Operator Manual

Generator Set
with PowerCommandR 2.2 Controller

DSGAA (Spec A−F)

DSGAB (Spec A−F)
DSGAC (Spec A−F)

English − Original Instructions 8−2010 961−0125 (Issue 3)

To avoid errors or delay in filling your parts order, The following symbols are used in Onan manuals
always give the MODEL, SPEC NO. and SERIAL to alert users to the potentially dangerous condi-
NO. from the Onan nameplate. tions relating to maintenance of equipment and re-
placement of parts. Please read and observe.
For handy reference, insert your nameplate infor-
mation in the spaces below.
This symbol warns of immedi-
ate hazards which will result in
severe personal injury or death.
MODEL AND SPEC NO.
This symbol refers to a hazard
or unsafe practice which can re-
SERIAL NO. sult in severe personal injury or
death.
This symbol refers to a hazard
DIGITAL CONTROL SOFTWARE VERSION or unsafe practice which can re-
AND DATE (IF APPLICABLE) sult in severe personal injury or
product or property damage.

Service and repair of Onan equipment must be performed by trained, experienced personnel only. Im-
proper service or repair may result in property damage, severe personal injury or death. Do not use this
catalog as a guide to servicing your equipment. Read and follow the IMPORTANT SAFETY IN-
STRUCTIONS in the Service Manual appropriate for the equipment you are working on.

Contact with USED ENGINE OILS has been identified by a United States federal agency and some USA
state agencies as causing CANCER or REPRODUCTIVE TOXICITY. When checking or changing engine
oils take all necessary precautions not to ingest, breathe the fumes or contact the used oil.

Contact with ASBESTOS has been identified by a United States federal agency and some USA state
agencies as causing CANCER or REPRODUCTIVE TOXICITY. When handling engine gaskets take all
necessary precautions not to ingest, breathe or contact the dust from the gaskets! Use adequate ven-
tilation and wear protective gloves, masks and clothing!

Contact with BENZINE and LEAD, found in gasoline, fuel additives and solvents has been identified
by a United States federal agency and some USA state agencies as causing CANCER or REPRODUC-
TIVE TOXICITY. When checking, draining or adding gasoline and fuel additives or using solvents take
all necessary precautions not to ingest, breathe the fumes or contact the liquids. Use adequate ventila-
tion and wear protective gloves, masks and protective clothing!

PSP-1
Table of Contents

SECTION TITLE PAGE

I MPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3. PRESTART CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Line Circuit Breaker (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Control and Diagnostics VIA Network or PC (Laptop) . . . . . . . . . . . . . . 4-2

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.

i
SECTION TITLE PAGE

5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Generator Set Maintenance (Battery Disconnected) . . . . . . . . . . . . . . . . 5-4
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Oil and Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
6. OPERATING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Low Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
High Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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 op-
 Engine exhaust and some of its constituents are
erator, 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 per-
sonal 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-16L
iii
ELECTRICAL SHOCK CAN CAUSE  Keep multi-class ABC fire extinguishers handy.
SEVERE PERSONAL INJURY OR DEATH Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
 Remove electric power before removing protective and flammable liquid fuels and gaseous fuels; Class
shields or touching electrical equipment. Use rub- C fires, live electrical equipment. (ref. NFPA No. 10).
ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around  Make sure that rags or combustible material are not
electrical equipment. Do not wear damp clothing left on or near the generator set.
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not  Make sure generator set is mounted in a manner to
wear jewelry. Jewelry can short out electrical con- prevent combustible materials from accumulating
tacts and cause shock or burning. under or near the unit.
 Use extreme caution when working on electrical
components. High voltages can cause injury or  Remove all unnecessary grease and oil from the
death. DO NOT tamper with interlocks. unit. Accumulated grease and oil can cause over-
heating and engine damage which present a poten-
 Follow all applicable state and local electrical tial fire hazard.
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open  Keep the generator set and the surrounding area
switches to avoid accidental closure. clean and free from obstructions. Remove any de-
 DO NOT CONNECT GENERATOR SET DI- bris from the set and keep the floor clean and dry.
RECTLY TO ANY BUILDING ELECTRICAL SYS-
TEM. Hazardous voltages can flow from the gen-  Do not work on this equipment when mentally or
erator set into the utility line. This creates a potential physically fatigued, or after consuming any alcohol
for electrocution or property damage. Connect only or drug that makes the operation of equipment un-
through an approved isolation switch or an ap- safe.
proved paralleling device.
 Substances in exhaust gases have been identified
GENERAL SAFETY PRECAUTIONS by some state or federal agencies as causing can-
 Coolants under pressure have a higher boiling point cer or reproductive toxicity. Take care not to breath
than water. DO NOT open a radiator or heat ex- or ingest or come into contact with exhaust gases.
changer pressure cap while the engine is running.  Do not store any flammable liquids, such as fuel,
To prevent severe scalding, let engine cool down
cleaners, oil, etc., near the generator set. A fire or
before removing coolant pressure cap. Turn cap
explosion could result.
slowly, and do not open it fully until the pressure has
been relieved.  Wear hearing protection when near an operating
 Used engine oils have been identified by some state generator set.
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil,  To prevent serious burns, avoid contact with hot
take care not to ingest, breathe the fumes, or con- metal parts such as radiator system, turbo charger
tact used oil. system and exhaust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv
 1. Introduction

