DG Maintenance Work list and Maintenance Track Record:HT DG NAME PLATE DETAILS:

HT DG commissioned on 16th May 2014 and load trail with 605 KW load for 1
hour taken and all parameters were recorded.
Model Details:
Engine:
Make
Model
Sr. No.
Cooling system
Type of coupling
Governer type

CUMMINS
QSK-60-G4
25393722
Radiator
Direct
PCC 3201

Alternator:
Make
Frame
Sr.No.
KW/KVA
Full Load Amps
AVR type

STAMFORD
MVSI80451
PI3i026450
1600/2900
485.3
PCC 3201

Control Panel:
Make
Sr.No.
Type
Swithgear
C.T.Ratio
AMF unit

LT DG NAME PLATE DETAILS:

POWERICER
07 PCA-A1310/1049
AMF
ABB/VCB/conserve
400/1A
VSR

LT DG commissioned on 22th April 2014 and load trail with 70 KW load for 2 hour
taken and all parameters were recorded.
Model Details:
Engine:
Make
Model
Sr. No.
Cooling system
Type of coupling
Governer type

CUMMINS
KTA-50 G3
25395844
Radiator
Closed
Electrical

Alternator:
Make
Frame
Sr.No.
KW/KVA
Full Load Amps
AVR type

STAMFORD
P1734B1
N13B051462
1000/1250
1739
PCC 3.3

Control Panel:
Make
Type
Swithgear
C.T.Ratio
AMF unit

POWERICER
AMF
ACB ABB
2000/5
MFM

General Maintenance Work list to be carried out for different check up for
both LT and HT DG are as follows:A Maintenance Checks-Daily
The A-Check covers the daily monitoring parameters that are required for
the satisfactory operation of the Diesel engine for power production. It provides a
detailed report that helps us to analysis for the fault in the event of a failure.
Comparison and intelligent interpretation of the daily report from the
parameters along with a practical follow-up action will eliminate practically all
failures and emergency repairs.
The following conditions are to be noted with caution:

1.
2.
3.
4.
5.
6.
7.

Low lubricating oil pressure.

Low Power.
Abnormal water or Oil Temperature.
Unusual engine noise.
Excessive Smoke.
Excessive use of coolant, Fuel or Lubricating Oil.
Any fuel , Coolant or lubricating oil Leak.

Check Engine Oil Level:

It is done with the dipstick oil gauge located on the engine. If necessary, add
oil of same quality and brand to maintain the oil level as required.
Drain sediment from Fuel tanks/ Fuel filter/Water separator:
The diesel that we use for the DG is of moisture free but if presence of water
from the fuel tank drain cock or plug, it I advisable to install a water separator.
Drain plugs are located in the bottom of fuel filter cases and in the sumo of
the fuel supply tanks.
Air Cleaner Service Instructions:

Dont remove element for inspection

Never rap a filter to clean it
Never judge the filters life by looking at it..Measure the air
flow restriction.
Never leave an air cleaner open longer than necessary.
Dont ignore the worn or damaged gasket in the housing of
the filter unit.
Dont use a damaged or bunched filter.
Never use a warped cover on a housing.
Never substitute an incorrect element model number for the
filer element.

Proper Service of Air Filters:

Proper air cleaner servicing is essential for maximum engine protection
against the ravages of dust. Proper servicing can also save you time and money by
maximizing filter life and air cleaning efficiency.
TWO of the most common Problems are:
A. Over Servicing. New Filters increase in dust cleaning efficiency as dust
builds up in the media. Dont be fooled by the filter appearance.
B. Improper servicing. Your engine id vulnerable to abrasive dust
containments during the servicing process. The most common cause of
engine is careless servicing procedures.

The following steps listed can avoid unnecessary risk to the engine.
1. Remove the old element gently that dirty filter carefully, until you get it
clear of the housing. Accidentally bumping it whilw still inside drops the
containment inside the housing itself leaving contamination to enter
inside the engines.
2. Always clean the inside of the housing carefully dirt left in the air
cleaner housing. Use a clean, damp cloth to wipe every surface.
3. Always clean the gasket sealing surface of the housing. Improper
gasket seal is one of the most common causes of the engine
contamination.
4. Check for uneven dirt patterns. A pattern on the element clean side is
a sign that the filter element was not firmly sealed or that a dust leak
exists.
5. Press your fresh gasket to see that it springs back to ensure proper
sealing of the filter elements.
6. Make sure that the gasket seats evenly.
7. Ensure air-tight fit on all connections and ducts.
A Maintenance Check- Weekly:
The weekly check includes the visual check of belts for looseness. If there is
evidence of belt slippage or so appropriate measures to be taken to rectify it.
The belts systems available are as follows:

In-Line Engine Water pump Belts

Fan Drive Belts
Generator /Alternator Belts

B-Maintenance Checks
At each B Maintenance check, perform all the A checks in addition to
the following. This check should be carried out at every 300 hour of operation or at
every six month.
B-check interval is a very important factor in preventing the integrity of an
engine. It involves the following steps for engine maintenance.

