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The Maintenance Manual of Cummins(8)

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11. Standards for Genset Technical Maintenance
Genset technical maintenance is periodically to examine, to regulate and to wash---- the genset accessories systematically and carefully, so that we can supply it necessary good operation conditions for gensets, prevent from wearing and tearing earlier and from various accidents happening and accordingly bring the diesel genset into play effectively and economically. Therefore in the appliance of the diesel genset, realistic plan and maintenance regulations must be established so that we can perform better in various work of maintenance.
A. Daily Safeguard:
1. Examine the oil level of the crankcase. If it is inadequate, please add oil to it.
2. Examine if there‟s leakage among the oil pump, water pump, filters and each joint. Remove it if any leakage is found.
3. Examine if the fuel in the fuel tank is adequate. If not, add fuel to the tank in time.
4. Examine the genset pedestal and check the tightness degree of the connecting bolts.
5. Examine if each joint of the instrument meters is loose or if the indicators return to the zero point.
6. Examine if the operation structures are nimble, accurate and reliable.
7. Examine the tightness degree of the triangle transmission belt. If not available, regulate it in time.
8. Keep the generator room clean and tidy.
B. First Class Maintenance for Diesel Genset:
1. Regularly clean and wash the generator room, get rid of the oil track, water track and dust on the surface of genset parts, keep them clean and tidy.
2. Examine and regulate the leakage between the air entry and air-vent.
3. Add lubricate oil to the oil filler points and the lubricate parts.
4. Examine the “four leakages” (leakages of oil, water, gas and electricity) and remove each of them.
5. Examine the tightness degree of the transmission belt of the charging genset fan (Regularly 3kg to 5kg pressure can be added to the neutral point of the V belt, which can be pressed into within a suitable distance of 10mm to 20mm.)
6. Change the “three filters” (oil, fuel and air).
7. Examine the tightness degree transmission connecting bolts of the fuel injection pump, regulate the advance angle of the oil jet accordingly.
8. Examine if there‟s water in the fuel tank and oil-water filter. If there‟s any, check the cause and remove it.
9. Change the lubricating oil in time according to the regulations of different type of genset as well as its oil quality.
10. Examine the tightness degree of the transmission belt, the installation of the safety protection cover, and the reliability of the electric protection backtrack (low oil pressure and high water temperature.)
11. Regularly examine the exhausting pipelines of the waste-gas turbo pressure booster as well as their joints, check if there‟s some leakage or if the intake pipes or the air filters have been washed or blown dry. (Every other 200 hours, the filters must be handled with once.)
12. Survey the insulating resistance, which must be higher than 0.5 ohm.
13. Examine the situation of bearing lubrication and temperature. If the temperature is over speed, analyze the cause and remove it. Add some lubricating oil to it.
C. Genset Maintenance (Class II)
(This is only available for experts.)
The Class II maintenance must be added to the following items besides the ones in the procession of the class I maintenance.
1. Wash the piston with its brake, the rocker set, piston and ring set, double bearing and examine the state of wearing and tearing.
2. Examine the rolling big end bearing and check inside and outside of them if they are loose.
3. Clarify the dirt or mud in the pipes of the coolant system.
4. Clarify the accumulated coal in the burning room of the cover gasket and in the exhausting pipelines.
5. Examine the state of wearing and tearing about the valve, valve pipelines and valve stand, push the rod and the rocker and then grind and regulate them.
6. Wash and examine the oil pump, oil cooler and their pipelines.
7. Examine the producing valve of the oil spraying cylinder plug complete set.
8. Examine and regulate the state of oil-sprayer, oil spraying pressure and atomizer.
9. Clarify the accumulated coal in the turbocharger rotor, and examine the state of wearing and tearing about the bearing and impeller. If necessary, repair or change it.
10. Examine if the connector bolt of the generator and diesel engine is loose or tooth-slip. If something problem, repair or change it.
11. Examine if the insulation packing is super heated and aging so as to hurt somebody. If there‟s some damage, repair it in time.
D. Genset Maintenance (Class III)
The Class III maintenance must be added to the overhauling besides the ones in the procession of the Class II maintenance.
12. List about How to Fix a Common Breakdown
Breakdown phenomenon/ Causes to the breakdown and settlements/ Failed to start / An attempted start/ Low or unsteady rotational speed/ Low voltage frequency or zero indication/ Additional installation without operation/ Non-transmission genset/ Low oil pressure/ Water temperature/ Hypervelocity (Over speed)/ Low oil level/ Battery warning/ Engine smoking/Different sounds from engine/ Causes/ Settlements
1) Abnormal circuit operation/ examine the electric causes or contact FDK Co.
2) Inadequate battery power/ examine and charge the battery, change it when necessary.
3) Battery joint is rotten or cable connector is loose./ Examine the connecting role which connects the cable, twist the nut tight and change the connectors and nuts which are rotten heavily.
4) Cable connecting in bad condition or breakdown from charger or battery/ Check the connector between charger and battery.
5) Breakdown from motor start/ Contact FDK Co. and ask for help.
6) Inadequate fuel in the engine cylinder/ Examine fuel tank and fill with oil.
7) Air within fuel pipeline/ Get rid of the air in the fuel system.
8) Fuel filter blocked up/ Change the fuel filter.
9) Abnormal fuel system operation/ Contact with fuel filter.
10) Air filter blocked up/ Change the air filter.
11) Over low ambient humidity/ Examine the oil viscosity and brand.
12) Abnormal governor/ Contact FDK Co. and ask for help.
13) Breakdown from the start circuit of control system/ Examine the starter of control system and stop the control circuit.
14) Low ambient humidity or under preheated engine/ Examine the engine‟s preheating system, operate the engine no load and make it reach the operation temperature.15) Abnormal operation of AVR/DVR/ Contact FDK Co. and ask for help.
16) Over low hypervelocity of engine/ Examine the engine governor.
17) Breakdown from the indicating meters/ Examine the meters, change them when necessary.
18) Breakdown from the meters connection/ Examine backtrack of the meters‟ connection.
19) Overload/ Lower the load of genset.
20) Overload and tripping operation/ Lower the load of genset and survey if the ambient humidity is over height or not.
21) Short circuit or overload causes tripping operation/ Examine the genset exit installation and its backtrack.
22) Abnormal operation of additional installation/ Contact FDK Co. and ask for help.
23) Vanished power source/ Examine the power backtrack.
24) High oil level/ Drain off the unnecessary oil.
25) Lacking oil/ Add oil to oil tank and examine if there‟s leakage or not.
26) Oil filter blocked up/ Change the oil filter.
27) Abnormal load of oil pump operation/ Contact FDK Co. and ask for help.
28) Lacking cooling water/ Examine the water tank after the engine is cool and check if the coolant level is normal and if there‟ any leakage too. Add coolant if necessary.
29) Breakdown from pump/ Contact FDK Co. and ask for help.
30) Breakdown from sensor, control system and connecting lines/ Examine if the connecting lines are loose or cut off, which are of sensor, control system and connecting lines to the ground. Check if it is necessary to change the sensor.
31) Water tank/ intercooler blocked up or too dirty/ Examine and clarify the water tank/ intercooler and check if there‟s some impurity obstructs the airflow around the water tank.
32) Other possible breakdowns/ Contact FDK Co. and ask for help.

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