GENERAL tor (www.cumminspower.com). Factory-trained

Parts and Service representatives are ready to han-
This manual provides generator set maintenance dle all your service needs.
and operating recommendations.
To contact your local Cummins Power Generation
Operating and troubleshooting information is pro- distributor in the United States or Canada, call
vided in the appropriate control Operator Manual.
1-800-888-6626 (this automated service utilizes
touch-tone phones only). By selecting Option 1
Each operator should read this manual and the con-
(press 1), you will be automatically connected to the
trol Operator Manual before operating the genera-
distributor nearest you.
tor set (genset) for the first time. A genset must be
operated and maintained properly if you are to ex-
pect safe and reliable operation. This manual in- If you are unable to contact a distributor using the
cludes a troubleshooting guide and a maintenance automated service, consult the Yellow Pages. Typi-
schedule. cally, our distributors are listed under:

WARNING Improper operation and mainte- GENERATORS-ELECTRIC or

nance can lead to severe personal injury or loss ELECTRICAL PRODUCTS
of life and property by fire, electrocution, me-
chanical breakdown or exhaust gas asphyxi- For outside North America, call Cummins Power
ation. Read Important Safety Instructions Generation, 1-763-574-5000, 7:30 AM to 4:00 PM,
pages and carefully observe all instructions Central Standard Time, Monday through Friday. Or,
and precautions in this manual. send a fax to Cummins Power Generation using the
fax number 1-763-528-7229.
HOW TO OBTAIN SERVICE
When contacting your distributor, always supply the
When the generator set requires servicing, contact complete Model, Specification, and Serial Number
your nearest Cummins Power Generation distribu- as shown on the generator set nameplate.

WARNING

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN-

JURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED
AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

1-1
THIS PAGE LEFT INTENTIONALLY BLANK

1-2
2. Specifications

MODEL DSGAA, DSGAB, DSGAC

Engine
Cummins Diesel Series QSB7−G3
Generator Set Control PowerCommand 2.X
Generator kW Rating See Genset Nameplate for rating information.
Engine Fuel Connection
Inlet/Outlet Thread Size Refer to Generator Outline Drawing
Fuel Flow
Max. Fuel Inlet Restriction 5 in. Hg. (127 mmHg)
Max. Fuel Return Restriction 6 in. Hg. (152 mmHg)
Exhaust
Outlet Size 3 in. NPD 3 in. NPD 3 in. NPD
Max. Allowable Back Pressure 40 in. H2O (10 kPa) 40 in. H2O (10 kPa) 40 in. H2O (10 kPa)
Exhaust Flow at Rated Load 996 cfm (28.2 m3/min) 1129 cfm (32 m3/min) 1256 cfm (35.6 m3/min)
Exhaust Temperature 832 F (444 C) 871 F (466 C) 924 F (496 C)
Electrical System
Starting Voltage 12 Volts DC
Battery One, 12 Volt
Group Number 4D
CCA (minimum)
Cold Soak @ 0 F (-18 C) 1080
Cooling System
Capacity with Standard Radiator 6.1 Gal (23.1 L)
Lubricating System
Oil Capacity with Filters 18.5 Qts (17.5 L)
Oil Type*
* Refer to Cummins engine Owners Manual for lubricating oil recommendations/specifications.

FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)

MODEL DSGAA DSGAB DSGAC
US gph (L/hr) 8.45 (32.0) 10.0 (37.9) 12.25 (46.4)

OIL PRESSURE/COOLANT TEMPERATURE

WARNING AND SHUTDOWN LIMITS
Normal Oil Pressure 40-60 psi (276-414 kPa)
Warning Limit 34 psi (236 kPa)
Shutdown Limit 30 psi (207 kPa)
Coolant Temperature Normal
Warning Limit 220 F (104 C)
Shutdown Limit 230 F (110 C)

2-1
THIS PAGE LEFT INTENTIONALLY BLANK

2-2
 3. Prestart Checks
GENERAL Fuel
This section covers prestart checks. Before start- Make sure the fuel tanks have sufficient fuel and
ing, be sure the following checks have been made that fuel system is primed. Check to make sure
and the unit is ready for operation. there are no leaks and that all fittings are tight.

Ventilation

PRESTART CHECKS Make sure the generator set cooling inlet/outlet and
exhaust ventilation openings are clear (not blocked)
Lubrication and operational.
Remove all loose debris from surrounding area of
Check the engine oil level. Keep the oil level as near generator set. Air flow from the radiator fan can
as possible to the dipstick high mark without overfil- blow loose items around and into ventilation open-
ling. ings.
Coolant Exhaust
Check the engine coolant level. Refer to “Cooling Check to make sure entire exhaust system is tight,
Systems” in the Maintenance section of this manu- that no combustible materials are near system, and
als for proper procedure. gases are discharged away from building openings.

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon
monoxide is poisonous and can cause unconsciousness and death. Symptoms of
carbon monoxide poisoning can include:
w Dizziness w Throbbing in Temples
w Nausea w Muscular Twitching
w Headache w Vomiting
w Weakness and Sleepiness w Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT
INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention.
Shut down the unit and do not operate it until it has been inspected and repaired.
Protection against carbon monoxide inhalation includes proper installation and
regular, frequent visual and audible inspections of the complete exhaust system.

3-1
THIS PAGE LEFT INTENTIONALLY BLANK

3-2
4. Troubleshooting
GENERAL WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
The generator set control continuously monitors the equipment, flame, pilot lights and sparks can ig-
engine for abnormal conditions when genset is op- nite battery gas. Do not smoke, or switch
erating, such as low oil pressure and high coolant trouble light ON or OFF near battery. Discharge
temperature. If any of these conditions occur, the static electricity from body before touching bat-
control will display a message on the graphical dis- teries by first touching a grounded metal sur-
play. face.
Ventilate battery area before working on or near
Refer to the appropriate control Operator Manual battery—Wear goggles—Stop generator set
and disconnect charger before disconnecting
which lists the warning and shutdown codes/mes-
battery cables—Disconnect negative (−) cable
sages, and suggests troubleshooting procedures. first and reconnect last.
CAUTION Disconnect battery charger from AC
SAFETY CONSIDERATIONS source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits
WARNING Contacting high voltage compo- of the generator set.
nents can result in severe personal injury or
WARNING Accidental starting of the generator
death. Keep the control box and circuit breaker set can cause severe personal injury or death.
box covers in place during troubleshooting. Prevent accidental starting by disconnecting
the negative (−) cable from the battery terminal.
High voltages are present when the generator set is When troubleshooting a generator set that is shut
running. Do not open the generator control box or down, make certain the generator set cannot be ac-
the circuit breaker box while the generator set is cidentally restarted as follows:
running.
1. Press the button to switch to the Off mode.