Cooling system:

Change engine lubricating oil .

Lubricating oil analysis
Change lubricating oil filter elements
Change super lub oil by-pass filter element
Clean/change crankcase breather
Check hydraulic governor oil level

Check coolant additive concentrate.

Change fuel filter element

Change fuel tank breather
Check throttle linage
Check air piping

Fuel System:

Lubricating Oil System/Analysis:

Cummins Diesel engine recommends use of multigraded lubricating oil with
viscosity grades at various ambient temperatures. Quality of lubricating oil is one of
the key factors to decide the performance, durability and total cost of operation of
diesel engine.
SAE 15W 40 grade lubricating oil with API CH-4 is the recommended for
over diesel engines.
This oil provides following advantages:

Reduces wear and tear

Better high temperature oxidation stability
Optimum lube oil consumption
Less sludge formation due to improved dispersancy.
Increased control on acid formation resulting in less
corrosion of bearings and other components.

VALCOLINE CUMMINS PREMIUM BLUE, API CH-4.

-Recommended oil.

Lub oil and filter change period can be determined by laboratory tests of used
oil.
It is recommended that new engine be operated through at least one oil change
interval of 300hrs/6months.
Oil sample should be taken from each of the engines in the sub-group at
every 48-operating hour interval. The sampling intervals can be varied according to
the operational frequencies.
The oil sample can be collected by
1. Sample valve method
2. Vacuum pump method
3. Oil drain method.
Oil contamination guidelines:

Property
Viscosity change @ 100C
Fuel Dilution
Total acid number
Total base number
Water content
Potential contaminants:
Silicon(si)
Sodium(Na)
Boron(B)
Potassium(k)
Soot

Guidelines
4 cSt from new oil
5 percent
2.5 numbers increased from new oil
maximum
2.5 minimum or half original value
0.2 percent maximum
15ppm increase from new oil
20 ppm increase from new oil
25 ppm increase from new oil
20 ppm increase from new oil
1.5 % mass of used oil maximum

Coolant Specifications:
Cooling system:
Cummins engines are provided with fleet cool XB coolant Additive
concentrate-CAC and premix coolant. To ensure adequate corrosion protection,
checking coolant at every B check is essential .
CAC is available in two forms,
a) Coolant Additive , which can be mixed with water of 1:16 portion and
b) Pre-mixer coolant, which can be directly added to cooling water
system.
Coolant checking:
In normal conditions coolant checking is suggested as audit check, at every
1500 hrs/6 months during operation. During checking two coolant properties
namely coolant concentration and pH value of coolant are to be checked.
Concentration:
Done with Test kit as follows
i.
ii.
iii.
iv.

v.

Collect the sample from the radiator.

Allow coolant to reach room temperature.
Dip a test strip for 3 seconds.
Remove excessive coolant and wait for 45 seconds and check for the
color change in the stip and compare it with colour chart within 30
seconds.
Take action accordingly.

pH of coolant

The pH range is pink in test paper i.e. 8.5 to 10.0pH.

Coolant replacement :
At 6000 hrs of operation or after 2years.

Water used in cooling system specification.

Hardness as CaCO3
Chlorides as CL
Sulfate as SO4
pH
TDS

170ppm max
40ppm max
100ppm max
5-9
Less than 400ppm
-----Every 300Hrs/6 months.

First 1500Hrs check:

All steps of B check to be repeated.
Adjust injectors and valves.
Replace rocker cover gasket.
---- 1st 1500 hrs only.
C-Check:
Repeat A & B maintenance steps and additional works are to follows:
Fuel system:

Change Hydraulic Governor oil

Change Aneroid Oil
Check Aneroid breather for any chokes or sludge deposition.
Clean Fuel Tank Inside.

Cooling System:
Clean Radiator/Charge air cooler externally
Fan hub, idler and water pump cleaning.
Other maintenance:
Inspect for any damages in Alternator/starter and replace.
Check air cleaner and evacuator valves.
D-Check:
Repeat A, B & C maintenance works and additional works as follows.

Fuel system:

Clean & calibrate injectors if required.

Replace rocker cover gaskets.
Fuel pump calibration.
Replace Aneroid belows and Calibration.

