CUMMINS DFBF, DFAC, DFAB, DFCC, DFCE Installation Manual
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Installation Manual
Redistribution or publication of this document,
by any means, is strictly prohibited.
PowerCommand Control
2100 Series
Generator Sets
Printed in U.S.A.
Models
DFAB, DFAC, DFBF, DFCB, DFCC, DFCE
960-0634C 02-2004
Table of Contents
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by any means, is strictly prohibited.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aligning Generator with Engine (750 kW Gensets and Larger) 3-5. . . . . . . . .
4 MECHANICAL CONNECTIONS
General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation and Cooling 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 DC CONTROL WIRING
Control Wiring 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TB1 Remote Monitor/Control Connections 5-2. . . . . . . . . . . . . . . . . . . . . . . . . .
TB2 Power Transfer Control (PTC) Connections (Optional) 5-2. . . . . . . . . . . .
Control Relays (K11, K12, K13) 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
California
Proposition 65 Warning
i
SECTION TITLE PAGE
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by any means, is strictly prohibited.
6 AC ELECTRICAL CONNECTIONS
General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Wiring 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Heater (Optional) 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Heater (Optional) 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Heater (Optional) 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Transfer Pump (Optional) 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Fault Alarm Relay (Optional) 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 ENCLOSURE ELECTRICAL CONNECTIONS
General 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional AC Distribution Panel 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Motorized Inlet/Outlet Louvers 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Transfer Fuel Pump 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PRESTART PREPARATION
General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC Options Prestart Checks 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 INSTALLATION CHECKLIST
General 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Support 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Air Flow 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Fuel System 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC and DC Wiring 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Prestart 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 WIRING DIAGRAMS
General 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
IMPORTANT SAFETY INSTRUCTIONS
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by any means, is strictly prohibited.
SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator and batteries.
Before operating the generator set (genset), read the
Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal injury or death.
WARNING
This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.
CAUTION
This symbol refers to a hazard or unsafe practice which can result in personal injury
or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result
from improper practices.
• DO NOT fill fuel tanks while engine is running, un-
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential
fire hazard.
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source
near the generator set or fuel tank.
• Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be
made with an approved flexible line. Do not use zinc
coated or copper fuel lines with diesel fuel.
• Be sure all fuel supplies have a positive shutoff
valve.
• Be sure battery area has been well-ventilated prior
to servicing near it. Lead-acid batteries emit a highly
explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.
EXHAUST GASES ARE DEADLY
Provide an adequate exhaust system to properly
•
expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to
heat a compartment.
• Be sure the unit is well ventilated.
• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
•
Keep your hands, clothing, and jewelry away from
moving parts.
• Before starting work on the generator set, discon-
nect battery charger from its AC source, then disconnect starting batteries, negative (−) cable first.
This will prevent accidental starting.
• Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
in position over fans, drive belts, etc.
• Do not wear loose clothing or jewelry in the vicinity of
moving parts, or while working on electrical equipment. Loose clothing and jewelry can become
caught in moving parts.
• If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed and
become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
intake and stop the engine. The owners and operators of
the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power
Generation distributor for more information.
LS-14L
iii
ELECTRICAL SHOCK CAN CAUSE
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by any means, is strictly prohibited.
SEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protective
•
shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not
wear jewelry. Jewelry can short out electrical contacts and cause shock or burning.
• Use extreme caution when working on electrical
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.
• Follow all applicable state and local electrical
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
switches to avoid accidental closure.
• DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set
into the utility line. This creates a potential for electrocution or property damage. Connect only
through an approved isolation switch or an approved paralleling device.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling point
•
than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running.
Allow the generator set to cool and bleed the system
pressure first.
• Used engine oils have been identified by some state
or federal agencies as causing cancer or reproductive toxicity . When checking or changing engine oil,
take care not to ingest, breathe the fumes, or contact used oil.
• Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
and flammable liquid fuels and gaseous fuels; Class
C fires, live electrical equipment. (ref. NFP A No. 10).
• Make sure that rags are not left on or near the en-
gine.
• Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
under the unit.
• Remove all unnecessary grease and oil from the
unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.
• Keep the generator set and the surrounding area
clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry.
• Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
or drug that makes the operation of equipment unsafe.
• Substances in exhaust gases have been identified
by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
• Do not store any flammable liquids, such as fuel,
cleaners, oil, etc., near the generator set. A fire or
explosion could result.
• Wear hearing protection when going near an oper-
ating generator set.
• To prevent serious burns, avoid contact with hot
metal parts such as radiator, turbo charger and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
iv
1. Introduction
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by any means, is strictly prohibited.
