After Good operation, Maintenance is one key to

diesel generator set reliability

Customer’s Training or instruction for Good Operation:
1. Cleanliness is very important; always keep the Gen set and surrounding area
clean.
2. Before start up checks should be made in which oil level, coolant level and fuel
level.
3. Start the Gen set, check for any un-usual noises and leaks, monitor & record the
parameter like Oil pressure, water temperature, RPM and voltages output.
4. Put the load gradually after having the Water temperature around 35°C
5. Load (amps) should be balanced on all three phases and run the set >35% up to
80% of Gen set capacity keeping in view of altitude and local ambient
temperature tendency.
6. Log Sheet should be maintained for recording the above-mentioned parameters
or as per any of specific application.
7. At the time switching off, always switched off the load first and run the Gen set
for at least 5minutes to cool down the Engine temperatures.
8. Always operate the Gen set via its controller given start/stop button or switches
instead of Emergency push button because it’s built for only in emergency cases.
9. In case of non-availability of static battery charger, always exercised twice in
week for 15mintues to keep the Batteries healthy.

Maintenance instructions for Operators:

1. Daily, Weekly & Monthly checks should be performed and recorded via log book.
2. First Maintenance will be performed after 50hours or one month after initial
startup or commissioning.
3. Next Maintenance will be performed after every 250hours or 6months as per
Engine family via manufacturer recommendation.
4. Maintenance should be done via qualified or trained technician.

Preventive maintenance
Because of the durability of diesel engines, most maintenance is preventive in nature.

Preventive diesel engine maintenance consists of the following operations:

A. General inspection
B. Lubrication Service
C. Cooling system Service
D. Fuel system Service
E. Air Intake System Service
F. Servicing and testing starting batteries

It is generally a good idea to establish and adhere to a schedule of maintenance and service based on
the specific power application and the severity of the environment. For example, if the generator set will
be used frequently or subjected to extreme operating conditions, the recommended service intervals
should be reduced accordingly.

Some of the factors that can affect the maintenance schedule include:
▪ Using the diesel generator set for continuous duty (prime power)
▪ Extreme ambient temperatures
▪ Exposure to weather
▪ Exposure to salt water
▪ Exposure to dust, sand or other airborne contaminates
Maintenance Service time
250Hrs.
1000Hrs
Items Daily Weekly Monthly or 6
or Yearly
months

Inspection /cleaning & house keeping

Check Coolant level *

Check oil level

Check fuel level(diesel)

Check charge air piping (turbo charger)

Check/clean air cleaner

Check static battery charger

Drain water from water separator (if
installed)
Drain Water from fuel tank(in case of day
tank)
Check coolant concentration

Check drive belts

Drain exhaust condensate (if required)

Check starting batteries

Change oil and filter

Change coolant filter

Change air cleaner element

Change fuel filters

Clean crankcase breather

Check radiator hoses

Fan bearing Greasing

Check coolant heater(if installed)

Clean cooling system
Tappet Adjustment

Main Alternator bearing greasing

Safety tests via simulation (if applicable)

A. General inspection When the generator set is running, operators need to be alert for
mechanical problems that could create unsafe or hazardous conditions. Following are several
areas that should be inspected frequently to maintain safe and reliable operation.

Exhaust system: With the generator set operating, inspect the entire exhaust system including
the exhaust manifold, muffler and exhaust pipe. Check for leaks at all connections, welds,
gaskets and joints, and make sure that the exhaust pipes are not heating surrounding areas
excessively. Repair any leaks ASAP.

B. Lubrication Services for Engine: Monitor fluid levels, oil pressure and coolant
temperatures frequently. Most engine problems give an early warning. Look and listen for
changes in engine performance, sound, or appearance that will indicate that service or repair is
needed.
For accurate readings on the engine’s dipstick, shut off the engine and wait approximately 10
minutes to allow the oil in the upper portions of the engine to drain back into the crankcase. Keep
the oil level as near as possible to the “full” mark on the dipstick by adding the same quality and
brand of oil.

Cummins Inc. recommends the use of a high quality, diesel oil such as Valvoline premium blue or
Valvoline premium blue extreme life.

