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ADVANCED RESEARCH CENTER INTERNATIONAL ELECTRICAL

DEPARTMENT
FOR POWDER MATALLURGY AND NEW MATERIALS

PROCEDURE FOR THE MAINTENANCE


OF
DG SETS

SL.NO. ITEMS TO BE INSPECTED/ACTION FREQUENCY

1. Depending upon the individual site conditions frequent maintenance


should be practiced. Before carrying out any maintenance work the
generator should be stopped and isolated electrically from all external
loads or supplies.

GENERAL CLEANING
-Both interior and exterior of the machine (particularly the windings,
bearing, ventilation openings, static exciter, etc) should be kept free
from any oil or dut by blowing out frequently with clean dry air at a
Quarterly
2. pressure not exceeding out frequently with clean dry air at a pressure
not exceeding 3.5kg/cms2. if the blowing is ineffective to remove oil or
dust, the parts should be carefully cleaned with a rag lightly damped in
with spirit.

Cooling system
3. - Change crankcase breather Halfyearly
- Clean Water air cleaner element

Air intake system


4 - Clean crankcase breather Halfyearly
- Or change air cleaner element

Fuel System
5 - Drain sediments from tanks Halfyearly
- Change fuel filters
- Change float tank breather
Electrical System
- Check Battery charging system
6 - Battery electrolyte level & specific gravity Halfyearly
- Safety control & alarms

Main Generator
- Check air inlet & outlet for restriction
7. - Winding and electrical connection Halfyearly
- Apply grease over the bearing
- Check winding resistance

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ADVANCED RESEARCH CENTER INTERNATIONAL ELECTRICAL
DEPARTMENT
FOR POWDER MATALLURGY AND NEW MATERIALS

PROCEDURE FOR THE MAINTENANCE


OF
DG SETS

SL.NO. ITEMS TO BE INSPECTED/ACTION FREQUENCY

CONNECTIONS:
All the external and internal connections (including rotating rectifier
8 assembly and GCU) must be checked for tightness at joints and Halfyearly
continuity. Fuse links should make a good fit in the holders. All the
hardware, including those of terminals, should be tightened if
necessary.

LOSS OF RESISUAL
If the generator is completely lost because of long storage or
9 demagnetizing due to any male operation, it will be necessary to Halfyearly
disconnect the excittor field terminals at the GCU and connect a 12
Volts car battery directly across the field (with correct polarity) for a
few seconds, to re-establish the residual.

ROTATING RECTIFIER ASSEMBLY


The health condition of the diodes can be checked when required as
followed.
1. The pigtail terminal of each diode is disconnected.
2. Using as Ohmmeter with at lest 1.5 Volts source (e.g. AVO
meter mark-8, Simpson 200) on the appropriate range (say
10 ohms XI) the resistance of the diode between stud and pigtail Halfyearly
in both directions is measured.
Diodes in good condition will show a low (up to a few
hundred ohms) resistance in the forward direction and a very
high resistance (up to 1 meghaohm) in the reverse direction
high resistance in both the direction or a low resistance in
both directions indicates a faulty diode which should be
replaced. Failure of surge suppressor Can be detected by
smell and appearance. Failure of fuses (When Can be
detected by smell and appearance. Failure of fuses (When
provided) can be detected by checking its continuity using an
AVO meter.

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ADVANCED RESEARCH CENTER INTERNATIONAL ELECTRICAL
DEPARTMENT
FOR POWDER MATALLURGY AND NEW MATERIALS

PROCEDURE FOR THE MAINTENANCE


OF
DG SETS

SL.NO. ITEMS TO BE INSPECTED/ACTION FREQUENCY

GENERATOR CONTROL UNIT:-


The details given in G.C.U. user handbook may be refered to
BEARINGS: -
The roller bearing or ball bearing will run for long periods without
any attention as the bearing housing is charged without any attention
as the bearing housing is charged with the right quantity and quality
of grease before dispatch. The bearings are to be relubricated with
correct quantity of grease in the interval stated on the nameplate of
the generator, in order to replenish any grease lost during running.
Lithium base grease conforming to grade 3 of IS: 1002 1956 is
recommended. The lubricants spherol AP3 (castrol) and Mobilube
11. No.3 (Indian Oil) are equivalents for the above. If the grease is Halfyearly
caked before commissioning it has to be completely replaced.
Grease of different makes and grades should not be mixed.
The original grease should not be removed, unless it has become
dirty, deteriorated or caked. Unnecessary disturbance of
the bearing cap should be avoided.
Where disturbance is necessary, great care must be exercised when
handling the bearing and cover to avoid the ingress of
dirty or moisture into the grease on the bearing. when the
machine has to be stationary for a long period the rotor
should be turned periodically to avoid setting of grease at
the bottom of the housing.

REMOVAL AND REPLACEMENT:


REPLACEMENT OF EXITER COVER
Remove ventilation grids and exciter cover: -
The rectifier assembly can be removing the exciter cover. The faulty
12 diode can be removed from the sink after removing the nut at the Halfyearly
back of the diode stud and disconnecting the pigtail from its
terminal. The heat sink is cleaned well the diode mounting area and
a coating of silicone grease (eg AFCO heat sink from its terminal.
The heat sink is cleaned well the diode mounting area and a coating
of silicone grease (eg AFCO heat sink compound) is applied on the
diode-mounting surface. The diode of correct polarity is mounted
such that the diode base mounts directly on the heat sink without
any intervening washers or spacers. The diode must be tighten
against the heat sink with a torque wrench to a torque of 0.9 Kg.m.
Care should be taken not to stress its glass sealer or the pin to which
the pigtail is attached.Pigtail connection is made to respective
terminal.

