Operation Manual of Cummins Diesel Generators

1.Diesel generator set name plate

When user meet technical problem to require provide related service or need to buy spare parts, please provide the name plate and related information to us first. We will according to the name plate to check if the genset is manufactured by us. Usually, name plate of genset is near the controller.

Diesel generator name plate includes genset model, serial number, power capacity, voltage, frequency, speed etc.

Diesel engine name plate: engine model, serial number, power capacity, rated speed.

Alternator name plate: alternator model, serial number, voltage, frequency,speed, AVR.

2.Consumables specifications and capacity.

1)Diesel fuel specifications          

Use 0# or -10# light diesel. When the temperature is lower than 0 ℃, use -10# diesel oil. Using above 0# diesel will increase fuel consumption. The sulfur content in diesel oil shall be less than 0.5%, otherwise the engine oil shall be replaced more often. In special areas, available diesel oil provided by oil companies can be selected.

Warning: do not use gasoline or alcohol mixed with diesel fuel for the engine. This oil mixture will cause the engine to explode.         

2)Lubricating oil specification

Use high quality lubricating oil that meet requirement, and replace filter regularly to ensure diesel engine has a good lubrication performance, so that can extend diesel engine life. The lubricating oil used for the engine shall comply with API standard CD, CE, CF, CF-4 or CG-4 heavy duty diesel engine lubricating oil.

The use of lubricating oil that does not meet the requirements will cause great damage to the generator set.

Viscosity requirements:the viscosity of lubricating oil is measured by flow resistance, and the American Society of Automotive Engineers classifies lubricating oil by viscosity. The use of multi-stage lubricating oil can reduce fuel consumption. SAE15W / 40 or SAE10W / 30 is recommended.

3) Cooling coolant specifications

In addition to cooling the engine, the coolant can also prevent the freezing crack of various components of the cooling system and the corrosion of metal components.

For the cooling system, the hardness of water is very important. If there are too many water alkalis and minerals in the water, the unit will overheat, and too much chloride and salt will cause corrosion of the cooling system.

When there is a danger of icing, the antifreeze suitable for the local minimum temperature shall be replaced, which can be used all year round and replaced regularly.

When there is no danger of icing, the cooling water of the unit uses antirust additives. After filling, the heat engine circulates the coolant to give full play to the maximum protection performance of the additives.

Note: in order to ensure the anti-corrosion and anti freezing performance, it should be used according to the requirements of anti freezing liquid.

Warning: antifreeze and antirust agent are toxic and harmful to health.

Do not use different brands of antifreeze and antirust liquid mixture, otherwise the foam will seriously affect the cooling effect, resulting in high temperature alarm shutdown, affecting the life of the engine.

Check the coolant regularly. If it needs to be added, the coolant of the same brand must be added.

3.Initial use guidance

A.Diesel engine

a.Cooling coolant

Check coolant level. If need to fill, please use same brand coolant. Check if water pipe has leakages. The cooling liquid level shall be about 5cm lower than the sealing surface of the sealing cover.

Tip: fill the cooling system:

During this operation, special attention should be paid to that during the addition process, the air remaining in the system pipeline cannot be eliminated at one time, which will cause false full replenishment, so it should be added in stages. After the first addition, wait until the liquid level is seen in the water inlet pipe, and then observe for a few minutes. Run the engine for 2 to 3 minutes and stop it for 30 minutes. Then recheck the liquid level and add it if necessary.

b.Cooling system exhaust air

Open the engine water tank cover, open the exhaust bolts from the bottom to the top in turn, let the coolant flow out until there are no bubbles, and then close the exhaust bolts in turn. If there is a heater, the valve must be opened.

c.Use antifreeze

The performance of antifreeze and water preparation shall meet the local climate and environment. The freezing point of antifreeze is required to be less than 5 ℃ below the annual minimum temperature.

B.Diesel fuel

Only fill the tank with clean and filtered fuel that meets the requirements, and check the oil delivery pipe and hot spot for oil leakage. Check the delivery line for restrictions.

C.Lubricating oil

Check whether the amount of lubricating oil in the oil pan meets the requirements. If necessary, add the same standard lubricating oil.

a. Add lubricating oil from the lubricating oil filler into the oil pan, and the oil level reaches the upper limit of the dipstick.

b. When the engine is filled with water and lubricating oil and checked to be correct, start the unit and run for a few minutes.

D. Shutdown, cooling

e. Measure the lubricating oil level through the dipstick, and the oil level shall be close to the upper limit of the dipstick. Then check the filter and oil drain system, and there is no oil leakage.

E.Battery

First use:

a. Remove the seal cover.

b. Add the special stock solution for battery according to the following specific gravity requirements:

Temperate zone 1.25-1.27

Tropical 1.21-1.23

This specific gravity is applicable to the environment of 20 ℃. If the temperature is high, the specific gravity will decrease by 0.01% for every 15 ℃ increase. If the temperature is low, the specific gravity increases at the same rate.

Comparison between specific gravity of battery liquid and ambient temperature:

1.26（20℃）

1.27（5℃）

1.25（35℃）

c.After liquid filling, let the battery stand for 20 minutes to make the battery plate fully react (if the temperature is lower than 5 ℃, it needs to be placed for 1 hour), then gently shake the battery to discharge bubbles, and add electrolyte to the low liquid level scale if necessary.

d.Now can use the battery. However, in case of the following phenomena before use, the battery shall be charged before use:

After standing, if the specific gravity decreases by 0.02 or more or the temperature increases by more than 4 ℃, if the start is in cold weather below 5 ℃. Adjust the charging current according to 5% ~ 10% of the battery capacity. For example, the charging current of 40Ah battery is 2 ~ 4A. Until the charging completion flag appears (about 4-6 hours). These signs are: all compartments have electric bubbles. The specific gravity of electrolyte in each compartment shall be at least equal to that of refiling the specific gravity of electrolyte and keep it stable for 2 hours.

Reconnect the battery cable.

Note: for the self starting generator set, ensure that the start switch is in the stop position, or the function selection switch is in the stop position, or press the emergency stop button, otherwise the generator set may start suddenly.

4.Alternator and controller

Important tips: For the self starting generator set, do not connect it to the power supply before checking whether the cooling system is full. Otherwise, the coolant heating pipe may be damaged.

Check the insulation between each phase of the silent diesel generator and the ground and between phases. In this process, the regulator (AVR) must be disconnected and the megger (500V) must be used for insulation test. Under the cold state, the normal insulation value of the electrical part shall be more than 10m Ω.

Be careful:

Whether it is a new or old generator, if the stator insulation is less than 1m Ω and other windings are less than 100k Ω, it shall be tightened prohibited.

5.Installation

Ensure that the generator set base is placed on the foundation smoothly. If it is not stable, it can be leveled with a wedge and then fastened. Unstable installation will cause unexpected consequences to the unit.

Check that the exhaust pipe has been connected to the outside and ensure that the effective diameter is not less than the muffler diameter. The pipe must be hung in a suitable way. It is not allowed to be rigidly connected with the generator set (unless we allow it or the original machine does). Check whether the bellows is correctly connected with the unit and exhaust system.

Carefully check the cooling system according to the requirements of the manual and confirm that there is sufficient air inlet channel.

Carry out routine inspection before startup according to the attached data.