ABOUT THIS MANUAL
This manual provides installation instructions for
the generator set models listed on the front cover.
This includes the following information:
Mounting Recommendations - for fastening
generator set to base and space requirements
for normal operation and service.
Mechanical and Electrical Connections covers most aspects of the generator set installation.
Prestart − checklist of items or procedures
needed to prepare generator set for operation.
Initial Startup − test complete system to ensure proper installation, satisfactory perfor-
mance, and safe operation. Refer to Operators
Manual for troubleshooting information.
Installation Checklist − reference checks
upon completion of installation.
This manual DOES NOT provide application information for selecting a generator set or designing the
complete installation. If it is necessary to design the
various integrated systems (fuel, exhaust, cooling,
etc.), additional information is required. Review
standard installation practices. For engineering
data specific to the generator set, refer to the
fication
tion, refer to Application Manual T-030, “Liquid
Cooled Generator Sets”.
and
Data Sheets
. For application informa-
Speci-
1-1
INSTALLATION OVERVIEW
Redistribution or publication of this document,
by any means, is strictly prohibited.
These installation recommendations apply to typical installations with standard model generator
sets. Whenever possible, these recommendations
also cover factory designed options or modifications. However, because of the many variables in
any installation, it is not possible to provide specific
recommendations for every situation. If there are
any questions not answered by this manual, contact
your nearest Cummins Power Generation distributor for assistance.
Application and Installation
installed, maintained, and operated. However, the
overall safety and reliability of the complete system
is dependent on many factors outside the control of
the generator set manufacturer. To avoid possible
safety hazards, make all mechanical and electrical
connections to the generator set exactly as specified in this manual. All systems external to the generator (fuel, exhaust, electrical, etc.) must comply
with all applicable codes. Make certain all required
inspections and tests have been completed and all
code requirements have been satisfied before certifying the installation is complete and ready for service.
A standby power system must be carefully planned
and correctly installed for proper operation. This involves two essential elements: application and
installation.
Application (as it applies to generator set installations) refers to the design of the complete standby
power system that usually includes power distribution equipment, transfer switches, ventilation equipment, mounting pads, and cooling, exhaust, and
fuel systems. Each component must be correctly
designed so the complete system will function as intended. Application and design is an engineering
function generally done by specifying engineers or
other trained specialists. Specifying engineers or
other trained specialists are responsible for the design of the complete standby system and for selecting the materials and products required.
Installation refers to the actual set-up and assembly of the standby power system. The installers set
up and connect the various components of the system as specified in the system design plan. The
complexity of the standby system normally requires
the special skills of qualified electricians, plumbers,
sheetmetal workers, etc. to complete the various
segments of the installation. This is necessary so all
components are assembled using standard methods and practices.
Safety Considerations
The generator set has been carefully designed to
provide safe and efficient service when properly
Standby Heating Devices
In accordance with NFPA 110, Cummins Power
Generation recommends installing diesel standby
generator sets (life safety systems) equipped with
engine jacket water coolant heaters in locations
where the minimum ambient temperature is above
40
°F (4°C). NFPA also requires that the engine
jacket water coolant be maintained at a minimum of
°F (32°C) and, for most applications, accept the
90
emergency load in 10 seconds or less. Although
most Cummins Power Generation generator sets
will start in temperatures down to −25
when equipped with engine jacket water coolant
heaters, it might take more than 10 seconds to
warm the engine up before a load can be applied
when ambient temperatures are below 40
The Engine Cold (Code 1435) message, in con-
junction with illumination of the Warning LED, is provided to meet the requirements of NFPA 110. The
engine cold sensing logic initiates a warning when
the engine jacket water coolant temperature falls
below 70
ent temperature falls below 40
°F (21°C). In applications where the ambi-
°F (4°C), a cold en-
gine may be indicated even though the coolant
heaters are connected. Under these conditions, although the generator set may start, it may not be
able to accept load within 10 seconds. When this
condition occurs, check the coolant heaters for
proper operation. If the coolant heaters are operating properly, other precautions may be necessary to
warm the engine before applying a load.
°F (−32°C)
°F (4°C).
Copyright2003 Cummins Power Generation. All rights reserved.
Cummins and PowerCommand are registered trademarks of Cummins Inc.
1-2
2. Specifications
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by any means, is strictly prohibited.
MODEL DFAB/DFAC DFBF DFCB/DFCC DFCE
Cummins Diesel Series LTA10 NT855 NTA855 NTA855
Generator kW Rating See Genset Nameplate for rating information.
