DG SET- CHECKS & MAINTENANCE

Main Topics
 Source and Types of Energy.
 Types of Fuel.
 Diesel generator:
 Classification of Diesel Generator
 Working Principle of Diesel generator
 Main Parts and their Function
 Fuel Pump , Governor & ECP
 Safeties on Diesel Engine
 Coolant System , Lubricating System
 Maintenance Checks: A, B, C & D checks
 Alternator:
 Working , types of alternator
 Parts of alternator and their function
 Troubleshooting of diesel generator

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 What is a Diesel Generator?

Diesel Generator: is the combination of a diesel engine

with an electrical generator (often called an alternator)
to generate electric energy.
Working: The prime mover of the Generator set will be a
diesel engine, which is coupled to the shaft of an alternator
(single phase for small units).
The rotating shaft of the diesel engine rotates the rotor of
an alternator, and due to electromagnetic induction the
output of an alternator is electricity.
Primary part of a DG
 Diesel engine
 Alternator
Available sizes

 5kVA up to 5MVA

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 Use of Diesel Generator
 To protect the critical systems from power
failures caused by power outages.
 Standby Diesel Generators are commonly used
by all major
 Hospitals
 Military forces
 Government buildings
 Data centers
 Corporate offices
 Residence Buildings
 Factories
 Industrial sectors

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 Classification of Diesel Generator
 According to cooling system
 Air cooled Diesel generator
 Radiator type cooling system
 Water Cooled Diesel Generator
 Heat exchanger and cooling tower type cooling
system
Air Cooled Diesel Generator Water Cooled Diesel Generator

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 Diesel Engine
PARTS OF ENGINE
 Radiator
 Water pump
 Radiator fan
 Fuel pump
 Injector
 Cylinder head
 Piston
 Cylinder liner
 Connecting rod
 Crankshaft
 Cam shaft
 Flywheel
 Turbochargers
 ECP
 Governor
 Anti-vibration mounting pad
 Battery
 Anti-vibration damper
 Coolant
 Cam follower
 Safety (HWT / LLOP / over speed safety)
 Air filter / lubricating filter
 Silencer
 Silent canopy
 Fuel tank
 Lubricating oil pump
 Thermostat
 Water and oil temperature meter

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PARTS OF ENGINE
Diesel Engine
 Radiator
 Water pump
 Radiator fan
 Fuel pump
 Injector
 Cylinder head
 Piston
 Cylinder liner
 Connecting rod
 Crankshaft
 Cam shaft
 Flywheel
 Turbochargers
 ECP
 Governor
 Anti-vibration mounting pad
 Battery
 Anti-vibration damper
 Coolant
 Cam follower
 Safety (HWT / LLOP / over
speed safety)
 Air filter / lubricating filter
 Silencer
 Silent canopy
 Fuel tank
 Lubricating oil pump
 Thermostat
 Water and oil temperature 7
 Engine Strokes
 Working of Engine
 Induction stroke : Piston move from
TDC to BDC, air inlet valve opens
and air enters into the low pressure
area.
 Compression stroke: Both air intake
and exhaust valve remain closed
and piston moves from BDC to TDC
and air is compressed . At the end of
stroke fuel is injected.
 Ignition/Power stroke : Injected
fuel ignite and burnt fuel turn into
gases at high Pressure due to which
piston moves towards BDC.
 Exhaust stroke: Exhaust valve
opened piston moves from BDC to
TDC the burnt gases out the
cylinder.

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 Fuel Pump & Governor

 Fuel Pump: supply fuel from the fuel tank to

the injector as per combustion cycle.

 Governor: It controls the speed of engine by

increasing or decreasing the fuel quantity.

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 Electronic Control Panel
 Electronic Control Panel (ECP) is used on
engines for Monitoring engine parameters and
governing engine speed with software to
govern the engine speed.

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 Governor
 Governor
 Governor controls the engine speed solely by the
amount of fuel injected into the engine by the
injector.
 The governor provides the engine with the feedback
mechanism to change speed as needed and to
maintain a speed .
 The governor is essentially a speed-sensitive device,
designed to maintain a constant engine speed .

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 Engine Safeties
 Engine Safeties
 HWT (High water temperature)
 Engine Coolant Temperature indicator. If the Engine
Coolant Temp is too high, then there is an indication or
alarm in the AMF (Auto main failure) annunciation.
 Max. temperature: 90 degree C.
 LLOP (Low Lube Oil Pressure)
 Engine oil Pressure indicator. The pressure should not be
less than 2.5 Kg/cm².
 LCWL (Low Coolant Water Level)
 Radiator coolant water indicator. The level should not be
less than 95 % of overall volume.
 OS (Over Speed)
 The speed should be in between 1490-1515 RPM.