Question: Why Oil consumed?

Yes, normally the engine oil must have consumed sputtering
• To adhesion layer of oil on the cylinder wall,
• Piston rings scraper oil left in the cylinder wall in the high-temperature gas
under some burning With the exhaust together discharge
• There are some oil evaporates and is discharged into the crankcase.
 (Approximately, 5% ~25% or with respect to Engine family & Manufacturer)
C. Cooling system service Check the coolant level during off periods, Remove the
radiator cap after allowing the engine to cool and, if necessary, add coolant until the level is about
3/4-inch below the radiator cap lower sealing surface. Heavy duty diesel engines require a
balanced coolant mixture of water, antifreeze and coolant additives. Use a coolant solution as
recommended by the engine manufacturer. Inspect the exterior of the radiator for obstructions
and remove all dirt or foreign material with a soft brush or cloth. Use care to avoid damaging the
fins. If available, use low pressure compressed air or a stream of water in the opposite direction
of normal air flow to clean the radiator. Check the operation of the coolant heater by verifying that
hot coolant is being discharged from the outlet hose.

By definition we think of cooling system has something that cools but actual has four functions
and must all work cohesiveness for the engine to survive

1. It absorb the unwanted heat generated by the engine

2. Circulate that heat
3. Dissipate the heat
4. Control the heat

Let’s take a moment to talk about all the components that actual make that happened;

1. The heat absorbed by the coolant itself and this means coolant must have good heat
absorbing and heat transferring capabilities. Glycol or Antifreeze mixed with 50/50% with
pure water has much superior heat transferring characteristics, either pure water or pure
glycol.
2. Coolant is continuously circulating with in the cooling system and this function is
performed by water pump. Interestingly enough typical water pump can circulate between
11 to 15000gallons of water /hour and it’s critical that this pump functions flawlessly.
3. Heat is dissipated or radiated and this takes place in radiator. The efficiency and
effectiveness of radiator is critical.
4. Finally, the cooling system controls the heat and this is done by the thermostats, again
imperatively that thermostat operates flawlessly.
 OR
ES Compleat
It is already Mixed as per required
Ratios. (Complete Mixture)
✓ A good coolant has properties that inhabit things like liner
pitting, reduce or eliminates scale or corrosion which can affect
things like radiator, water pumps and thermostat.
✓ A good coolant also contains many other additives that protect
specific engine component based on their design and type of
metal.

REAL™ Performance

• Lifetime coolant with service interval at 150,000 mi, 250 km, 4000 hrs.
• Provides antifreeze and antiboil protection
• Best liner pitting and corrosion protection
• Best aluminum and solder protection
• Compatible with gaskets, elastomers and other non-metallic in the engine
• Optimizes cooling system performance and water pump life
• Contains proprietary scale inhibitors

Coolant Testing
Field Maintenance Tools for Engine Coolants

Quik-Chek™ Coolant Quality Test Strips

With proper maintenance, Fleetguard ES Compleat™

coolant can last for the major overhaul life of the
engine. However, when poor quality make-up water is
added to the system or when minimum coolant
maintenance is not observed, pH levels can rise or fall
to dangerous levels and contaminants (Sulfate and
Chloride) can rise to unacceptable levels. When this
occurs, coolants must be drained and replaced
immediately. To help customers determine the quality
of their coolants, Fleetguard has developed
revolutionary Quik-Chek™ Coolant Quality Test Strips.
In a matter of minutes the pH, Sulfate and Chloride levels in a coolant can be
determined. If results fall within acceptable limits, the coolant can be used until the
next service interval with confidence. The Quik-Chek™ Coolant Quality Test Strips
are available in bottles of 10 test strips (CC2718).
Fuel system service with the generator set operating; inspect the fuel supply lines,
return lines, filters and fittings for cracks or abrasions. Make sure the lines are not
rubbing against anything that could cause an eventual breakage. Repair any leaks or
alter line routing to eliminate wear immediately.

