Planned Maintenance

Recommendations

High Range Standby Diesel Generator Set

DFEx
DFGx
DFHx
DQCx
DQFx
DQGx
DQKx
DQLx
DQMx

English Original Instructions 82009 A035G976 (Issue 1)

 Table of Contents
Subject Page Number
2
Background
2
Service Support
3
Technical Publications
3
Warranty
4
Task List

Revision A 1 of 6
Revision Date: 08/03/09
1.0 Background
The purpose of this document is to outline the Cummins Power Generation factory recommended maintenance tasks to be
used with high range commercial standby diesel gensets. This material is supplementary to the owners, install, and service
manuals; and not intended to replace any one of those manuals.

This task list is an approved list of maintenance tasks that can be used for purposes of marketing, expanding, and
implementing a common process for the Cummins Distributor. This list provides an improved and more optimized list of
planned maintenance events for the end user.

1.1 Product Inclusions

This list provides maintenance tasks for the following diesel standby gensets.

DFEx
DQMx
DQCx
DFGx
DFHx
DQFx
DQGx
DQKx
DQLx

2.0 Service Support

CPG Service will provide technical service support to Distribution in the event technical assistance is needed during or after a
maintenance event. The primary interface and documentation mechanism for CPG Service for field issues is the Issue
Tracking System (ITS). CPG Service is tasked with the following responsibilities:
Track all product related issues
Document and communicate issue resolution to the Field
Provide common database for tracking product issues
Communicate important issues monthly through the DFSE-C conference call or as necessary
Issue Product Support Bulletins (PSB) and Parts & Service Bulletins as required

2.2 Aftermarket Support Plan

The support structure consists of three main levels: 1) Distributor Service Technician; 2) Distributor Power Generation DFSE-
C; and 3) Factory Service. This general process is governed globally by the CPG Parts and Service Support process and
regional by a Distributors Support & Escalation process.

In general, when a field issue has been identified, a Distributor Service Technician is engaged to resolve the issue. The
Cummins Power Generation DFSE-C supports the Service Technician with necessary information and resources. If the event
requires factory support, the DFSE-C engages with CPG Service. An ITS Issue is created and assigned to the CPG Service
group, which will be tasked with supporting the DFSE-C to closure.

2.3 Service Tools

No special tools are required to carry-out the tasks listed in this document.

2.4 Parts Return Process

A Parts Return process has been established to ensure that failed components can be returned to the Factory for failure
analysis and product improvement.

Process Steps:
An ITS issue has been created to document the event and resolution.
A CPG Service Engineer will determine whether the failed component(s) is of interest and in need of return.
A CPG Service Engineer will create a Notes/Discussion entry within in the Issue, with subject title Shipping
Instructions that details shipping information.
As applicable, a Short Term Solution will be issued with title Failed Parts Return Request.
The DFSE-C is required to follow the shipping instructions to ensure that the failed component(s) is received in a
timely, efficient manner.

Revision A 2 of 6
Revision Date: 08/03/09
 The DFSE-C will create a Notes/Discussion entry within in the Issue, with the subject title Tracking Information,
which details the method of shipping and provides the applicable Tracking Number. NOTE: The Issue Number is to
be noted on the package prior to shipment as well.
The CPG Service Engineer must ensure that the package is received and the analysis conducted.
The CPG Service Engineer must communicate all results to the DFSE-C by documenting such within the Issue

3.0 Technical Publications

Please continue to reference the genset manuals for the specific product. This reference is a planned maintenance event
recommendation only. In the event a question is raised about the product or procedure, refer to the genset manual for more
information.

4.0 Warranty
Implementing this list of maintenance tasks will not void the warranty of the products listed in this document. Subsequently, if
this list is not followed AND the maintenance tasks in the generator manual are, the warranty will not be voided.

5.0 Task List

Below is the task list. It lists all the factory recommended tasks for generator maintenance on high range standby diesel
gensets.

5.1 Using the Task List

The following is a brief description of the columns:
Column A = major generator subsystem
Column B = specific maintenance task
Column C-G = define a method of procedure to use: visually inspect, check, change, clean, or test. In some cases
only as required.
Column H = defines when during the maintenance event to implement the procedure: pre, during, or post the genset
exercise
The row above the H designee describes explains how often a procedure should be preformed: monthly, quarterly, semi-
annually or annually.

