Preventative Maintenance

Introduction

Scheduled planned maintenance programs are the most effective process for ensuring a generator system
is maintained fully operational and ready to start and take its load when primary power is off-line for any
planned or unplanned reason.

The diesel engine generator is the most commonly used prime mover in standby power generators. This
information sheet details the routine preventative maintenance to ensure high reliability

Principal reasons for preventative maintenance programs

Reliability - Diesel power systems provide standby power to many critical applications including
hospitals, airports, military installations, telecommunications, nuclear plants, data systems and others.

Performance - Preventative maintenance greatly reduces the risk that an internal or ancillary component
malfunction will cause the generator to produce insufficient power. By identifying problems before
generator power is needed, users can schedule backup power while the primary standby unit is being
serviced.
Safety - Component failure presents risks both to personnel on site and to those relying on the output of
the generator set. Preventative maintenance programs are designed to detect normal life-cycle
deterioration of components within the system and replace those components before they fail.

Economics - Early detection of internal or external problems enables the correction of those problems
before a failure occurs. This yields significant savings through shorter down times and lower repair costs.
It can prevent larger economic losses that would occur if a standby system failed to come online when
needed.
 REGULAR MAINTENANCE IN DETAILS

A. DAILY CHECK:-

1. Check engine oil level, top up if necessary.

2. Drain water and sediments accumulated at the bottom of fuel tank before starting the engine.

3. Fill up the fuel tank at the end of each working day.

4. Remove dust accumulated in the dry type in filter bowl, through vacuator valve.

5. Check coolant in the radiator, top up if required.

B.AFTER 50 HRS
1. Check engine oil level, top up if necessary.

2. Drain water and sediments accumulated at the bottom of fuel tank before starting the engine.

3. Fill up the fuel tank at the end of each working day.

4. Remove dust accumulated in the dry type in filter bowl, through vacuator valve.

5. Check coolant in the radiator, top up if required.

6. In very dusty condition, clean the bowl of dry type air cleaner and if necessary change the element.

7. Check ‘V’ belt tension and adjust if required.

8. Check electrolyte level in battery.

9. Check the cable connection at starter, battery, dynamo/alternator and control panel.

C.AFTER 300 HRS

1. Check engine oil.

2. Clean centrifugal filter.

3. Drain sediments and water accumulated at the bottom of fuel filter bowls.

4. Clean the filter and sieve with clean diesel, fitted on feed pump inlet.

5. Check tightness of fine drive pulley.

6. Replace pre-filter and micro filter insert first at 200 hrs to 250 hrs.

7. Check and tightness of the drive belt after every 300 hrs.

D. AFTER 600 HRS

1. Check engine oil level, top up if necessary.

2. Drain water and sediments accumulated at the bottom of fuel tank before starting the engine.

3. Fill up the fuel tank at the end of each working day.

4. Remove dust accumulated in the dry type in filter bowl, through vacuator valve.

5. Check coolant in the radiator, top up if required.

6. In very dusty condition, clean the bowl of dry type air cleaner and if necessary change the element.
7. Check V belt tension and adjust if required.

8. Check electrolyte level in battery.

9. Check the cable connection at starter, battery, dynamo/alternator and control panel.

10. Clean centrifugal filter.

11. Drain sediments and water accumulated at the bottom of fuel filter bowls.

12. Clean the filter and sieve with clean diesel, fitted on feed pump inlet.

13. Check tightness of fine drive pulley.

14. Replace pre-filter and micro filter insert first at 200 hrs to 250 hrs.

15. Check and tightness of the drive belt after every 300 hrs.

16. Change main oil filter.

17. Replace the pre-filter insert of fuel filter.

18. Change air cleaner element.

19. Check valve tappet clearance, adjust if required.

20. Grease fan drive pedestal.

Items covered by generator preventative maintenance programs

Fuel Systems -Diesel fuel degrades over time and is susceptible to contamination. The fuel, pipes, filters
and injection equipment are key items to check in any preventive maintenance program.

