Diesel Generator Sets

Training Materials

Cummins Power (China) Co., Ltd.

Cummins Confidential

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Generator electrical schematic diagram

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For operation team ， there are total of 4 Cummins diesel generator sets of model C1400D5, of
which 2 are container-type in the terminal building, and 2 are open-type in the central
substation. The maximum power of the four units is 1120KW for one hour, and the normal
power is 1000KW. All of them have the function of self-starting ， they will provide good power
supply services

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The engine model is KTA50-G3, which is a V-series, water-cooled engine.
The engine is mainly composed of five systems:
1: Intake system (air filter, turbocharger, intake manifold)
2: Exhaust system (exhaust manifold, turbocharger, muffler)
3: Fuel system (fuel line, fuel filter, fuel pump)
4: Lubrication system (oil pump, oil filter, oil passage, oil pan)
5: Cooling system (radiator, fan, water pump, thermostat ,water jacket)

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  The generator is mainly composed of stator, rotor, excitation coil,
AVR electronic governor, bearing ,casing, etc. This is a 4-pole
brushless rotating field alternator with class H insulation.

Cummins Confidential

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Main functions of the controller

 Start-stop engine
 Keep the alternator output voltage constant
(400V)
 To protect the generator set, when the water
temperature is high (>97°C), the oil pressure is
low (310kPa), and the speed is low (<1350rpm),
it will automatically stop.
 Keep the engine speed constant at 1500±5rpm

Cummins Confidential

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Control Panel and Display
Sealed film panel
-
graphic display LED status indicator

Backlight switch
Line 2
Line 1 Failure data
Alarm
Controller
status/reset
Working status
Page
Manual operation, start and Line 3
stop X/Page Y
Switch and status indicator in total
Screen
Name Data and status
screen
Buttons
Browse buttons

Button options

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 Operation Instructions for Diesel
Generator Set Control

PC3.3 Controller Panel

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Display Operation Panel
Genset operation-LED
Remote start-LED
Not in automatic mode-
LED
Off-LED
Graphic display Warning-LED

Selection buttons
(four)
"Lamp Test"
button
"Home" button
"Reset"
button
"Stop" button
"Auto" button
Four switches "Start"
Select button button

CB close
"ltem Select"
button CB open
"Manual Run" button
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"Previous Screen" button
Buttons

"MANUAL RUN": Supply

power to the equipment, and
if the "Start" button is
pressed within ten seconds,
the generator set will be
started.
"START" must be pressed
within ten seconds after
pressing the "Manual"
button to start the generator
set.

"AUTO": The generator set

is automatically started by
the remote start signal.

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Automatic Running

 In the automatic position, if the controller receives the remote start signal (the Remote
start indicator light on the panel is on), the unit will enter the startup program to start
operation.
 Remote signal “stop” (the Remote start indicator light on the panel is off), the unit
shuts down after the finish shutdown procedure, and the engine operation indicator
Gesnet Running light is off.

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Emergency Stop Switch
 The emergency shutdown mode is allowed only in case of emergency.
 Once the "emergency stop" button is pressed (mushroom head), the LCD will have a
fault code (1433 local emergency stop), and the "stop" light will be lit, at this time,
the running machine group will stop directly without the cooling process.
 After pressing, the switch needs to return to original position, and then press the
reset key to reset the system.

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Genset Data Query-Genset Data

Press the Home button to return to the main menu at any time.
Press the C button to return to the previous menu. Press this button, the
settings will not be saved. 1
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Alternator Data Query—Alternator Data

Press the Home button to return to the main menu at any time
Press the C button to return to the previous menu. Press this button, the settings
will not be saved
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Mainly include generator voltage, current, frequency, power factor, load, etc. 4
Engine Data Query-Engine Data

Press the Home button to return to the main menu at any time.
Press the C button to return to the previous menu. Press this button, the
settings will not be saved.

Mainly include the engine speed (1500±5rpm), water temperature (<97℃), oil pressure
(310~600KPa), battery voltage (24V~28V), etc. 1
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Warning fault information query—Faults—Active -Warning

Press the Home button to return to the main menu at any time.
Press the C button to return to the previous menu. Press this button, the settings
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will not be saved.