Diesel fuel is subject to contamination and deterioration over time, and one
reason for regular generator set exercise is to use up stored fuel over the course
of a year before it degrades. In additional to other fuel system service
recommended by the engine manufacturer, the fuel filters should be drained at
the interval. Water vapor accumulates and condenses in the fuel tank and must
also be periodically drained from the tank along with any sediment present.

Don't Compromise on

➢ Quality of Fuel
➢ Cleaning of base tank & bulk storage tanks.
➢ Additional Water separators(filter) installation
➢ Periodic replacement of Fuel Filter its replacement also relates to
the quality of fuel
Today we like to draw your attention to the reasons of early clogging of Fuel filter which
is not the fuel filter quality issue but the contaminated fuel. Contaminated particles as
small as 4microns which is 12 times smaller than human hair and these Particles
invisibles to the human eye, can premature wear fuel injector, is not only decreased
engine performance and higher fuel consumption but could also lead to costly damage
and down time.

Today diesel engines operator are facing many fuel related challenges and first, which
is fuel quality.
Worldwide fuel chartered has stated that 50% of the diesel fuel dispensed around the
world, does not meet the international standard organization or ISO code for
cleanliness. Add to the fact that fleets (off & on highway) are challenged with fuel that is
transported, loaded & offloaded several times and its delivery to the actual equipment
fuel tank, each time adding to the possibility of contaminations.
Therefore, today challenge are:
▪ Fuel quality & cleanliness
▪ Fuel delivery & transfer
▪ Filter loading (filter actual loses efficiency overtime)
▪ Fuel pressure surges
▪ Filter vibration

This is not a good combination for the engine therefore to overcome the situation,
Cummins recommends to install the additional Water separator between fuel tank and
engine. Please go through an article and at least solution.
Longer Life, Reduced Costs
All fuel filtration systems are engineered with precision to MEET customer demands for
longer life and improved performance. Fuel filters using proprietary StrataPore® multi-
layered media offer superior micron efficiencies, removing large particles, as well as the
smallest debris. Each StrataPore layer offers unique properties to extend fuel filter life and
improve performance.

The Most Technologically Advanced Fuel Filtration Systems

As the industry leader, Cummins Filtration has always remained a step ahead of market
needs by introducing innovative fuel filtration systems. Recent technological advances
include:

• Fleetguard Fuel Filters featuring NanoNet® Advanced Filtration Media

With extensive field-testing over a three-year development cycle, NanoNet advanced
filtration media is the latest in the Fleetguard fuel product lineup. Engineered to deliver
unmatched protection and superior uptime for customers using revolutionary manufacturing
technology, NanoNet media is a major leap FORWARD over competitive media in several
ways. The first of its kind for fuel filtration, NanoNet has the capability for increased
filtration efficiency while also extending filter life beyond the capacities of conventional
premium fuel filter media available on the commercial market today. Trapping 98.7 percent
of all particles as small as 4 microns (12 times smaller than the smallest particle visible to
the human eye) means that NanoNet is ten times more effective at hard particle removal
than the next best competitive product—Fleetguard’s own StrataPore media.
• Fuel Pro®, Diesel Pro® & Industrial Pro™ Remote Mount Diesel Fuel Filtration
System
Cummins Filtration's unique "Seeing is Believing®" filter clear cover technology lets you see
the fuel filter and shows when the filter needs changing. Fuel level is low on a new filter and
as it is used the fuel level rises to show how much filter life remains. You know when NOT to
change your Fuel Pro® filter, Diesel Pro® filter, and Industrial Pro™ filter thus reducing
filtration costs, reducing maintenance costs, and much more. They can be used with
conventional Diesel fuel, JP-5, JP-8, and Jet-A fuel. Available SINGLE housing units are
rated for fuel flows up to 200 GPH (757 LPH), 180 GPH (681 LPH), 90 GPH (341 LPH), and
60 GPH (230 LPH) providing best-in-class filtration and fuel/water separation.