Batteries - Inadequate battery maintenance and neglecting to monitor the condition of the battery charger
and starter motor are among the most common reasons generator sets fail.

Coolant - Leaking coolant or a poor coolant mixture can lead to overheating of the system.

Filters - Filters are used to avoid contamination of a system that can lead to failure and reduced
performance. PM programs will ensure air, fuel and oil filters are inspected and changed when required.

Contacts - Switch contacts in the electrical control systems must be regularly checked. Poor contacts
generate excessive heat and carbon deposits that ultimately cause the contact to fail.
Connections - Technicians performing preventative maintenance should verify that radiator hoses and
other fuel or electrical connections are working properly and not leaking.

Corrosion - Preventative maintenance schedules call for specific checks for corrosion of wiring, piping,
fixtures, ancillaries and other components exposed to the elements.

Mechanical - Any mechanical system is subject to wear and a reduction in structural integrity due to
load, vibration and other causes. Preventative maintenance technicians check known vulnerable
components, such as belts, for tightness or wear. They also verify that all fittings are tightened to the right
torque settings and not showing signs of excessive wear or stress.

Always turn battery chargers off, disconnect negative battery cables and be sure that the Auto-Manual-
Off switch on a systems’ control panel is in the ‘Off’ position before doing any maintenance work.
Afterward, run the generator set at its rated load for at least two hours.

DO’s AND DON’Ts

Do’s:

1. First study the operator s and technical manual before handling or operating the power plant.

2. Ensure good ventilation around the power plant.

3. Ensure all protective guards and covers are securely in place before starting the DG sets.

4. Ensure proper and effective earthing or DG set and control panel frames.

5. Be attentive to any unusual sound from a running DG set and find out the cause of such sound.

6. Apply or remove load a gradual manner.

7. Use only proper tool and testers while carrying out repair and maintenance.

8. Ensure all filter elements/ strainers are replaced cleaned at recommended intervals.

9. Use only genuine parts.

10 Carry out frequent and regular monitoring of all meters indicators while the power plant is running.

11. Clean the centrifugal cleaner at every 250 hrs or at the time of oil changing.

12. Daily check the condition of rubber hoses and hose clip before starting the engine.

Damage hoses / clip must be replaced immediately.

DON’Ts

1. Don’t Operate the DG set with any parts of the protective guards or covers removed or loose.

2. Don’t switch on load immediately after starting the sets. Allow at least five minutes of no load running.

3. Don’t stop the engine immediately after switching off the load allow at least 10 minutes of ‘No load
running.

4. Don’t bring a naked flame near the battery while it is on charge.

5. Don’t run the DG set without load for long periods.

6. Don’t load the set beyond its capacity.

7. Don’t turn off the fuel supply to stop the engine.

8. Don’t try to carry out any repairs while the set is running.

9. Don’t allow untrained persons to operate the power plant.

10. Never try to clean and re-use the old filter inserts.

11. Don’t tamper with FIP, concern authorize dealer if any trouble.

TROUBLESHOOTING GENSETS
GENSET

No. PROBLEM CHECK & ACTION TO BE TAKEN

1 Engine does not CRANK Batteries are very weak. Check whether start relay operates.
when start PB is pressed.
Use properly charged batteries
OR Fault in starter motor
The engine doesn't start but Air lock in fuel system.
cranks. Restriction in a fuel pipe.
Before engine starting ensure that load switch (MCCB) is off.
2 High water temperature Temp. switch end wire may be on body earth. Temp. switch may be
Indication lights and engine faulty. Actual water temp. may be high. No water in radiator. Water
stops. circulation system may be faulty.

3 Charge fail indication 'ON' Check if 'IND' terminal is connected properly. Check the wiring. Check
alternator is developing voltage or not.

4 Engine fires and stops after Lop Switch end wire is not working properly. Actual Lub oil pressure is
sometime and LOP not developed. Pressures switch connecting wrong. Wiring is not
indication lights. correct. No oil in engine. Lub oil pipe not connected to gauge.