Such as emergency stop, low battery voltage, high or low output voltage and so on.
Fault Reset
If the fault is an alarm fault (Warning yellow indicator light is on), the unit can continue to
start. When the fault is eliminated, press the "Reset" button, the indicator light will go out.

If it is a shutdown fault (the Shutdown red indicator light is on), the unit is shut down and
cannot be started. When the fault shutdown condition is eliminated, press the "Stop"
button, and then press the reset button (Reset), the indicator light goes out. can be started
again. Similar faults such as antifreeze temperature>103℃, low liquid level alarm, high
speed>1650rpm lower than 1350rpm

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Introduction to Diesel Generator Set
Operation and Maintenance

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Check before starting
 Check the engine oil level: verify whether the engine oil level meets the requirements;
 Check the cooling liquid level of the radiating water tank:
 ensure that the ventilation is unobstructed;
 Exhaust channel inspection: ensure that the exhaust is unblocked/no leakage/no bend/no
looseness; no flammable products nearby
 Fuel pipeline inspection: the fuel level in the fuel tank is appropriate, the fuel valve is
opened, the pipeline and valve has no leakage;
 check the battery terminal is in good contact, there is no impurities on the surface, the
control panel shows that the voltage > 24V ; the positive and negative cable connections are
correct

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Starting and Running
 If you want to start in auto model,
Press “AUTO” button, confirm the it’s light is on. when utility
power is off, the generator will automatic start.

 If you want to start in manual model,

Press the “STOP” button ,confirm the “AUTO” light is off. Press
“MANUAL RUN” button, confirm the it’s light is on. Then press
“START” button in 10 second, the generator will start.

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Starting and Running
 If generator does not start after pressing the start button for 30 seconds, press the
stop button, wait for 2 minutes, and then restart. If it fails to start three times, the
unit will give alarm.
 Sufficient oil pressure must be reached within 15 seconds after the unit is started. If
the panel displays an abnormal oil pressure alarm, shut down the unit immediately
to avoid damage to the engine
 The no-load running time of the unit shall not exceed 15 minutes. Long-term idle
speed will cause carbon deposits to form on the injector nozzles and piston rings,
and may also lead to poor lubrication
 engine coolant temperature should between 74~91°C. Coolant temperature below
60°C or above 100°C for long time running can damage the engine;
 Before shutting down the unit after running with load, the controller will control the
engine to idle or run at no-load for 3 to 5 minutes before shutting down, and try to
avoid emergency shutdown (the panel displays fault code 611)
 The frequency of the generator set should be 50Hz/1500RPM: The no-load line
voltage should be 400±1%V, The no-load current reading should be zero, and the
current of each phase should be roughly the same when loaded.
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 Check list for every 3 months
Static check
1. Check if the oil level is normal
2. Check the air filter intake resistance indicator, if it is red, it needs to be replaced.
3. Check the intake line for looseness and cracks.
4. Drain water and sediment from the diesel filter.
5. Check the ground or pipes for signs of engine oil leakage.
6. fuel tank level check
7. Fuel system leak check.
8. Check whether the connection cable of the battery terminal is tightened,
whether it is firm, and the voltage is about 27V.
9. Check whether the automatic charger has an alarm.
10.Check coolant level
11.Visually inspect the belt and pulley for deviation and cracks.
12.Check coolant hoses and joints for leaks.
13.Cooling system leak check.
14.Check if there any cracks in the exhaust line
15.Exhaust pipe bolts check for firmness
16.Check that the air filter, piping and joints are securely connected.
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Check list for every 3 months
Running check

1. Check if the manual start/stop function normal

2. Whether there is abnormal sound and abnormal vibration
in the operation of the unit
3. .Leak inspection of each system.
4. Smoke status and leak inspection, no black smoke, blue
smoke, white smoke
5. Check the operation of the water pump and cooling fan
for vibrations. Check if there is a sharp rise in coolant
temperature
6. Check the three-phase voltage deviation ≯ 1%.