FH239 Series Industrial PRO® ALL in One Fuel/Water Separator

With NanoNet ™
With the best fuel processor available today to protect your valuable equipment.
Caution: Don’t fill diesel in base tanks while the Gen set or engine in
operation; it can mix all the sediments and water which can create wear & tear in
fuel pump, nozzles/injectors and symptom can be low frequency, low power or
early chocking of fuel filters. Therefore base tank or storage day tank should be
cleaned once in two year. Can be varied as per diesel quality

These contaminations can be from the supplier, means like dirty drums, buckets
or by diesel handler.
D. Air Intake System:

The charge-air piping and hoses should be inspected daily for leaks, holes, cracks or loose
connections. Tighten the hose clamps as necessary. Also, inspect the charge-air cooler for dirt and
debris that may be blocking the fins. Check for cracks, holes or other damage.
The engine air intake components should be checked. The frequency of cleaning or replacing air
cleaner filter elements is primarily determined by the conditions in which the generator set operates.
Air cleaners typically contain a paper cartridge filter element which can be cleaned and reused if not
damaged.
Cleaning of Air filter Element with pressure Air is strictly prohibited.

For every gallon of fuel the typical diesel engine burns, it’s require about 1500gallons of air and that is
Clean Air.

Following are the air filter servicing guidelines will go long way to ensuring long engine life.

➢ Ensure correct replacement air filter on hand before starting.

➢ Remove the dirty air filter carefully to prevent trapped dirt from being dislodged and probability
entering the air intake housing.
➢ Thoroughly clean the air filter housing and components with damp rag and or a vacuum cleaner if
available. Make sure the seal or gasket contact surfaces are clean.
➢ Have the new replacement filter nearby to replace quickly, shorting the time to open air cleaner is
exposed to the environment. Ensure the Gasket of air filter sealing the housing properly.
 ➢ Check for contact 100% of the gasket area, Appling a small amount of grease to the Gasket,
installing the filter and properly fastening all covers and then removing to inspect for square fit
can accomplish this.
➢ When the old filter has been removed, inspect it for uneven dirt pattern that are indicators of dust
leakage or sealing problems.
➢ Inspect all air system, duck works, especially between air filter and the engine. Insure that all
clamps and connections are tight and all piping is free of cracks and holes.
➢ Always replace the air filter with correct part number cross. Air filter element is shorter by a
fraction of an inch may make a positive and seal impossible and allow dirt into the engine.
➢ Use restriction indicator to term, when to change the air filter element. Otherwise change it at the
time of routine maintenance at 250~500hours of operation. Never open air cleaner just to look,
don’t take chances and risk contamination the engine for frequent useless inspection.

Special note: Cummins Engine manufacturer & filtration discourage to clean the filter with pressurized Air
or any other means due to inadequate and incomplete process, non-availability of effective quality
measure to make sure filter is free of holes and leaks in both media and Gasket area.

E. Servicing and testing of Starting batteries

Weak or undercharged starting batteries are the most common cause of standby power system
failures. Even when kept fully charged and maintained, lead-acid starting batteries are subject to
deterioration over time and must be periodically replaced when they no longer hold a proper charge.
Only a regular schedule of inspection and testing under load can prevent generator starting problems.

• Cleaning batteries: Keep the batteries clean by wiping them with a damp cloth whenever dirt
appears excessive. If corrosion is present around the terminals, remove the battery cables and
wash the terminals with a solution of baking soda and water (1/4-pound baking soda to one quart
of water). Be careful to prevent the solution from entering the battery cells, and flush the batteries
with clean water when done. After replacing the connections, coat the terminals with a light
application of petroleum jelly.

• Checking specific gravity: Use a battery hydrometer to check the specific gravity of the
electrolyte in each battery cell. A fully charged battery will have a specific gravity of 1.260. Charge
the battery if the specific gravity reading is below 1.215.

• Checking electrolyte level: Check the level of the electrolyte in the batteries at least every 200
hours of operation. If low, fill the battery cells to the bottom of the filler neck with distilled water.

• Recommended Method of Removal/Installation of Batteries: before removal always push the

emergency push button than remove or install the Batteries, at the time of removal always
remove the negative cable from Battery than positive cable. At the time of installation, always put
the positive cable than the negative cable.

Note: These are General Instruction and for any of specific Maintenance, please consult relative
Operation & Maintenance Manual