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 Lubricating oil pump
 A Oil pump is part of a
lubrication system
transporting the oil to
various moving parts
inside the engine.
 FUNCTIONS OF
LUBRICATING OIL IN AN
ENGINE
 Provide a film of proper
thickness between the
bearing surfaces under all
conditions of operation
remain stable under
changing temperature
conditions.
 It do not corrode the
metal surfaces.
 If the lubricating oil is to
meet these requirements,
the engine operating
temperature must NOT
exceed a specified limit.
 Lubricating Oil in an Engine

Function of lubricating oil :-

 Controls friction
 Reduces wear
 Limits the temperature
 Reduces corrosion
 Dampers mechanical shock in gears
 Forms a seal on the walls of the cylinders

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Charger Alternator

 It is coupled to the
engine shaft through a
grooved belt.

 It’s a type of a dynamo,

which charges the
battery while running.

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 Cranking Motors/Self Starter
A DC motor, which takes power from battery and automatically
couples and rotates the flywheel.

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 Coolant
 Coolant: is a fluid which flows through a device in order to prevent its
overheating, transferring the heat produced by the device to other devices
that utilize or dissipate it.
 Coolant Replacement
 At 6000 hrs. of operation or after two years, it is necessary to
replace the coolant.
 pH of coolant
 Special colour indicator. When colour of the coolant is pink the
pH is within limit. If coolant becomes colourless, then it
indicates very low level of concentration.

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Engine Cooling System

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 Thermostat

 A device which regulates the temperature of a

system and maintains the system's
temperature near a desired set point
temperature is called thermostat.
 Turbocharger
 Turbocharger consists of a Turbine and a
compressor linked by a shared axle.
 The turbine inlet receives exhaust gases from
the engine exhaust manifold causing the
turbine wheel to rotate. This rotation drives
the compressor, compressing ambient air and
delivering it to the air intake of the engine.
 Alternator
 Electrical generator (alternator) is an electromechanical
device that converts kinetic energy to electrical energy,
generally using electromagnetic induction.

Generator / Alternator

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 Parts of an Alternator

 STATOR
 ROTOR
 EXCITER ROTOR
 DIODE
 AVR
 SLIP RING
 SURGE SUPPRESOR
 RECTIFIER ASSEMBLY
 TERMINALS

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AMF Panel

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 AMF Control panel is designed to monitor & to start
Generator automatically when the mains source fails partially or
fully.
 When mains fail, then it is sensed by Line Voltage Monitor
(L.V.M.) and three starting pulses are given to Gen set.
 If Gen set does not start within three attempts, then „STARTING
FAILURE‟ alarm is sounded and stop signal is given to Gen set
to stop it fully & no start signals are given further.
 When Gen set starts successfully, it builds up the rated voltage
and Gen set contactor/breaker is closed automatically. The load
then is switched on / transferred to the Gen set.

 When Mains restores, which is checked by L.V.M. for its

healthiness, the generator is then disconnected from the load
and automatic transfer back to the mains source takes place.
Load is now connected to the mains.
 Gen set is then run for about 5 minutes time set, on no load and
it is stopped automatically.
 Safeties like L.L.O.P., H.W.T. and Over speed are operative when
the Gen set is running. For any of the above faults, Gen set
stops immediately.

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 Fault Indication

 Low oil press

 High room temp.
 Over speed
 Fail to start
 DC battery rev. polarity
 Engine hours run counter
 RPM
 Frequency
 Voltage
 Current
 Engine temperature

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 Shutdown Protections

 Low oil pressure

 High room temp.
 Over speed
 Fail to start
 Under speed
 Over current
 V belt failure
 Blower failure
 Earth fault

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 Maintenance Checks for DG set

 “A” check

 “B” check

 “C” check

 “D” check

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 “A” Maintenance Checks – Daily / Weekly

1. Check Engine Oil Level

2. Check Belts
3. Check Engine Coolant Level in radiator
4. Check for leakage of coolant, fuel,& lubricating oil and
rectify.
5. Check all instrument are functioning
6. Check all parameters.
7. Check battery
8. Check fuel level
REPORT TO THE MAINTENANCE DEPARTMENT ANY OF THE
FOLLOWING.
1. Low lubricating oil pressure.
2. Low power.
3. Abnormal water or oil temperature.
4. Unusual engine noise.
5. Excessive smoke.
6 Excessive use of coolant, fuel or lubricating oil.
7. Any fuel, coolant or lubricating oil leaks.
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8.Idle Engine A Few Minutes Before Shut-Down .
 “B” Checks –300Hrs./ 6 Month
1. Change Super Lubrication Oil By-Pass Filter
element
2. Change Fuel Filter Element
3. Change Lubricating Oil Filter Elements
4. Change Engine Oil
5. Check Coolant Additive Concentrate
6. Clean/Change Crankcase Breather
7. Clean fuel tank breather
8. Check Hydraulic Governor & Oil Level
9. Check Oil Levels
10. Clean and check battery terminals
11. Check air cleaner element
12. Check connection of starter motor and
alternator.
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 “C‟ Maintenance Checks - 1500 Hrs.
 First repeat A & B checks
 1. Check & adjustment Injectors and
Valves Setting.
 2. Check & Adjustment Injector
Plunger.
 3. Check & Adjustment Crosshead.