CAUTION Before disconnecting battery 2. Turn off or remove AC power from the battery
cable(s), press the Emergency Stop button and charger.
wait at least 30 seconds. Engine performance
3. Press the emergency stop button and wait at
may be affected (i.e., engine dying or hard start-
least 30 seconds before completing Step 4.
ing) if battery cable(s) is removed during the 30
second waiting period. Service personnel may 4. Remove the negative (−) battery cable from the
be required to correct fault. generator set starting battery.

4-1
 READING FAULT CODES the overload and correct as necessary. Manually re-
set the breaker to reconnect the load to the genera-
Refer to appropriate control Operator Manual, tor.
which describes how to view fault codes using the
graphical display.
CONTROL AND DIAGNOSTICS VIA
LINE CIRCUIT BREAKER (OPTIONAL) NETWORK OR PC (LAPTOP)
The optional line circuit breaker is mounted on the See your authorized Cummins Power Generation
power output box. If the load exceeds the circuit dealer regarding software, hardware and network
breaker current rating, the line circuit breaker will requirements for control and diagnostics via net-
open. If the circuit breaker trips, locate the source of work or personal computer.

4-2
 5. Maintenance
GENERAL  Exposure to salt water
 Exposure to dust, sand or other airborne con-
Establish and adhere to a definite schedule for
taminates
maintenance and service based on the application
and severity of the environment. Table 5-1 covers Consult with your local Cummins Power Generation
the recommended service intervals for a generator distributor if the generator set will be subjected to
set on STANDBY service. If the generator set will be any extreme operating conditions and determine a
subjected to extreme operating conditions, the time suitable schedule of maintenance. Use the Engine
between service intervals should be reduced ac- and Control Hours display to keep an accurate log
cordingly. Some of the factors that can affect the of all service performed for warranty support. Per-
maintenance schedule are the following: form all service at the time period indicated or after
the number of operating hours indicated, whichever
 Use for continuous duty (prime power)
comes first. Use Table 5-1 to determine the mainte-
 Extremes in ambient temperature nance required and then refer to the sections that
 Exposure to weather follow for the correct service procedures.

5-1
 TABLE 5-1. MAINTENANCE SCHEDULE

SERVICE TIME

MAINTENANCE ITEMS Daily Weekly Monthly Yearly Yearly

or after or after or after 100 or after 250 or after 500
8 Hours 50 Hours Hours Hours Hours
General Genset Inspection X1, 2
Check Coolant Heater X
Check Oil Level X
Check Coolant Level X
Check Fuel Level X
Check Charge Air Piping X1
Check Air Cleaner X3
Check Battery Charging System X
Drain Fuel Filter(s) X1, 5
Drain Water and Sediment from Fuel Tank X5
Drain Exhaust Condensate Trap X
Check Starting Batteries X
Check Drive Belt X4
Check Anti-freeze and DCA Concentration X1
Check Radiator Hoses for Wear & Cracks X
Change Air Cleaner Element X3
Change Crankcase Oil and Filter X6
Change Fuel Filters X1
Clean Cooling System X1, 3
Test Rupture Basin Leak Detect Switch X8
Check Valve Lash After 5000 hours1, 7
X1 Refer to Cummins Engine Owners Manual for maintenance information.
X2 Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any
leaks immediately.
3
X Perform more often in dusty conditions.
X4 Visually check belt for evidence of wear or slippage. Replace if hard or brittle.
X5 Drain 1 cup or more of fuel to remove water and sediment.
X6 If used for prime power application, refer to Cummins Engine Owners Manual for maintenance interval.
X7 Contact an authorized service center for service.
X8 Check leak detect switch in sub-base fuel tank, once a year or as required by safety code. Contact your authorized service center.