5 Engine over speed indication Check genset supply to control unit. Check engine rpm. Check for loose
(Frequency based) connections.

6 Low Fuel level Check fuel level in day tank and fill as required.

Ensure Fuel Transfer pump (if fitted) is operating as described in the

User manual.
7 Over volts Disconnect generators from load and restart.

Check voltage on panel meters. If voltage is normal ensure that the load
is non capacitive (power factor correction equipment may lead to a
capacitive load).
If voltage remains high and cannot be adjusted to the normal level refer
to the alternator section in the User manual.

BATTERIES
No. SYMPTOM POSSIBLE FAULT ACTION
1 No charging Incorrect or bad battery connections. Check connections and clean
current terminals.
No mains supply Check mains supply to charger.
2 Charging rate Low mains voltage Check mains voltage supply.
too low
Loose heavy current connections Check and tighten connection if
necessary.

ENGINE
No. TROUBLE CAUSE REDRESS
1 Engine does not start. No fuel in tank. Fill in fuel, vent fuel system.
Air in fuel system. Vent fuel system.
In sufficient speed of starter. Charger batteries.
 2 Engine starts up but Fuel tank cock closed.
stop after brief time. Dirt in primary fuel cleaner or
in fuel filter.
No fuel in tank, no conveyance
of fuel.
Water or dirt in fuel system.
3 No power and Interruptions of air supply or
misfiring of engine. heavy jamming of air filter.
Air in fuel system.
Fuel filter jammed.
Starts of fuel supply missed.
Defect of exhaust brake.
4 Engine grows Slipping of V-belts / V-belts
excessively hot. broken.
Defect of temperature
governor.
Defect of temperature
controller.
Lack of coolant.
Radiator is dirty.
Mis-setting of fuel supply.
Intake or exhaust system
jammed.
Heavy dirt accumulation on
cylinder elements.
5 Irregular speed of Defect of speed governor.
engine.
SYSTEM TROUBLESHOOTING
No. STEP NORMAL READING
TERMINALS
1 E (+) & F (-) Battery Supply Voltage 12 or 1. DC battery power not connected. Check for
24V DC
2 A (+) & B (-) 0-3.9 with speed trim
7.1-7.9 without speed trim
Open cock.
Clean or change filter cartridge
respectively.
Fill in fuel, vent fuel system, inspect
correct operation of fuel pump,
replace if necessary, and check safe
venting of tank.
Clean fuel tank, fill in clean fuel,
replace filter, and vent fuel system.
Inspect, replace if necessary, or clean.
Vent fuel system.
Change filter.
Reset start of fuel supply.
Inspect and repair.
Tighten or replace V-belts.
Emergency operation; forced opening
of valve plate.
Perform electrical check of
temperature controller.
Fill in coolant.
Clean radiator.
Set correct engine in fuel supply.
Redress cause of trouble.
Consult workshop.
Inspect fuel injection pump and
governor.
PROBABLE CAUSE OF
ABNORMAL READING
blown fuse.
2. Low battery voltage.
3. Wiring error.
1. Speed trim shorter or mis-wired.
2. Defective unit.
 BRUSHLESS ALTERNATORS

No. FAULT CAUSE REPAIR

1 No voltage build - Insufficient residual voltage Excite the rotor using a battery.
up
Improper connection Correct the connection.

Low speed Reset the speed to the nominal.

Faulty Winding Check the winding resistance and rewind if

required.

Rotating rectifier failure Replace the rotating rectifier.

Faulty AVR Replace the AVR.

2 Voltage Incorrect AVR setting Set the AVR stability pot.

oscillations
Thyristor load more than Reduce the Thyristor load.
specified limits

Insufficient engine flywheel

3 Unbalanced Unbalanced load Correct the load.

Voltage
Loose connections Tighten the loose connections.

Stator winding faulty Check winding resistance & rewind if

required.