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Check list for every 12 months
Static maintenance
1. Change the engine oil.
2. Change the engine oil filter.
3. Replace fuel filter.
4. Replace the oil-water separator
5. Replace the cooling water filter.
6. Check the air intake line for looseness and cracks.
7. Check coolant level
8. Engine oil leak check.
9. Fuel tank level check and water drain.
10. Fuel system leak check.
11. Battery terminal tightness inspection.
12. Automatic charger function check.
13. Belt and pulley inspection.
14. Check cooling water hoses and joints. 2
15. Cooling system leak check. 4
Check list for every 12 months

16. Cooling Tank Fan Check

17. Air filter, piping and joint inspection.
18. Whether the exhaust pipe is leaking and fixed firmly.
19. Exhaust line screw inspection.
20. Check and clean the generator air inlet and outlet.
21. Whether the connection of the output cable is firm.
22. Generator room cleaning and inspection.
23. External cleaning and inspection of generator.

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Check list for every 12 months

running check
1. Check if the manual start/stop function normal
2. Whether there is abnormal sound and abnormal vibration
in the operation of the unit
3. .Leak inspection of each system.
4. Smoke status and leak inspection, no black smoke, blue
smoke, white smoke
5. Check the operation of the water pump and cooling fan
for vibrations. Check if there is a sharp rise in coolant
temperature
6. Check the three-phase voltage deviation ≯ 1%.

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Engine appearance/sound inspection

 Check after each startup;

 Run the engine for 8 to 10 minutes to check for abnormal noise.
 Check the engine for leakage of organic oil, coolant, fuel, intake and
exhaust pipe.

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Check the oil level

 Wait at least 5 minutes after shutdown to check the oil level.

 After changing the oil or filter, wait for 15 minutes after the engine stop when the
engine oil flows back to the oil pan ,and then check the engine oil level.
 When the oil level is below L or above H of the dipstick, it is not allowed to
start the engine.
 Too high oil level will also cause engine overheating, high pressure / insufficient
power, etc.
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Check the coolant level
Cylinder liner cooling system filling hole cap

LTA cooling system filling hole

cap

 The coolant level must be checked before every start up;

 When the engine temperature is below 50℃, slowly remove the radiator filler cap to release
the system pressure
 Add coolant to the cooling system only needs to be added to the lower part of the filling
neck of the radiator or expansion tank.
 The coolant can only be filled when the engine temperature is lower than 50°C; adding
cold coolant to a hot engine will damage the engine castings;

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Engine Oil Discharge before Replacement
 Note: The oil must be drained when the oil is still hot, because dirt is suspended in the oil
at this time.
 Run the engine until the water temperature reaches 60°C. Stop the engine and drain the
oil.

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Oil Filter Replacement
 Clean around the oil filter seat and remove the filter.
 The O-ring may adhere to the filter seat and be sure to remove the O-ring.
 Add clean engine oil to the filter before installing the new filter. Apply a thin layer of oil to the
surface of the gasket.
 Install the filter and after the gasket touches the surface of the filter head, tighten 1 / 2 to 3 /4 turns.
Note that excessive tightening may deform the thread or damage the seal of the oil filter element.

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External drive inspection
Check the belt are aligned without deviation and no abnormal noise, also no crack on it.

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Check intake resistance (vacuum) / indicator (if matching)

 The more dust in the filter element of the air filter, the higher the red sign in the
indicator window.
 After replacing or clean the filter, press the reset button to reset the indicator.

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Check Exhaust System Leakage, Turbocharger

 Check leakage of installation gasket from turbocharger to exhaust

manifold and replace the gasket if there is any.
 Check whether there is air leakage on the sealing surface of the turbine
shell.
 Check the exhaust pipe bolts.
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Check the fuel line and joint seal
drain water and dust from the main fuel tank and fuel filter every three
months
Check the sealing of pipelines, filter interfaces and joints for leakage.

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 Fuel Filter Replacement
 Remove the threaded joint sealing ring and wipe the joint surface with a clean lint-free
cloth to remove dirt.
 Lubricate the O-ring seal with clean engine oil, and tighten the fuel filter

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Check the Cooling System
Observe whether there is any leakage through the pump leakage observation hole.

Check the hose joints and hoses for leakage.

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battery and cable terminal maintenance
Check whether the battery charger can charge battery normally every week;
Clean and fasten the battery terminal head.
Start the generator to check the battery status

 Check whether the terminals of the cable and the main junction box are corroded and
firm
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ALTERNATOR VENTILATION
 Clean the surface of the machine regularly to prevent dust and dirt from
accumulating and adversely affecting heat dissipation.
 Ensure that the air inlet and outlet are not blocked during operation.