Revision A 3 of 6
Revision Date: 08/03/09
 MAINTENANCE SCHEDULE
Cummins Power Generation Maintenance Schedule
High Range, Standby Duty Cycle
Frequency, whichever comes sooner:
M=Monthly or after 100 hrs, Q=Quarterly,
S=Semi-annualy or after 250 hrs, A=Annually or
C D E F G after 500 hrs || Assume genset is exercised
monthly. Designees pre, post and during indicate
Procedure (X - action, R - as required) when to inspect during monthly exercise
A B Visually H
Component Inspect Check Change Clean Test
FUEL Main supply tank level X Pre and Post, M
Day tank level X X Pre and Post, M
Day tank float switch X During, M
Supply/transfer pump operation X During, M
Solenoid valve operation X During, M
Fuel filter X R A, At oil change interval or high filter restriction
Strainer, water in system, dirt leg [contaminant] X X Pre and Post, M
Flexible hose and connectors X R Pre, During, and Post; M
Tank vents and overflow piping unobstructed X During, A
Piping X During, A
Fuel quality test X A
LUBRICATION Oil level X Pre and Post, M
SYSTEM Oil change X Per engine manufacturer
Oil filter(s) X Per engine manufacturer
Lube oil heater X Pre, M
Crankcase breather X S
COOLING SYSTEM Level X Pre and Post, M
Coolant freeze protection level X S
Antifreeze R 2 yrs or per coolant vendor specification
Adequate cooling water to heat exchanger X During, M
Adequate fresh air through radiator X During, M
Clean exterior of radiator X R A
Fan and alternator belt [drive belts] X R Visually (Pre and Post, M); R (S)
Grease fan bearing X A
Water pumps X Pre, During, and Post; M
Condition of flexible hoses, connections, and clamps X X R Visually (Pre and Post); R (S)
DCA / SCA level X S
Coolant filters X With oil change intervals or as needed for SCA, A

Revision A 4 of 6
Revision Date: 08/03/09
 Procedure (X - action, R - as required) Frequency, whichever comes sooner:
M=Monthly or after 100 hrs, Q=Quarterly,
S=Semi-annualy or after 250 hrs, A=Annually or
after 500 hrs || Assume genset is exercised
Visually monthly. Designees pre, post and during indicate
Component Inspect Check Change Clean Test when to inspect during monthly exercise
COOLING SYSTEM Jacket water heater X Pre, M
Low coolant sensor X Recommended, not required
Thermostat X Recommended, not required
Inspect duct work, clean louvers X X Pre and Post (M), Clean (A)
Louver motors and controls X Pre and Post, M
EXHAUST SYSTEM Leakage X Pre, During, and Post; M
Drain condensate trap X Pre and Post, M
Insulation and fire hazards X Pre, During, and Post; M
Exhaust system hangers and supports X Pre, During, and Post; M
Flexible exhaust section X Pre and Post, M
BATTERY SYSTEM Electrolyte level X Pre, M
Terminals clean and tight X Pre, A
Remove corrosion, case exterior clean/dry X X Pre, A
Specific gravity or state of charge X Pre, M
Cranking load test X Recommended, not required
Charger and charge rate X Pre and Post, M
Equalize charge X A
ELECTRICAL General inspection X Pre, M
SYSTEM Tighten control and power wiring connections X A
Wire chafing where subject to movement X Pre, M
Boxes, panels, and cabinets X X Pre, S
Circuit breakers, fuses X R X X Pre, A
Calibration of voltage-sensing relays/devices X X A
PRIME MOVER General inspection X Pre and During, M
Service air cleaner X X R Pre, M
Governor oil level and linkage X Pre, M
Governor oil R A
Block heaters X Recommended, not required
Ignition system - plugs, points, coil, cap, rotor, secondary wire
X R Pre, A
insulation
EPS at minimum of 30% nameplate rating X M
Performance testing per manufacturer X A
Performance testing per AHJ X 4 hrs every 36 months (see NFPA 110 8.4.9)
Starter motor X Recommended, not required
Valve clearance X Per engine manufacturer
Revision A 5 of 6
Revision Date: 08/03/09

Component
GENERATOR Rotor and stator and associated equipment
Check generator (alternator) air outlet
Bearing grease
Exciter
Winding heaters
Anchorage, alignment, grounding
Measure and/or PI testing and record resistance readings of
windings with insulation tester (Megger)
GENERAL General condition of EPSS, any unusual condition of
vibration, leakage, noise, temperature, or deterioration
Procedure (X - action, R - as required) Frequency, whichever comes sooner:
M=Monthly or after 100 hrs, Q=Quarterly,
S=Semi-annualy or after 250 hrs, A=Annually or
after 500 hrs || Assume genset is exercised
Visually monthly. Designees pre, post and during indicate
Inspect Check Change Clean Test when to inspect during monthly exercise
X A
X Pre and During
X R A, Per factory recommendation
X A
Recommended, not required
Recommended, not required
A, Per factory recommendation high and med volt
X
Stator and field stator PI phases, not the coils
X Pre, During, and Post; M

Service room or housing housekeeping X Pre, During, and Post; M

RESTORE Restore system to automatic operation condition X Post, M

5.2 Terminology
The following section explains the terminology and acronyms in the table above.

Visually inspect visually evaluate the state of the system, subsystem or component
Check examine or investigate as to determine accuracy, quality or condition
DCA Diesel coolant additive
SCA Supplemental coolant additive
EPS Emergency power system
EPSS Emergency power supply system
AHJ Authority having jurisdiction

Revision A 6 of 6
Revision Date: 08/03/09
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Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
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