5-2
 GENERATOR SET INSPECTION Frequency/RPM (Alternator/Engine Menu): The
generator frequency should be stable and the read-
During operation, be alert for mechanical problems
ing should be the same as the genset nameplate
that could create unsafe or hazardous conditions.
rating (50 or 60 Hz/1500 or 1800 RPM).
The following sections cover several areas that
should be frequently inspected for continued safe
operation. AC Voltmeter (Alternator Menu): At no load, the
line-to-line or line-to-neutral voltage(s) should be
Exhaust System the same as the genset nameplate rating.
With the generator set operating, inspect the entire
exhaust system visually and audibly including the AC Ammeter (Alternator Menu): At no load the
exhaust manifold, muffler and exhaust pipe. Check current ratings should be zero. With a load applied,
for leaks at all connections, welds, gaskets and each line current should be about the same.
joints and also make sure that exhaust pipes are not
heating surrounding areas excessively. If any leaks DC Electrical System
are detected, shut down the generator set and have
leaks corrected immediately. Check the terminals on the batteries for clean and
tight connections. Loose or corroded connections
WARNING Inhalation of exhaust gases can re- create resistance which can hinder starting. Refer
sult in severe personal injury or death. Be sure to BATTERIES later in this section for cleaning and
deadly exhaust gas is piped outside and away safety precautions.
from any windows, doors, vents or other inlets
to building and not allowed to accumulate in in-
habitable areas.
Engine

Fuel System Monitor fluid levels and oil pressure and coolant
Inspect the fuel supply lines, return lines, filters and temperatures frequently. Most engine problems
fittings for cracks and abrasions and make sure give an early warning. Look and listen for changes
they are not rubbing against anything that could in engine performance, sound, or appearance that
cause breakage. With the generator set operating, can indicate service or repair is needed. Some en-
check the fuel system for leaks. If any leaks are de- gine changes to look for are as follows:
tected, have them corrected immediately.  Misfire
WARNING Ignition of fuel can cause severe  Vibration
personal injury or death by fire or explosion. Do  Unusual noises
not permit any flame, cigarette, arcing switch or  Sudden changes in engine operating tempera-
equipment, pilot light, or other igniter near the tures or pressures
fuel system or in areas sharing ventilation.  Excessive exhaust smoke
 Loss of power
AC Electric System  An increase in oil consumption
Check the following while the generator set is oper-  An increase in fuel consumption
ating.  Fuel, oil, or coolant leaks.

5-3
 GENERATOR SET MAINTENANCE WARNING Accidental starting of the generator
(BATTERY DISCONNECTED) set can cause severe personal injury or death.
Prevent accidental starting by disconnecting
CAUTION Before disconnecting battery the negative (−) cable from the battery terminal
cable(s), press the Emergency Stop button and before beginning maintenance procedures.
wait at least 30 seconds. Engine performance
may be affected (i.e., engine dying or hard start-
ing) if battery cable(s) is removed during the 30 When performing the following maintenance proce-
second waiting period. Service personnel may dures, make certain the generator set cannot be ac-
be required to correct fault. cidentally restarted as follows:

WARNING Ignition of explosive battery gases

can cause severe personal injury or death. Arc- 1. Press the button to switch to the Off mode.
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- 2. Turn off or remove AC power from the battery
nite battery gas. Do not smoke, or switch charger.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat-
teries by first touching a grounded metal sur- 3. Press the emergency Stop button and wait at
face. least 30 seconds before completing Step 4.
Ventilate battery area before working on or near
battery—Wear goggles—Stop generator set 4. Remove the negative (−) battery cable from the
and disconnect charger before disconnecting generator set starting battery.
battery cables—Disconnect negative (−) cable
first and reconnect last.
Mechanical Inspection
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables. With the generator set stopped, check for loose
Otherwise, disconnecting cables can result in belts and fittings, leaking gaskets and hoses, or any
voltage spikes damaging to DC control circuits signs of mechanical damage. If any problems are
of the set. found, have them corrected immediately.

