Installation Method

Pre-installation Preparation

Environment and Tools

• The installation site must be well-ventilated, with the air outlet area at the diesel engine end not less than 1.5 times the water tank area. It should be far away from corrosive substances such as acids and alkalis, and fire-fighting equipment must be equipped.

• Prepare tools including a crane, level gauge, torque wrench, socket set, insulating tape, and shock pads. Meanwhile, prepare compatible accessories such as a flexible coupling, flexible pipes, and 24V suitable cables.

Component Inspection

• Verify the compatibility of the generator model with the ISLe340 and ISBE engine models. Check that the generator housing, rotating shaft, and terminal blocks are free of damage.

• Clean oil stains and impurities from the mating surfaces of the generator and diesel engine, and confirm that accessories such as the flexible coupling and sealing gaskets are intact.

• Additionally, confirm the generator's rotation direction marking, which must be consistent with the output rotation direction of the diesel engine.

Foundation Fixing

• Preferentially use a concrete foundation. The foundation must be cured with a horizontal error ≤ ±2mm, and its thickness shall be determined according to the unit weight (≥20cm is recommended for heavy-duty units).

• Install special shock pads between the foundation and the generator base. After placing the generator stably, adjust it to a horizontal state with a level gauge, then tighten and fix it with anchor bolts in a diagonal cross and step-by-step manner to prevent displacement during operation.

• For unit base frame installation, ensure only 4-point support to avoid vibration caused by multi-point statically indeterminate support.

Core Unit Docking

• Both engine models are mostly compatible with double-bearing generators. The key to docking is to ensure coaxiality and clearance.

• First, install the flexible coupling on the generator's shaft extension end, and sprinkle talcum powder on the flywheel holes and flexible ring surface to reduce jamming.

• Axially push the generator to align and insert the coupling pins into the diesel engine's flywheel holes.

• After docking, inspect:

• The axial clearance between the flexible coupling and the flywheel end face shall be controlled at 3-5mm.

• Adjust the center height by adding or removing generator base shims to ensure the radial runout of the coupling and flywheel ≤ 0.20mm and the end face runout ≤ 0.40mm.

• Finally, lock the anchor bolts with double nuts to prevent loosening.

Multi-system Connection

Electrical System

• Select cables suitable for 24V 150A power. Connect the generator's terminal blocks U, V, W to the phase wires, N to the neutral wire, and securely fasten the grounding bolt to the grounding wire.

• Wrap cable connections with insulating materials and use flexible cables to avoid line damage due to vibration.

• Install a bidirectional switch to prevent back feeding. The switch must be inspected and approved by the power supply department.

• Simultaneously connect the 24V starting battery to ensure stable power supply for the control circuit.

Fuel System

• Select fuel pipelines compatible with the engine models; avoid using galvanized pipes. Ensure sealed connections for pipelines to prevent leakage.

• The height difference between the fuel tank position and the crankshaft line shall not exceed 1.6m. If exceeded, an auxiliary fuel tank must be installed, and a flexible connection shall be provided in the middle of the pipeline to offset the impact of unit vibration on the pipeline.

Exhaust and Cooling Systems

• The diameter of the exhaust pipe shall not be smaller than the muffler interface. Install a flexible pipe between the turbocharger and the muffler. The number of pipe elbows shall not exceed 3, and the pipe shall be inclined downward by 5-10° to prevent rainwater backflow. A rain cover must be installed for vertical installation.

• Ensure the cooling water pipeline is unobstructed, with correct positions of the water inlet and outlet. Seal the interfaces with seals to avoid high-temperature damage caused by water leakage.

• Wrap the exhaust pipe with thermal insulation materials, and arrange the muffler outside the machine room as much as possible to reduce the temperature rise in the room.

Commissioning and Acceptance

No-load Commissioning

• Start the diesel engine to drive the generator. Observe that the unit has no abnormal vibration or noise, monitor that the generator's output voltage is stably maintained at 24V, check that all pipelines are free of leakage, and ensure the bearings do not overheat.

Load Testing

• Connect a matched load and operate continuously for a period of time. Verify that under the 150A output state, the cable temperature is normal, the wiring connections are not loose, and the parameters displayed on the control panel are stable.