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Controller Check
 Panel indicators: press the Test button on the control panel once, and
all lights should be lit for a few seconds.
 Check whether the buttons can operate normally and do not stick.

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Troubleshooting of Diesel Generator Set

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 Several troubleshooting methods for reference

1.Personal safety is the most important. In principle, maintenance with power off ,and do not
operate when the unit is running;
2.Routine inspection and maintenance are the best way to ensure the normal operation of
the unit;
3. When the unit fails and shuts down, the first thing is not to reset the fault;
4. Faults are often not as complicated as you think;
5. The elimination method is the most effective way to judge and locate the fault

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Phenomenon: The unit has no response or only a "click"

Reason Method:
1.Insufficient battery power; 1.Charge the battery or replace the battery;
2. Corrosion of battery terminal head; 2.Clean the battery terminal head;
3.The DC fuse in the control panel 3.Replace DC insurance;
melted down; 4.Reset the emergency stop button and clear
4.The emergency stop button has the alarm;
not been reset; 5.repair the current fault, reset the fault
5.There is a fault alarm currently, alarm;
but it has not been reset;

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 Phenomenon: The starter motor can rotate, but the unit cannot start the engine

Reason: Method:
1.The starting motor speed is too low;
2. No fuel supply; 1.Refuel the tank
2.Repair the leaks
3. Leakage of fuel line;
3.Remove the oil pipe screw and check whether
4. The fuel filter or fuel pipe is blocked there is fuel flowing out, if not, clean the
5. The air filter is blocked corresponding pipe.
4.Replace air filter or fuel filter

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 Phenomenon: black smoke from the exhaust of the unit

Reason: Method:
1.Overload; 1. Reduce the load;
2.The air filter is blocked; 2. Clean or replace the air filter;
3. Poor fuel quality; 3. Change the fuel;

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Phenomenon: white smoke from the exhaust of the unit

Reason Method
The diesel water Check the oil-water separator (drain)
content exceeds the and replace the diesel if necessary.
standard;

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 Phenomenon: blue smoke from the exhaust of the unit

Reason Method
1. Increase the load appropriately;
1.Long-term low-load operation;
2. remove the excess oil;
2. Too much engine oil is added;
3. Replace the engine oil
3.The engine oil grade or viscosity grade is
incorrect.

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 Phenomenon: The water temperature of the unit is extremely high

Reason Method
1.The unit is overloaded; 1.Unload part of the load;
2. Coolant is not enough; 2. Add the coolant
3.The fan belt is slipping or broken; 3. Re-adjust or replace the belt;
4.Too much scale in the water jacket and 4. Remove the scale;
water tank; 5.Improve the heat dissipation conditions of
5.The engine room has poor heat the engine room;
dissipation conditions and poor exhaust;

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 Phenomenon: The oil pressure of the unit is too low

Reason Method
1.The oil grade or viscosity
is incorrect;
Replace the oil or oil filter;
2.Check whether the oil has been
used for more than 3 years ;
3. The oil filter is blocked;
4.There is water or diesel in the
oil.

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Phenomenon: The engine oil pressure is too high

Reason Method
1.The oil grade or viscosity is 1.Replace the oil and oil filter;
incorrect; 2. Clean up the oil circuit;
2. The oil circuit is blocked;

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Safety Precautions
1. High temperature pressurized liquid: Contact with hot liquids can cause severe burns, do
not open the pressure cap while the engine is running, allow the engine to cool down before
removing the pressure cap, rotate the pressure cap slowly, and do not open it until the
pressure has been released.
2. Moving parts :Moving parts can cause serious personal injury and care should be taken
when working around moving parts.
3. Poisoning hazards: Waste oil, coolant, diesel, exhaust gas can all cause poisoning. Do not
ingest or breathe mist when checking or changing oil.
4. Power generation equipment: The generator and related equipment must be disconnected
from the power supply before overhauling. Do not operate the equipment after fatigue or
drinking or taking drugs.
5. Flammable liquids: Do not store fuel, detergent, oil, etc. in the generator room, which is
easy to cause fire and other accidents.
6. Automated machinery :Unexpected start-up of the generator set may result in serious
personal injury or death. If you need to repair and maintain the unit, it is necessary to press
the emergency stop button of the unit to ensure that the unit cannot be started.
Thank you

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