5-4
 LUBRICATION SYSTEM oil of the same quality and brand when necessary.
Install the oil fill cap after adding oil.
Gensets are shipped with oil added. Be sure to check
oil level before initial start. CAUTION Do not operate the engine with the
oil level below the low mark or above the high
Oil API Classification mark. Overfilling can cause foaming or aeration
of the oil while operation below the low mark
Refer to the Cummins engine Owners Manual for may cause loss of oil pressure.
lubricating oil classification.
OIL AND FILTER CHANGE
Oil Viscosity
Change the oil and filter at the intervals recom-
Refer to the Cummins engine Owners Manual for mended in the maintenance table. Use oil that
lubricating oil recommendations/specifications. meets Cummins recommendations/specifications.

Engine Oil Change

Engine Oil Level
Refer to the Cummins engine Owners Manual for
Check the engine oil level during engine shutdown lubricating oil and filter changing procedure. Refer
periods at the intervals specified in the Mainte- to Specifications in Section 2 of this manual for oil
nance Table. The dipstick is stamped with high and capacity. Use oil that meets Cummins recommen-
low marks to indicate the level of oil in the crank- dations/specifications.
case. For accurate readings, shut off the engine
and wait approximately 15 minutes before checking WARNING State or federal agencies have de-
the oil level. This allows oil in the upper portion of the termined that contact with used engine oil can
engine to drain back into the crankcase. cause cancer or reproductive toxicity. Do not
contact oil or breath vapors. Use rubber gloves
WARNING Crankcase pressure can blow out and wash exposed skin.
hot oil and cause severe burns. Do NOT check
oil while the generator set is operating. Used oil and filters must be disposed of proper-
ly to avoid environmental damage and clean-up
Keep the oil level as near as possible to the high liability. Check all federal, state and local regu-
mark on the dipstick. Remove the oil fill cap and add lations for disposal requirements.

FUEL FILTER
(SECONDARY)

OIL FILTER
(FAR SIDE)
OIL LEVEL
DIPSTICK

FUEL
FILTER
(PRIMARY)

OIL FILL

OIL DRAIN
VALVE

FIGURE 5-1. LOCATION OF OIL/FUEL SYSTEM COMPONENTS

5-5
 COOLING SYSTEM or cloth. Use care to avoid damaging the fins. If
available, use low pressure compressed air or
Gensets are shipped with coolant added. Be sure to stream of water (maximum of 35 psi/242 kPa), in
check coolant level before initial start. opposite direction of normal air flow to clean radia-
CAUTION The coolant heater must not be op- tor. If using water, protect the engine and the gener-
erated while the cooling system is empty or ator from over spray.
when the engine is running or damage to the
Coolant Heater
heater will occur.
Check the operation of the coolant heater by verify-
CAUTION Do not add cold coolant to a hot en- ing that hot coolant is being discharged from the
gine. Engine castings can be damaged. Allow outlet hose. Do not touch outlet hose − if heater is
the engine to cool to below 1205 F (505 C) before operational, radiant heat should be felt with hand
adding coolant. held close to outlet hose.
Coolant Level WARNING Contact with cooling system or en-

Check the coolant recovery tank level. Note the nor- gine can result in serious burns. Do not touch
mal level when the engine is cool. Add coolant to the cooling system or engine during genset mainte-
recovery tank to replace the normal loss of coolant. nance until they are cool.