 4. Check fan hub, Idler and water

pump
 5. Change Hydraulic Governor Oil
 6. Clean Radiator externally
 7. Check water pump
 8. Check end play for turbocharger
 9. Check air ducting hoses
 10. Check thermostat for proper
functioning and operating system.
 11. Change air cleaner .
 12. Drain sediment from fuel filter
and from water separator.

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 “D” Maintenance Checks - 6000 Hrs. / 2Year

Repeat all A,B,C Checks

1. Clean and Calibrate Fuel Pump

2. Clean and Calibrate Injectors
3. Repair heads
4. Check Crankshaft End Clearance
5. Check Fan and Drive Pulley Mounting
6. Check water cooling system
7. Check all drives clearance .
8. Check camshaft end play.
9. De-scaling and cleaning of Radiator
10.Replace Hose (As Required)
11.Check Turbocharger Bearing Clearance
12.Clean Cooling System
13. Inspect Vibration Damper

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 Daily Checks
When the gauge indicates locks in the Red range ,change or clean the air
cleaner
 Check the water Temp.
Check the oil Temp.
Check the all belt (fan ,water pump)
Repair any leaks, make major adjustments, tighten loose bolts, etc.
Observe the Service Meter reading.
Drain the water from water separator / diesel tank.
 Check the oil level. Oil level must be between the ADD and FULL marks
on the side of the dipstick .
 If the oil level is below the ADD mark, Before starting, add oil to the
FULL mark.
Stopping the Engine
Remove the load.
Reduce engine speed to half speed. RUN FOR 5-10 MINUTES to cool engine
Stop the engine.

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WARNING: DO NOT remove the pressure cap on an overheated engine. The
coolant is under pressure and relieving the pressure will cause the coolant to flash
into steam.
High Water Temperature Checks:
1. Check coolant level.
2. Check engine room vents and/or louvers. Be sure the engine is receiving
sufficient air.
3. Be sure temperature regulators are operating at proper temperature range.
4. Inspect all water hoses carefully for collapsing, external and internal failures.
Replace hoses as required.
5. Have the cooling system cleaned.

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Maintenance of Engines

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 Maintenance Recommendations
CAUTION: Fill fuel tank at the end of each day of operation.
•Do not fill the tank to the brim.
•Drain fuel tank of moisture and sediment as required by
prevailing conditions.
•After changing fuel filters, always bleed fuel system to remove
air bubbles from system.

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 Lubricating Grease

 Use Multipurpose-type Grease (MPGM) which contains

3-5% molybdenum disulfide conforming to MIL-M-7866,
and a suitable corrosion inhibitor.
 NLGI No.2 Grade is suitable for most temperatures.
 Use NLGI No. 0 or No. 1 Grade for extremely low
temperatures.

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 Trouble During Starting

 Read all the steps before checking.

 Correct fuel.
 ALL the fuel valves open.
 Is the fuel filter plugged.
 Do we have enough oil.
 Low oil pressure.
 The key off position.
 Fuel solenoid valve to cut off the fuel supply and shut down.
 The fuel valve is opened by a magnetic field.
 Remove the spring and plunger and let it operate as it is.
 To turn off the engine without the magnetic fuel valve
 Close the fuel tank valve.
 To remove the air we need to remove the supply line.
 Use a can or glass jar to catch the fuel that will spill out.
 Make sure the run/stop leaver is locked into the run position.
 If we loosen the high-pressure fuel line we should notice fuel
dripping out when cranking.

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 Breakdown Drills
 Increase in Water Temp
 Increase in LUB OIL Temp
 Low LUB OIL Pressure
 Hunting
 Voltage Fluctuating
 Black Smoke
 White Smoke
 Blue Smoke
 High Exhaust Temp
 Contamination
 Dilution
 Knocking 38
 Battery & Hydrometer
 Battery: is an electrical device which store chemical energy and
to convert this chemical energy into electrical energy. Battery is
used for starting the engine.
 Hydrometer: is an instrument used for determining the specific
gravity of electrolyte.

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 Checking the battery
 Open up the battery lead of both the batteries.
 Open up the cover of each of the individual cell of the
battery and top up with distilled water.
 Dip the gravity meter inside each of the individual cell of
the battery and note down its reading. (Approx. 1240
electrolyte)/ Sulphuric Acid 35% & Water 65%)
 By Multi meter note down the individual voltage reading
of each cell. (Reading will be approx. 12 V)
 By Multi meter note down the total voltage of the
battery. (Reading will be approx. 12 V)
 Same procedure is applied for the other battery
connected in series.
 After Checking of both the batteries is over, clean &
tighten the connections. Apply Petroleum Jelly.
 Materials Required
 · Distilled water.
 · Petroleum jelly
 Tools Required
 · Multi meter
 · Gravity meter
 EHS · Wear Rubber shoes.
 · Do not touch electric points with wet hands.
 · Use approved Chemicals only. 40