Cooling System
Capacity with Standard Radiator 13 Gal (49 L) 13.5 Gal (51 L) 13.5 Gal (51 L) 15 Gal (57 L)
Oil Capacity* 9.5 Gal (36 L) 10.5 Gal (40 L) 10.5 Gal (40 L) 10 Gal (38 L)
Engine Fuel Connection
Inlet/Oultet Thread Size
Fuel Flow
Max. Fuel Inlet Restriction
Max. Fuel Return Restriction
Exhaust
Outlet Size
Max. Allowable Back Pressure
H20
kPa
Electrical System
Starting Voltage
Battery
Group number
CCA (minimum)
Cold Soak @ 0° F (-18° C)
* Refer to Cummins engine
Operation and Maintenance Manual
4 in. Hg. (13.5 kPa)
6.5 in. Hg. (22 kPa)
4 in. NPT
41
10.2
for lubricating oil recommendations/specifications.
Refer to Generator Outline Drawing
4 in. Hg. (13.5 kPa)
6 in. Hg. (20.3 kPa)
5 in. NPT
41
10.2
24 Volts DC
Two, 12 Volt
8D
1400
6 in. NPT
41
10.2
6 in. NPT
41
10.2
FUEL CONSUMPTION (STANDBY/FULL LOAD/60HZ)
MODEL DFAB DFAC DFBF DFCB DFCC DFCE
US gph (L/hr) 15.6 (59) 16.8 (63.7) 20.4 (77.3) 22.5 (85.3) 24.4 (92.5) 29.1 (110.3)
2-1
THIS PAGE LEFT INTENTIONALLY BLANK
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2-2
3. Mounting the Generator Set
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by any means, is strictly prohibited.
GENERAL
• Discharge of exhaust gases
• Electrical connections
Generator set installations must be engineered so
the generator set will function properly under the expected load conditions. Use these instructions as a
general guide only. Follow the instructions of the
consulting engineer when locating or installing any
components. The complete installation must comply with all local and state building codes, fire ordinances, and other applicable regulations.
Requirements to be considered prior to installation:
• Level mounting surface
• Adequate cooling air
• Adequate fresh induction air
• Discharge of generator set air
• Non-combustible mounting surface.
• Accessibility for operation and servicing
• Noise levels
• Vibration isolation
LOCATION
Generator set location is decided mainly by related
systems such as ventilation, wiring, fuel, and exhaust. The set should be located as near as possible to the main power service entrance. Exhaust
must not be able to enter or accumulate around inhabited areas.
Provide a location away from extreme ambient temperatures and protect the generator set from adverse weather conditions. An optional housing is
available for outside operation.
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 COMPONENT INSTALLATION.
DEPENDING ON Y O U R L O C ATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LA WS
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.
IMPORTANT
3-1
MOUNTING
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by any means, is strictly prohibited.
Generator sets are mounted on a steel skid or fuel
tank that provides proper support. The engine-generator assembly is isolated from the skid frame by
rubber mounts that provide adequate vibration
isolation for normal installations. Where required by
building codes or special isolation needs, generator
sets may be mounted on rubber pads or mechanical
spring isolators. The use of unapproved isolators
may result in harmful resonances and may void the
genset warranty.
For fuel tank mounted generator sets, it is required
that the tank be mounted such that an air space is
provided between the bottom of the tank and the
floor underneath to reduce corrosion and permit
visual inspections for leaks.
Mount the generator set on a substantial and level
base such as a concrete pad. A non-combustible
material must be used for the pad.
Use 5/8 inch or 16 mm anchored mounting bolts to
secure the vibration isolators to the base. Secure
the vibration isolators using flat or bevel washer and
hexagonal nut for each bolt (see Figure 3-1). The
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
BASE
MOUNTING
BOLT
SUBBASE OR
VIBRATION
ISOLATOR
FLANGE
HEX NUT
FLAT OR BEVEL
WASHER
1-1/2 x 6 INCH
PIPE
12 IN.
(305 mm)
CONCRETE
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. (Increase
clearance by width of door if optional housing is
used.) 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, maintenance and service operations and should be connected on the load side of the transfer switch so that
it is available at all times.
3-2
MUFFLER
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by any means, is strictly prohibited.
THIMBLE
FLEXIBLE SECTION
DC CONTROL
WIRING
CONDENSATION
DRAIN TRAP
SWEEPING
ELBOW
AC POWER
WIRING
AIR
IN
AIR OUTLET
DUCT
SHIPPING SCREW
(DFCE ONLY) EACH SIDE
VIBRATION
ISOLATORS
COOLING AIR INLET MUST BE AT LEAST 1-1/2
TIMES LARGER THAN RADIATOR DUCT OUTLET
AREA ON RADIATOR COOLED MODELS
FLOW OR COOLING AIR AND HEATED AIR CAN
BE CONTROLLED BY AUTOMATICALLY
FIGURE 3-2. TYPICAL INSTALLATION
3-3
CONCRETE
BASE
IMPORTANT!