Key Precautions

I. Core Safety Operation Precautions

Electric Shock and Back-Feeding Prevention

• Before installation/maintenance, cut off all power supplies (including the starting battery) and hang a "No Switching On" sign to avoid electric shock caused by misoperation. Wear insulating gloves and use insulated tools during electrical connections.

• The bidirectional switch (for back-feeding prevention) must comply with national electrical standards (e.g., GB 14048.3) and be verified as qualified by the power supply department. It is strictly prohibited to omit or use unqualified switches, as this may cause conflicts between the power grid and generator power, leading to equipment burnout or personal injury/death.

• The generator's grounding bolt must be reliably connected to the grounding wire (grounding resistance ≤ 4Ω). Terminal blocks U/V/W/N must be clearly marked, and the cable cross-sectional area shall not be less than 16mm² (suitable for 150A current) to prevent overheating due to overload.

Mechanical Injury and Fire Risk Prevention

• Use special tools (e.g., torque wrench) during unit docking and bolt tightening. It is strictly prohibited to touch rotating components (couplings, flywheels, etc.) with hands, and protective barriers must be installed around the installation area.

• The exhaust pipe operates at extremely high temperatures (up to 600℃ or higher during operation) and must be wrapped with high-temperature resistant thermal insulation materials (e.g., ceramic fiber cloth). Keep it away from flammable substances such as fuel pipelines and cables. The machine room must be equipped with dry powder fire extinguishers (suitable for electrical/oil fires), and storage of flammable and explosive materials is strictly prohibited.

• Use genuine Cummins seals (e.g., special sealing rings for PT fuel systems) when connecting fuel pipelines to avoid leakage caused by ordinary gaskets. Conduct a pressure test after installation (fuel system pressure ≥ 0.3MPa, maintaining no leakage for 5 minutes).

1. References：

2. Official Maintenance and Parts Documents for Cummins Series

3. Specialized Maintenance Manual for ISBE Models

4. Refer to the Cummins ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines Service Repair Workshop Manual. This manual contains assembly details for core components of ISBE models, including mechanical connections, fuel systems, and cooling systems. Requirements such as fuel line sealing and exhaust pipe connection are consistent with the assembly specifications for engine-generator adaptation outlined in this manual.

5. Cummins Maintenance Manual (Publication No. 3801403)

6. This is a general maintenance manual developed by Cummins for multiple diesel engine models compatible with generators. The compatibility requirements mentioned earlier—such as flange matching and coupling selection between ISLe340/ISBE engines and generators—are all based on the core technical parameters for engine-generator docking specified in this manual.

7. Cummins Parts Catalog (Section 3020)

8. This section clearly defines the specifications of generator accessories for ISLe340 and ISBE models, including the number of pins for compatible flexible couplings and the dimensions of base shims. It serves as the core basis for the earlier emphasis on "strictly prohibiting the mixing of non-specialized accessories."

9. National Standard GB/T 2820-2019

10. This is a universal industry standard for reciprocating internal combustion engine-driven alternating current generators, specifying general requirements for generator set installation foundations, vibration control, and electrical connections. The previously mentioned requirements—such as anchor bolt fixing methods, grounding resistance ≤ 4Ω, and cable insulation protection—all comply with the specifications for unit installation and electrical safety in this standard.

11. Assembly and Machine Room Specifications of Cummins-Authorized Enterprises

12. Refer to the Diesel Generator Set Production Standards and Assembly Specifications issued by Cummins Power (Shenzhen) Co., Ltd. Installation details such as machine room ventilation requirements, thermal insulation wrapping for exhaust pipes, and flexible pipeline connections to offset vibration—including "exhaust pipes inclined downward by 5-10° to prevent rainwater backflow" and "4-point support for unit base frames"—are derived from the assembly requirements for industrial and civil diesel generator sets outlined in this specification.

13. General Maintenance Manual for Cummins Generator Sets

14. Maintenance cycle requirements mentioned earlier—such as "replacing generator bearing grease every 200 operating hours" and "testing stator winding insulation resistance every 1000 operating hours"—as well as operational specifications (e.g., checking cooling water level and fuel volume before startup, and operating under no-load for 3-5 minutes before shutdown) are all based on the general guidelines for daily maintenance and safe operation of generator sets in such manuals.

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