Refer to the Cummins engine Owners Manual for FUEL SYSTEM

coolant recommendations/specifications.
Refer to the Cummins engine Owners Manual for
WARNING To prevent severe scalding, let en- fuel system maintenance.
gine cool down before removing coolant pres-
sure cap. Turn cap slowly, and do not open it ful- Fuel Handling Precautions
ly until the pressure has been relieved. WARNING Ignition of fuel can cause serious
CAUTION Loss of coolant can allow engine to personal injury or death by fire or explosion. Do
overheat without protection of shutdown de- not permit any flame, cigarette, arc, spark, pilot
vice and cause severe damage to the engine. light, or other igniter near the fuel system.
Maintain coolant level for proper operation of To avoid condensation problems, keep fuel supply
the high engine temperature shutdown system. tanks as full as possible by filling up each time the
Coolant Requirements engine is used. In cold weather, warm fuel returning
from the injectors heats the fuel in the supply tank. If
Heavy duty diesel engines require a balanced cool- the fuel level is low, the upper portion of the tank
ant mixture of water, antifreeze and coolant addi- tends to form condensation. In warm weather, both
tives. the fuel and the tank will be warm during the day-
time. At night, cool air tends to lower the tempera-
Refer to the Cummins engine Owners Manual for all
ture of the tank more rapidly than the temperature of
cooling system maintenance, such as, coolant re-
the fuel. If the fuel level is low, the upper portion of
quirements, filling of cooling system, coolant filter
the tank will cool more rapidly and tend to form con-
replacement and flushing and cleaning.
densation.
Radiator Condensation (water) can cause clogging of fuel fil-
Inspect the exterior of the radiator for obstructions. ters with the sulphur in the fuel forms acid which can
Remove all dirt or foreign material with a soft brush corrode and damage engine parts.

5-6
 AIR CLEANER 1. Release the cover clip and turn the air cleaner
cover counterclockwise to remove.
The filter element should be replaced yearly or
2. Slowly remove the air filter to reduce the
sooner if the service indicator indicates excessive
amount of dust dislodged. There may be some
air restriction.
initial resistance when removing the filter.
The vacuator valve dumps collected dust automati- Gently move the end of the filter up and down
cally. and side to side or twist to break the seal.
3. Wipe out the interior of the air cleaner housing
CAUTION Holes, loose end seals, dented seal-
and cover with a clean, damp cloth. Make sure
ing surfaces and other forms of damage render that ALL dust is removed from ALL interior sur-
the cleaner inoperative and requires immediate faces of the air cleaner housing. Be careful not
element replacement. to damage the sealing area on the outlet tube.
Inspect all components of the air filtering system in- 4. Inspect new air filter for shipping damage. Pay
cluding all ducts and hoses. Verify that all connec- attention to the inside of the open end (sealing
tions and clamps are tight and inspect each compo- area). Do not install a damaged filter.
nent for cracks, dents, or other damage. Repair or 5. Install new air filter. The seal area is on the in-
service as required. side of the open end of the filter. The sealing
area will stretch slightly and adjust itself over
CAUTION Filters should be handled with care the outlet tube. To complete the seal, apply
to prevent damage. If the filter does become pressure at the outer rim of the filter, not the
damaged, install recommended replacement flexible center. No cover pressure is required to
part. hold the seal.
The following procedure should be followed when 5. Put on the air cleaner cover and rotate clock-
replacing the element. wise until cover clip engages.