OPERATED LOUVRES
VIBRATION ISOLATORS
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Installation and Adjustment Procedure
1. Place the vibration isolators (Figure 3-3) on the
genset support structure. The isolators should
be shimmed or grouted to ensure that all of the
isolator bases are within 0.25 inch (6 mm)
elevation of each other. The surface that the
isolator bases rest on must also be flat and level.
2. Loosen the side snubber lock nuts so that the
top plate of the isolator is free to move vertically
and horizontally. Be sure that the top plate is
correctly aligned with the base and springs.
3. Place the genset onto the isolators while aligning the skid’s mounting with the threaded isolator hole. The top plates will move down and approach the base of the isolator as load is applied.
4. Once the genset is in position, the isolators
may require adjusting so that the set is level.
The isolators are adjusted by inserting the leveling bolt through the skid and into the isolator
(the leveling bolt’s locking nut should be
threaded up towards the bolt head).
The leveling bolt will adjust the clearance between the top plate and the isolator base. A
nominal clearance of 0.25 inch (6 mm) or greater is desired. This will provide sufficient clearance for the rocking that occurs during startup
and shutdown. If the 0.25 inch (6 mm) clearance is not present, turn the leveling bolt until
the desired clearance is achieved.
5. The genset may not be level yet; therefore, adjust the leveling bolts until the set is level and
sufficient clearance still remains. (Clearance
on all isolators should be roughly equal). Once
all isolators have been set, lock the leveling bolt
in place with the lock nut.
6. The snubber nuts may remain loose and therefore provide better isolation between the genset and support structure.
7. Model DFCE only: With the genset in position
and secured to the isolators, remove the two
controller cabinet shipping screws (see Figure
3-2).
CAUTION
Remove shipping screws (two)
prior to genset operation. Genset operation
with shipping screws in place will damage
control components.
GENSET SKID
LEVELING BOLT
LOCK NUT
CLEARANCE
SNUBBER
BASE
FIGURE 3-3. VIBRATION ISOLATORS
3-4
ALIGNING GENERATOR WITH ENGINE
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(750 kW GENSETS AND LARGER)
Proper alignment of the generator and engine assemblies is necessary to avoid premature wear and
improper operation of the genset. Review the following alignment conditions and procedures for
aligning the generator assembly to engine flywheel
housing.
Angular Misalignment
Angular misalignment is the result of the generator
bearing center axis not aligning with axis of the engine crankshaft. This condition creates an angle
between the generator shaft axis and the crankshaft axis . The cause of this type of misalignment is
usually shimming error.
Axial Misalignment
Axial misalignment is the result of the generator
shaft axis not aligning with engine crankshaft axis.
The tolerances in the bolted flywheel and drive disc
connection may add up to displace the generator
axially relative to the crankshaft axis.
Misalignment Symptoms
If the assembly is allowed to run under these conditions, the discs must flex in alternate directions
twice for each engine revolution. It is important to
minimize the amount of disc flexing since, if it is excessive, the drive disc will crack. Although perfect
bearing alignment is desirable, it is more important
to keep disc deflection to the very minimum possible. This procedure assumes that the pilot bore of
the drive discs are in the exact center and the flywheel counterbore (pilot) has no practical runout.
Under these conditions, perfect Angular alignment
will be attained when no deflection of the discs is
measured.
Excessive Axial alignment will cause more generator vibration than Angular misalignment.
Axial misalignment needs to be checked only when
an objectionable vibration is present.
Either type off misalignment may be present in a
generator set assembly , with angular misalignment
being the most common problem. Angular alignment may also be effected by set installation conditions and/or mishandling during shipping of the genset.
GENERATOR
AND ENGINE
CRANKSHAFT
CENTERLINE
SHIMS
SEE DETAIL A
CLAMP
MOUNTING BOLT
TO DISC
MEASUREMENT
FIGURE 3-4. ANGULAR ALIGNMENT MEASUREMENT
AXIAL
ALIGNMENT
DIAL INDICATOR
FLEX
DISCS
DETAIL A
3-5
Angular Alignment Procedure
Redistribution or publication of this document,
by any means, is strictly prohibited.
WARNING
set during this procedure presents the hazard
of severe personal injury or death. Make sure to
disconnect the negative (-) battery cable(s) before beginning.