Air System:
Clean Turbo charger, compressor wheels and diffuser if required.
Turbocharger bearings cleaning.
Tighten manifold nuts or capscews.
Cooling system:
Complete draining of coolants.
Descaling of sludge from cooling water circuit.
Other Maintenance:
Vibration damper conditions to be checked.
Air compressor and safety controls to be checked.
-----Every 6000hrs or every 2 years.
1500hrs after every D check:
Repeat all C check maintenance work.
Adjust injectors and vales if required.
Replace rocker cover gaskets.
HT DG Maintenance track record:First Free A Check---16-04-2014.
Hours=8hrs.

Engine Running

Recommendation: To provide ladder for check the coolant level in radiator.

Check coolant pH-Blue and oil level in every starting.
General Check ---06-10-2014
Running Hours=60.3hrs.

Engine

Checked all systems and found normal.

2000KVA alternator cable line branch side rain water entered and
problem rectified.

B-Check ---14-11-2014
Hours=89hrs.

Engine Running

Changed oil, Oil filter, coolant filters and Diesel alters.

Changed coolant for radiators.
C-Check ---25-05-2015.
Hours=157hrs.

Engine Running

Checked and cleaned Air Filters.

Coolant level checked and found ok.
Engine oil filters and other filters replaced.
No load engine sound and smoke found normal.

A-Maintenance Check---14-08-2015.
Running Hours=170hrs.

Engine

A check weekly work done- Fan pulley and sleeve distance checked and found
ok.
Panel Replacement---25-01-2016.
Hours=208hrs.

Engine Running

On 25thJan 2016, HT DG Trail taken in front of Cummins Engineer and

During testing of Alternator HMI display card failed on power command
panel.
On 28th jan 2016 Card replaced and trail run taken.
JNM team modified wiring on MRP panel for auto closing of 3.3KV VCB
for temporary basic.
Faulty card replaced at free of cost basis on 5 th Feb2016.
Rectifier-6A 400VReplaced and DG started and running in good
condition on 24th Feb 2016.
B-Maintenance check10-03-2016.
Running Hours=258hrs.

Engine

Routine B-check maintenance work carried out and found ok.

D-Maintenance Check28-05-2016.
Running Hours=281hrs.

Engine

Carried out A & B check maintenance work.

Checked air system, fuel system and cooling system for normal
operation.
No filter replacement or coolant draining done.
Problems found:

 Engine mounting beat and Radiator mounting bed connection bolt

found loose.
Radiator Fan Hub pulley and bolts torque checked.
Current runnig hours details for HT DG= 342hrs.
LT DG Maintenance track record:First Free B Maintenance Check:--06-10-2014.
Engine Running Hours=251hrs.
B check maintenance activities carried out.
Coolant 30 liters added.
All systems found ok.
Oil Service:--04-12-2014.
Hours=537hrs.

Engine Running

B-check maintenance work carried out.

Fan hub bearing grease applied and found ok.
Oil and filter changed.
Contact Breaker not closing31-12-2014.
Running Hours=585hrs.

Engine

Inspected the engine for fault identification.

Wiring hardness control TB 5 1& 2 and 4&5 checked.
Found the TB5 4&5 continuity ok @ contact breaker open condition but
when press the close button no input given to PCC 3300 for TB 5 1&2
for closing.
Temporary wiring connection given for DG to start in auto mode.

HMI Panel replacement07-01-2015.

Running Hours=591.7hrs

Engine

CB open and close button not working.

HMI panel failure was conformed and New HMI PCC 3.3 fitted and found
ok.
Regular B check---09-04-2015.
running Hours= 832.5hrs

Engine

Normal B check maintenance work carried out.

Fuel system, cooling system and air system checked and found ok.
First Free C Maintenance check:--28-5-2015
Running Hours=894hrs.

Engine

 Carried out valve settings work

All systems checked and found ok
Air filter cleaned.
Breaker Tripping problem28-08-2015.
Hours=1062hrs.

Engine running

Inspected and found breaker tripping from PCC panel.

Wiring and hardness found ok.
PCC settings and programming found ok.
AMF panel side wiring connection checked.
Traveling the breaker removed in dust and moisture condition found
and cleaned.
All systems checked and found ok.
DG trail run taken and found ok.

B-check Maintenance23-02-2016.
Running hours=1153.7hrs.

Engine

General B check maintenance work carried out.

Oil servicing done.
Old oil removed and new oil top up done. Oil filters replaced.
Air Filter cleaning and battery check done.
Trail run of LT DG taken and found ok.

B-check maintenance03-02-2016.
running hours=1495 hrs.

Engine

General B check maintenance work carried out.

New air filter replaced.
Fan belt tension, oil and coolant level checked.
B-check Maintenance--28-03-2016.
Running Hours=1834hrs.

Engine

Regular B-check Maintenance work carried out.

New air filter replaced.
Fan belt tension, oil and coolant level checked.
VCL CH4 oil replaced.

Current Running hours details=2140.9hrs

Next B-Check Maintenance is Due as of Engine Running Hours=2128hrs.