOR (50C)
5 1 0130−5997−04 RADIATOR (50C)
6 1 0130−5997−05 RADIATOR (50C)
7 1 0319−5235−02 FRAME−CABINET
8 1 0300−5812 CONTROL ASSY (RADIATOR)
9 1 0338−4403−01 HARNESS−POWER
10 1 0338−4403−02 HARNESS−POWER
11 1 0338−4403−03 HARNESS−POWER
12 1 0338−4403−04 HARNESS−POWER
13 1 0338−4407 HARNESS−CONTROL
14 1 0501−0811 HOSE ASSY (1” BSPX1” BSP 90DEG FM/FM)
15 4 0505−2161−02 ADAPTER−PIPE (1” BSPTX1−1/2”NPT M/M)
16 4 0800−3017−20 SCREW−HEX HD M8 X 25 LONG
17 4 0862−0026−55 NUT−HEX (REG STL)
18 4 0526−0399−60 WASHER−FL
19 0.1 0850−0114−54 WASHER−LOCK SPRING M8 716370
20 4 0524−0826 SEALANT−THREAD
21 4 0098−8094 LABEL−WARNING (PRESS LIQUID)
22 5 0098−8095 LABEL−WARNING (HOT SURFACE)
23 1 0098−8104−01 LABEL−WARNING
1 0098−8104−04 LABEL−WARNING (VARIOUS VOLTAGES)
24
25 2 0098−8104−05 LABEL−WARNING
26 1 0098−8106 LABEL−INFORMATION (TAG−WATER FILL)
0098−8130 LABEL−CAUTION (ROTATING PARTS)
No. 179-3302 sh 18 of 19
Rev. E
Modified 1−2015
9-48
27 1 0338−3832 HARNESS−LCL
No. 179-3302 sh 19 of 19
Rev. E
Modified 1−2015
9-49
THIS PAGE INTENTIONALLY LEFT BLANK
9-50
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email ask.powergen@cummins.com
www.cumminspower.com
CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
E2015 Cummins Power Generation, Inc. All rights reserved.

Installation Manual: Generator Set

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Installation Manual: Generator Set

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Installation Manual

SECTION TITLE PAGE

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

Copyright 2004 Cummins Power Generation. All rights reserved.

MODEL DQLA DQLB

INCORRECT INSTALLATION, SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE

FIGURE 3-1. BOLT DIAGRAM

FIGURE 3-2. TYPICAL INSTALLATION

FIGURE 3-3. VIBRATION ISOLATOR (SPRING TYPE)

FIGURE 3-4. VIBRATION ISOLATOR (RUBBER TYPE)

FIGURE 3-6. GENERATOR TO ENGINE ALIGNMENT

FIGURE 3-7. ALTERNATOR COMPONENTS

120 MESH FUEL

FIGURE 4-1. TYPICAL FUEL SUPPLY INSTALLATION

FIGURE 4-2. MOUNTING EXHAUST THIMBLE

IF EXHAUST LINE MUST BE

FIGURE 4-3. CONDENSATION TRAP

Generator sets create considerable heat that must

Vents and Ducts

For indoor installations, locate vents so incoming air

Size the vents and ducts so they are large enough to

Wind will restrict free airflow if it blows directly into

RADIATOR FLEXIBLE DUCT DISTANCE SHOULD NOT

FIGURE 4-5. TYPICAL RADIATOR SET INSTALLATION

WATER WARM FLEXIBLE

FIGURE 4-6. TYPICAL HEAT EXCHANGER INSTALLATION

The procedure for checking and filling the cooling

FIGURE 4-7. TYPICAL COOLANT FILTER

FIGURE 5-1. ELECTRONICS BOX

K11, K12, K13

K11, K12, K13

K11 K12 K13

FIGURE 5-2. OPTIONAL RUN RELAYS (K11, K12, K13)

FIGURE 5-3. OPTIONAL ALARM RELAY (K10)

MINIMUM RESISTANCE (MEG)

600 VAC or less 500 5.0 − 1.0 5.0 − 1.0

601 thru 5000 VAC 2500 400 − 50

1000 5.0 − 1.0

5001 thru 15000 VAC 5000 1000 − 200

1000 5.0 − 1.0

FIGURE 6-1. TYPICAL LOAD TRANSFER

The generators are available at the voltages shown Load Balancing

SERVICE ENTRANCE GENERATOR SET

SERVICE ENTRANCE GENERATOR SET

FIGURE 6-2. TYPICAL SYSTEM GROUNDING ONE-LINE DIAGRAMS

FIGURE 6-3. OPTIONAL CONTROL HEATER

FIGURE 6-4. TYPICAL COOLANT HEATER

FIGURE 6-5. TYPICAL GENERATOR HEATER INSTALLATION

FIGURE 7-1. GENSET BATTERY CONNECTIONS

FIGURE 7-2. ADJUST SUBMENU

DIESEL FUEL SYSTEM

GENERATOR SET PRESTART

CUSTOMER CONNECTIONS (PAGE 1 OF 2)

CUSTOMER CONNECTIONS (PAGE 2 OF 2)

CUSTOMER CONNECTIONS (PAGE 1 OF 2)

CUSTOMER CONNECTIONS (PAGE 2 OF 2)

CUSTOMER CONNECTIONS (PAGE 1 OF 2)

CUSTOMER CONNECTIONS (PAGE 2 OF 2)

CUSTOMER CONNECTIONS (PAGE 1 OF 2)

CUSTOMER CONNECTIONS (PAGE 2 OF 2)

COOLING SYSTEM INSTALLATION (405 C HIGH AMBIENT)

COOLING SYSTEM INSTALLATION (405 C HIGH AMBIENT)

COOLING SYSTEM INSTALLATION (405 C HIGH AMBIENT)