Accidental starting of the generator
-.015”.) The indicator is closer to the top and further
away at the bottom. This example indicates that the
generator bearing is high. Since the side readings
are equal, the generator is centered side to side. T o
lower the generator, remove equal shims from under both generator mounting feet. To approximate
the amount of shims to remove or add:
Fasten a dial indicator to either the generator shaft
or the cooling fan with the sensing point resting on
the capscrew head or the flat surface of the drive
disc at the bolt circle diameter, see Figure 3-4. Bar
the engine over in a clockwise rotation as viewed
from engine flywheel. Do not allow it to roll back on
compression at the end of the travel of each reading. It is unnecessary to zero the indicator since the
total indicator reading (T.I.R.) of the deflection measurement to the bolt heads is what is required. T.I.R.
will be the sum of the maximum positive and negative dial indicator readings as the engine completes
one revolution.
CAUTION
Do not bar engine over by prying on
fan blade. This may damage the blade and result
in premature, sudden blade failure.
Sample Generator Runout Readings: When taking
the deflection readings described, make a diagram
similar to the example shown in Figure 3-5, with a
total indicator reading of .025”. (The highest positive value of +.010” and the largest negative value of
1. Measure the distance between the center of
the generator shaft to the point the indicator is
measuring at. (For example; a SAE 18 Disc
coupling distance is 10.7”).
2. Measure the distance from the generator side
of the flex discs to the center of the generator
mounting bolt, refer to Figure 3-4. (For example; a HC6 Frame’s distance is 28.4”.)
3. Compare the distance measured in steps 1 and
2. (28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiply
this ratio times one half the T.I.R. (In our example, .025” divided by 2 is .0125”. This, times
2.65 equals .033”. Therefore, remove .033” of
shims from under both mounting feet.)
In general, the T.I.R. should not be more than .001”
for each inch of radius (center of shaft to indicator
axis). If w e use our example of 10.7 inches, then the
maximum T.I.R. would be .011”. This would only require a correction of .014” from the T.I.R. of .025”. (A
reading of +.002 at the top and −.009 at the bottom
would fall within the satisfactory range.)
FIGURE 3-5. ANGULAR ALIGNMENT MEASUREMENT READINGS (EXAMPLE)
−.004
−.010
+.010
MEASURED AT
BOLT CIRCLE
DIAMETER
−.015
−.015
3-6
+.010
−.002
10.7 IN.
−.010
Axial Alignment Procedure
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by any means, is strictly prohibited.
Axial misalignment needs to be checked only when
an objectionable vibration is present.
If excessive vibration remains after the angular
alignment, check for concentric alignment of the
generator shaft/engine crankshaft axis.
to the varying surface quality of the generator
shaft’s drive disc mounting hub.
The goal of the Axial alignment is to reduce the
vibration level of the genset while it is operating. A
small improvement in the T.I.R. runout may have
dramatic effects in the mechanically measured or
physically observed vibration levels.
Fasten dial indicator holding device to skid base,
engine block, or generator shell with a magnetic
base or clamp and position so the sensor point of in dicator rests on the generator shaft hub, see Figure
3-6. Bar the engine over in a clockwise rotation as
viewed from engine flywheel, through a couple of
rotations. Record indicator readings in eight equally spaced points around the shaft diameter. This will
provide a T.I.R. for Axial shaft misalignment.
The maximum allowable T.I.R. runout is subjective,
the optimal T.I.R. for runout would be .000 inches,
however that may not be attainable. The recommendation of this procedure will be to reduce the
measured T.I.R. runout by one half. Specific out-oftolerance runout levels are difficult to establish due
ANGULAR ALIGNMENT
To correct for an out-of-tolerance T.I.R. indication,
remove the capscrews connecting drive discs and
flywheel. Mark the drive discs and flywheel with respect to each other. Rotate either the engine or generator so that drive discs holes are repositioned 180
degrees from their original location. Put the drive
discs capscrews back in and retorque. Recheck
shaft alignment as before. If shaft T.I.R. runout remains unchanged then discs should be rotated to
either 30, 60 or 90 degrees from original location to
correct the out-of-tolerance condition. If the T.I.R.
does not improve after repositioning, a closer inspection of the flywheel pilot and drive disc runouts
is required. This will help determine the cause of the
Axial misalignment.
SEE DETAIL A
GENERATOR
AND ENGINE
CRANKSHAFT
CENTERLINE
GENERATOR
SHAFT
HUB
DIAL
INDICATOR
CLAMP
FAN HOUSING
DETAIL A
FIGURE 3-6. AXIAL ALIGNMENT MEASUREMENT
3-7
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3-8
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