Mechanical

Alternator
Engine
Energy

Chemical
Energy of
Fuel
Electrical
Energy
A Block Diagram -Engine Alternator
An Installation
When the fuel ignites in the combustion
chamber, energy in the form of heat and
gases is generated. The rapid expansion
of hot gases creates pressure in the
combustion chamber which pushes the
piston away. The reciprocating motion of
the piston is converted in to the circular
motion by the engine crankshaft, which is
connected to the piston by the connecting
rod.
Principle of operation of
Engine
ADMISSION STROKE
The piston draws fresh air into the
cylinder on its downward travel
through the open admission valve.
With turbo charged engines the air is
first compressed by a blower and
admitted to the cylinder under
increased pressure.
COMPRESSION STROKE
On its upward travel the piston
compress the fresh air in the cylinder
with the valves closed. The
temperature of the fresh air is thus
increased to exceed the ignition
temperature of the fuel. Shortly
before the piston reaches the top
dead centre, fuel is injected into the
combustion space.
POWER STROKE
The fuel injected ignites in the hot air
and burns. The combustion causes a
high pressure which forces the
piston down. Resulting into
reciprocating movement of the shaft.
EXHAUST STROKE
The piston moving upward forces the
exhaust gas through the open
exhaust valve into the exhaust pipe.
When the exhaust stroke is
terminated the exhaust valve close
and the admission valve opens for a
new operation cycle.
SYSTEMS OF
AN ENGINE
LUBRICATION SYSTEM
The moving parts of the diesel
engine are lubricated for their
optimum operation by this
lubrication system. A dipstick in the
oil sump serves to check the oil
level. The lub oil level and the
lubrication oil pressure have to be
checked for satisfactory performance
and long life of the engine.
FUEL SYSTEM
Depending on the position of the
fuel, the fuel is supplied to the
distributing pipe through fuel filter
either by natural head from an
elevated tank or by a fuel pump. Fuel
is supplied inside the cylinder by
injection nozzles.
AIR EXHAUST SYSTEM
For the combustion of fuel sufficient
quantity of the filtered air is taken in
the combustion chamber. After the
combustion the exhaust gases are
taken away from the engine through
suitable ducting or piping. This is
known as air exhaust system.
COOLING SYSTEM
Cooling System is essential for
cooling the engine body, and to act
as a heat exchanger for lubricating
oil. This can be either water-cooled
or air cooled.
STARTING SYSTEM
The Diesel Engine can be equipped
with the starting system i.e. with
an electric starter with a pinion,
which engages with the fly wheel of
the engine. The power to the electric
starter is provided by means of a
battery which is kept in charged
condition by means of a dynamo or
electric rectifier.
ALTERNATOR
Alternator works on Faradays law of
Electromagnetic induction. There are two
requirements for the functioning of Alternator
(1) Magnetic field & (2) Rotation. Magnetic field
is produced by passing direct current through
the field winding of the Alternator and rotation
is achieved by means of coupling the alternator
from engine. The Automatic Voltage regulator
(AVR) is provided in the alternator for
maintaining the terminal voltage within the
close limits over wide operating condition.
INDICATIONS OF A HEALTHY
ENGINE
Good Compression:
The temperature of the induced air when
entrapped and compressed in the
combustion chamber is about 540 deg C
to 560 deg C.
Good Combustion:
Fuel is sprayed in atomized form to ensure
proper ignition of the fuel. Burning
temperature is about 1425 deg C.
Clean exhaust:
The exhaust system is clean and
back pressure is with in permissible
limits. The general condition of the
Engine can be determined by the type
of smoke it emits. This can be said as
The pulse of the engine. Smoke
should be of brown colour (Barely
visible haze). Any other colour of smoke
indicates some problem in the engine.

IMPORTANT MAINTENANCE CHECKS
FOR ENGINE ALTERNATOR SET
Daily
Check Engine oil level and leakage if any.
Check Radiator for water level and leakage if any.
Check fuel level.
Check that ventilation of the EA Room is proper.
Check oil pressure.
Check if lights and exhaust fan are working properly.
Check physically before start for loose connection/nut
bolt.
Weekly
Check Air filter.
Check fan belt, and its tension
Fortnightly
Check Battery voltage, Terminals, Electrolyte
level (Top up if necessary) .
Check Specific Gravity of Electrolyte.
(After the above checks, start the
Engine for No Load/Connected Load and test
for 10 minutes the following)
Check for any abnormal noise. Shut down the
E/A immediately and cause be examined.

Check frequency, out put voltage, colour
of exhaust etc.
Record various readings in the logbook.
Monthly
Check for tightness of connections in
Engine and Control Panel.
Watering of earth pits and tightening of
connections.
Check functioning of safety devices.
Check belt tensions.
Check battery charger.
Check for leakage of fuel line.
Check for leakage in exhaust pipes.
Half Yearly
Cleaning of bus bars chambers and
tightening of nut bolts.
Checking of protective devices
Earth testing and Meggering.
Yearly
Tighten all mounting, nut and bolt.
Clean and calibrate all injectors.
Check fuel pump calibration.