COVER
SERVICE
CLIP
INDICATOR
AIR
CLEANER
COVER

AIR
OUTLET

VACUATOR
VALVE

FIGURE 5-2. AIR CLEANER

5-7
 BATTERIES In case of contact, immediately wash skin with
soap and water. In case of contact, immediately
CAUTION Before disconnecting battery flood eyes with large amounts of water for a
cable(s), press the Emergency Stop button and minimum of 15 minutes. IMMEDIATELY CALL A
wait at least 30 seconds. Engine performance PHYSICIAN.
may be affected (i.e., engine dying or hard start- Keep the batteries clean by wiping them with a
ing) if battery cable(s) is removed during the 30 damp cloth whenever dirt appears excessive.
second waiting period. Service personnel may
be required to correct fault. If corrosion is present around the terminal connec-
tions, remove battery cables and wash the termi-
nals with a solution consisting of 1/4 pound of bak-
WARNING Ignition of explosive battery gases
ing soda added to 1 quart of water. (This solution is
can cause severe personal injury or death. Arc- also used for washing down spilled electrolyte.)
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig- Be sure the vent plugs are tight to prevent cleaning
nite battery gas. Do not smoke, or switch solution from entering the cells.
trouble light ON or OFF near battery. Discharge
static electricity from body before touching bat- After cleaning, flush the outside of the battery and
teries by first touching a grounded metal sur- surrounding areas with clean water.
face. Keep the battery terminals clean and tight. After
making connections, coat the terminals with a light
Ventilate battery area before working on or near application of petroleum jelly or non-conductive
battery—Wear goggles—Stop genset and dis- grease to retard corrosion.
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and Checking Specific Gravity
reconnect last. Use a battery hydrometer to check the specific
gravity of the electrolyte in each battery cell.
CAUTION Disconnect battery charger from AC
Hold the hydrometer vertical and take the reading.
source before disconnecting battery cables.
Correct the reading by adding four gravity points
Otherwise, disconnecting cables can result in
(0.004) for every ten degrees the electrolyte tem-
voltage spikes damaging to DC control circuits
perature is above 80 F (27 C). A fully charged bat-
of the set.
tery will have a corrected specific gravity of 1.260.
Charge the battery if the reading is below 1.215.
Check the condition of the starting batteries at the
interval specified in the Maintenance Table. To pre- Checking Electrolyte Level
vent dangerous arcing, always disconnect the neg-
ative ground cable from the battery before working CAUTION Do not add water in freezing weather
on any part of the electrical system or the engine. unless the engine will run long enough (two to
Disregard the sections On Checking Specific Gravi- three hours) to assure a thorough mixing of wa-
ty and Checking Electrolyte Level if using a “mainte- ter and electrolyte.
nance-free” battery. Check the level of the electrolyte (acid and water
solution) in the batteries at least every 200 hours of
Cleaning Batteries operation.
Fill the battery cells to the bottom of the filler neck. If
WARNING Electrolyte is a dilute sulfuric acid cells are low on water, add distilled water and re-
that is harmful to the skin and eyes. Do not get charge. If one cell is low, check case for leaks. Keep
the substance in your eyes or contact with skin. the battery case clean and dry. An accumulation of
Wear goggles and protective, rubber gloves moisture will lead to a more rapid discharge and
and apron when servicing batteries. battery failure.

5-8
Battery Replacement NiCad Batteries
Always replace the starting battery with the same
number and type (vented, lead acid). Properly dis- NiCad (nickel-cadmium) battery systems are often
pose of battery in accordance with local environ- specified where extreme high or low ambient tem-
mental agency requirements. perature is expected because their performance is
less affected by temperature extremes than that of
WARNING Electrolyte or explosion of battery lead-acid batteries.
can cause severe personal injury or death. Do
not mutilate or burn the battery in a fire for dis-
posal. NiCad batteries require special battery chargers in
order to bring them to the full-charge level. These
Damage to case will release electrolyte which is chargers must be provided with filter to reduce
harmful to the skin and eyes and is also toxic. “charge ripple” which can disrupt engine and gener-
Burning of battery may cause an explosion. ator control systems.

5-9
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5-10
 6. Operating Recommendations
NO-LOAD OPERATION Exercise the generator set at least once a month for
a minimum of 30 minutes, under not less than 30
Periods of no load operation should be held to a percent of the nameplate rating.
minimum. If it is necessary to keep the engine run-
ning for long periods of time when no electric output
is required, best engine performance will be ob- LOW OPERATING TEMPERATURE
tained by connecting a load bank of at least 30 per-
cent of nameplate rating. Use a coolant heater if a separate source of power
is available. The optional heater will help provide re-
EXERCISE PERIOD liable starting under adverse weather conditions.
Be sure the voltage of the separate power source is
Generator sets on standby duty must be able to go correct for the heater element rating.
from a cold start to being fully operational in a matter
of seconds. This can impose a severe burden on
engine parts. HIGH OPERATING TEMPERATURE

Regular exercising keeps engine parts lubricated, Refer to the genset Specification/Data Sheet for the
prevents oxidation of electrical contacts and in gen- maximum ambient operating temperature, if appli-
eral helps provide reliable engine starting. cable.

6-1
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6-2
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 [email protected]
www.cumminspower.com
CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
E2010 Cummins Power Generation, Inc. All rights reserved.