SECTION 2

MAINTENANCE PROCEDURES

CONTENTS

2. Maintenance Procedures 13
2.1 Safety 13
2.1.1 General Precautions 13
2.1.2 Natural Gas Precautions 14
2.2 Daily Maintenance 16
2.2.1 Daily Check List 16
2.3 Weekly Maintenance 17
2.3.1 Weekly Check Lists 17
2.4 Monthly Maintenance (Code 0) 19
2.4.1 Monthly Check Lists 19
2.5 3 x Monthly / 500h Maintenance (Code 5) 21
2.5.1 3 x Monthly / 500h Check Lists 21
2.6 6 x Monthly / 1000h Maintenance (Code 10) 23
2.6.1 6 x Monthly / 1000h Check Lists 23
2.7 12 x Monthly / 2000h Maintenance (Code 20) 25
2.7.1 12 x Monthly / 2000h Check Lists 25
2.8 24 x Monthly / 6000h Maintenance (Code 60) 27
2.8.1 24 x Monthly / 6000h Check Lists 27

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2. Maintenance Procedures
FOR ENGINE & ALTERNATOR MAINTENANCE, REFER TO THE ENGINE MANUAL AND THE
ALTERNATOR MANUAL (VOL 2). REFER ALSO TO THE SAFETY ADVICE GIVEN BELOW
AND OVERLEAF.

The following pages include suggested routines for maintaining the overall genset and its
equipment in prime condition. Maintenance intervals are shown in elapsed time/running
hours, and codes are included to comply with the codes provided in the engine manual.
Maintenance is performed on a rolling basis, therefore it is suggested that you photocopy
the pages from Daily Maintenance onward. Then each maintenance item can be ticked off
as it is carried out. Start the routine again past the 24-monthly/6000h period.

2.1 Safety
The following text is provided for your safety. A number of warnings and cautions are
included, but read and understand them all before carrying out any maintenance.
Remember that over-familiarity with potentially dangerous equipment can and often does
result in serious injury or death.

2.1.1 General Precautions

Some maintenance work, particularly in confined areas, should be carried out by two
engineers working together.
If the lifting of engine components is planned, refer to Part 5, Section 1 for component
weights.

WARNING
Before carrying out genset maintenance, always immobilise the genset as detailed in
Part 4, Section 1.

WARNING
High voltages are present, even when the genset is not running.
Do not open any terminal box covers without first isolating the high voltage supply.
Keep terminal box covers in place during Troubleshooting.

WARNING
When carrying out maintenance inspections with the engine running, exercise extreme
caution and wear the necessary personal protective equipment as detailed in Part 1 of
this volume.

Continued

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 WARNING
Do not remove a cooling system pressure cap when system is hot. Failure to observe this
precaution may result in personal injury.

WARNING
If coolant is not released from engine when engine cooling system is drained, hot coolant
may be released when engine components are removed. Ensure that engine circuits are
fully drained via the two drain plugs located on the engine (Refer to the Engine Manual).

Caution
Do not add cold coolant to a hot engine, as this may cause damage.
Allow engine to cool below 500C before adding coolant.

WARNING
Avoid contact with hot exhaust components.

Caution
Never steam clean the Alternator.
If steam cleaning the Engine, first, take steps to waterproof the Alternator.

2.1.2 Natural Gas Precautions

If servicing is required on natural gas pipes or components, refer to the Safety section in
Part 5, Section 1 for General Safety Notes.
Only Competent Persons are to work on natural gas equipment.
Refer to the BRITISH GAS CODE OF PRACTICE IM / 17 before working on UK
installations.
On Non-UK installations, comply with all local and national gas regulations.
Contact Cummins Power Generation if you require details or copies of UK regulations.

DANGER
IF A GAS LEAK IS SUSPECTED:
DO NOT OPERATE ANY ELECTRICAL EQUIPMENT OR SWITCHES IN THE PLANT
ROOM WHICH CAN CAUSE SPARKS.
EVACUATE ALL PERSONS FROM THE PLANT ROOM IMMEDIATELY AND
VENTILATE BUILDING.
SHUT DOWN THE GENSET (S) BY FULLY SHUTTING THE GAS TRAIN SHUT-OFF
VALVE (S).
FULLY SHUT OFF ALL EXTERNAL GAS SUPPLY VALVES TO THE GENSET.
ALERT THE EMERGENCY SERVICES AND LOCAL GAS SUPPLIER.

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