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ADVANCED RESEARCH CENTER INTERNATIONAL ELECTRICAL
DEPARTMENT
FOR POWDER MATALLURGY AND NEW MATERIALS

PROCEDURE FOR THE MAINTENANCE


OF
DG SETS

SL.NO. ITEMS TO BE INSPECTED/ACTION FREQUENCY

MAINTENANCE SCHDULE

CUMMIN DIESEL ENGINE

A-CHECK
Lubrication
Check engine oil level
Check oil bath cleaner oil level

FUEL SYSTEM

Drain sediment from fuel tanks


13. Daily/weekly

AIR SYSTEM

Clean pre-cleaner dust pan


Check air cleaner restriction
Clean/change air cleaner element
Check oil bath cleaner oil

COOLING SYSTEM

Check coolant level

OTHER MAINTENANCE

Drain air tank Check leaks correct


Drain water separator daily.

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ADVANCED RESEARCH CENTER INTERNATIONAL ELECTRICAL
DEPARTMENT
FOR POWDER MATALLURGY AND NEW MATERIALS

PROCEDURE FOR THE MAINTENANCE


OF
DG SETS

SL.NO. ITEMS TO BE INSPECTED/ACTION FREQUENCY

B-CHECK

REPEAT A

LUBRICATION
Change engine oil
Change engine full flow oil filter
Change turbo lub filter
Change BY-pass filter
Record oil pressure

FULL SYSTEM
Check aneroid oil
14. Check hyd.gov.oil Halfyearly
Check throttle linkage (Every 250 Hrs)
Change fuel filter
Clean fuel tank breather

AIR SYSTEM
Clean change crankcase breather
Check air piping
Clean air piping
Clean oil both air
Cleaner tray screen

COOLING SYSTEM
Change water filter/water softener
Check adjust belts

NOTE
Turbo filter should be changed when low lub oil pressures which
trips the engine due to choked turbo filter.

Page 5 of 8
ADVANCED RESEARCH CENTER INTERNATIONAL ELECTRICAL
DEPARTMENT
FOR POWDER MATALLURGY AND NEW MATERIALS

PROCEDURE FOR THE MAINTENANCE


OF
DG SETS

SL.NO. ITEMS TO BE INSPECTED/ACTION FREQUENCY

C-CHECK
Repeat A and B

LUBRICATION
None

FUEL SYSTEM

Adjust injectiors and valves


Change Hyd.governer oil
Check aneroid adustment
Replace aneroid breather

AIR SYSTEM
15. Annualy
Clean oil bath (Every 5000Hrs)
Air cleaner

COOLING SYSTEM

Clean radiator external


Check fan hub idler and water pump

OTHER MAINTENANCE

Inspect units replace as


required(Alternator/Generator, Starter etc.)
Check air compressor
Check vibration damper
Check water pump idler
Clean/change magnetic screen

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ADVANCED RESEARCH CENTER INTERNATIONAL ELECTRICAL
DEPARTMENT
FOR POWDER MATALLURGY AND NEW MATERIALS

PROCEDURE FOR THE MAINTENANCE


OF
DG SETS

SL.NO. ITEMS TO BE INSPECTED/ACTION FREQUENCY

D-CHECK

Repeat A, B&C

LUBRICATION
None

FUEL SYSTEM

Clean and calibrate injectiors.


Replace fuel pump filter screen and maganetic.
Check fuel pump calibration.
Replace aneroid bellows and calibrate.
16. 2Years
(Every 5000Hrs.)
AIR SYSTEM

Clean terbocharger comprssor wheel and diffuser.


Check turbocharger-bearing clearance.
Tighten manifold nut or capscrews.

COOLING SYSTEM

Change coolent.
Descale cooling system.

OTHER MAINTENANCE

Check vibration damper

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ADVANCED RESEARCH CENTER INTERNATIONAL ELECTRICAL
DEPARTMENT
FOR POWDER MATALLURGY AND NEW MATERIALS

PROCEDURE FOR THE MAINTENANCE


OF
DG SETS

SL.NO. ITEMS TO BE INSPECTED/ACTION FREQUENCY

E-CHECK

Repeat A, B, C and D
This maintenance check is often referred to as in frame inspection 4 Years
17. where some key parts such as bearings, are checked for (Every 8000Hrs.)
wear to determine if the engine may be operated for
another service period, like wise oil consumption, oil
pressure and other signs of wear should be analysed
during the check wear limits and other information is
available from Kriloskar Cummins distributor and
dealers.

SEASONAL

Replace hose as required.


Clean electric connection.
Check cold start aid.
18 Check thermal control.
Check heat exchanger zink plugs
Check crankshafts end clearance.
Tighten mounting bolts and nuts.
Steam clean engine.
Check fan and driver pulley mounting.

The major engine overhaul for all engine series is estimated at


three E-check or 25000 hours whichever is earlier. However this
major overhaul period will largely depend upon the condition of
critical components revealed during every e-check.

1. Any time cooling system is completely drained or flushed


check coolant using coolant-checking kit.
2. Under extremely dusty condition perform at more
frequent intervals.

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