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KPC Training Center
Purpose : Stability and reliability of the genset
Standby Generators must be ready to operate at any time
Establishing a PM maintenance program :
 Minimize Downtime
 Reduce Engine Operating Costs
 Increase Engine Life
Service Repair Time :
 Run-to-Failure Management
 Preventive maintenance Management
Run-to-Failure Management
 High spare parts inventory cost
 High overtime labor cost
 High machine down time
 Low production availability
Run-to-Failure Management
The net result
High maintenance cost
Low availability
Preventive Maintenance (PM)
 Recommended spare parts
 Genuine parts
 Oil, fuel, coolant specification
 Maintenance schedule:
- Daily
- Weekly
- 250 Hours or 6 month
- 1500 Hours or 1 year
- 6000 Hours or 2 years
- Others
Walk -Around Inspection :
Importance Lubrication System
70-80% crank failures are due to oil contamination.
Check Oil Level (Add oil as needed )
Oil Level & crankshaft :
Consider these factors when you select engine oil:
 Oil types (API service classifications)
 Engine design and construction.
 Fuel characteristics.
 Oil viscosity (SAE service classifications)
 Operating conditions.
Causes of Lube System Wear & Failure
 Single largest problem is short engine life due to
excessive soot in the oil
 Poor quality/low performance engine oil
 Extended oil change intervals
 Fuel dilution
 Wear (Lube System Caused)
 Seals/Bearings
Turbo
Crank - Main/Rod
Valve, Guide
Over-filling the engine oil leads to :
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Check Coolant Level (Add coolant as needed )
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Importance of Cooling System
40-60% Of All Engine Downtime Is Associated With Cooling
System Problems
Important Customer Reminders:
Use proper start up procedures
Clean debris from the radiator and fan
Check radiator cap seal
Inspect the water pump for leaks
Select the right coolant
Causes of Cooling System Wear & Failure
 Single most common problem  poor coolant quality
Due to
 Not maintaining adequate levels of coolant additives
 Using coolant that does not meet Cats specifications
 Not keeping the cooling system topped off
 Using coolant past its useful life
 most cooling system problems can be avoided with proper maintenance practices!
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Effects of Poor Fuel Quality
excessive wear and premature failure of
injectors and fuel pump
Poor lubricity
create combustion chamber deposits => These
reduce the life of cylinder liners and rings
Fuels that are a heavier
grade
engine knock, trouble starting, and black
exhaust smoke.
Low cetane numbers
Symptoms...
 Clogged and slimy filters
 Dark, hazy fuel
 Sludge build up in tanks
 Loss of power and RPM
 Excess smoke
 Corroded, pitted injectors
 Foul odor
Battery capacity (minimum recommended cold cranking
amps):
K50 Generator-Drive
Above 10属C [50属F]- Ambient Temperature
1280- Cold Cranking Amperes
Above 0 to 32属C [-18 to 0属F]- Ambient Temperature
1800- Cold Cranking Amperes
Batteries (Specific Gravity)
Battery State of Charge Specific Gravity (at 27属C [80属F])
100% 1.260 to 1.280
75% 1.230 to 1.250
50% 1.200 to 1.220
25% 1.170 to 1.190
DISCHARGED 1.110 to 1.130
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Genset Services Key points
 慍悋 惆惘 惠惘 惺擧惘惆 悋慍 悋愀悋  拆悋惆悋惘悋惷愀惘悋惘 Standby Power
 Fast Start (NFPA 110 3 times start)
 Rated Speed (Voltage , Freq.)
 Take a load
 Battery
 Fuel
 Oil
 Water heater
Genset Services Key points
 惘悋惆悋 悋慍悋愆
Installation ( Cooling, Room Design, Fan,
Exhaust)
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
 Fuel level is low in the tank
 Battery charge low
 Fuel shutoff valve(s) closed
 Fuel filter or fuel suction line is restricted
 Air intake system restriction is above specification
 Exhaust system restriction is not within specification
 Fuel is waxing due to cold weather
Engine Difficult to Start or Will Not Start (Exhaust Smoke)
 Fuel quality is poor
 Air intake system restriction
 Exhaust system restriction
 Engine cranking speed is too slow
 Overhead adjustments are not correct
Engine Will Not Crank or Cranks Slowly (Electric Starter)
 Battery cables or connections are loose or corroded
(excessive resistance)
 Lubricating oil does not meet specifications
 Battery capacity is below specification or Battery voltage is
low
 Battery temperature is below specification
 Crankshaft rotation is impaired
Combustion chamber temperatures drop so low the fuel will not burn completely.
carbon to clog the injector
spray holes and piston rings
and can cause valves to stick.
 If the engine coolant temperature becomes too low, 60属C [140属F] ,
 raw fuel from incomplete combustion ,
 will wash the lubricating oil off the cylinder walls and dilute the crankcase oil;
 all moving parts of the engine will not receive the correct amount of lubrication.
Thanks for your Attention

More Related Content

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  • 2. Purpose : Stability and reliability of the genset
  • 3. Standby Generators must be ready to operate at any time Establishing a PM maintenance program : Minimize Downtime Reduce Engine Operating Costs Increase Engine Life
  • 4. Service Repair Time : Run-to-Failure Management Preventive maintenance Management
  • 5. Run-to-Failure Management High spare parts inventory cost High overtime labor cost High machine down time Low production availability
  • 6. Run-to-Failure Management The net result High maintenance cost Low availability
  • 7. Preventive Maintenance (PM) Recommended spare parts Genuine parts Oil, fuel, coolant specification Maintenance schedule: - Daily - Weekly - 250 Hours or 6 month - 1500 Hours or 1 year - 6000 Hours or 2 years - Others
  • 9. Importance Lubrication System 70-80% crank failures are due to oil contamination.
  • 10. Check Oil Level (Add oil as needed )
  • 11. Oil Level & crankshaft :
  • 12. Consider these factors when you select engine oil: Oil types (API service classifications) Engine design and construction. Fuel characteristics. Oil viscosity (SAE service classifications) Operating conditions.
  • 13. Causes of Lube System Wear & Failure Single largest problem is short engine life due to excessive soot in the oil Poor quality/low performance engine oil Extended oil change intervals Fuel dilution Wear (Lube System Caused) Seals/Bearings Turbo Crank - Main/Rod Valve, Guide
  • 14. Over-filling the engine oil leads to :
  • 18. Check Coolant Level (Add coolant as needed )
  • 20. Importance of Cooling System 40-60% Of All Engine Downtime Is Associated With Cooling System Problems Important Customer Reminders: Use proper start up procedures Clean debris from the radiator and fan Check radiator cap seal Inspect the water pump for leaks Select the right coolant
  • 21. Causes of Cooling System Wear & Failure Single most common problem poor coolant quality Due to Not maintaining adequate levels of coolant additives Using coolant that does not meet Cats specifications Not keeping the cooling system topped off Using coolant past its useful life most cooling system problems can be avoided with proper maintenance practices!
  • 23. Effects of Poor Fuel Quality excessive wear and premature failure of injectors and fuel pump Poor lubricity create combustion chamber deposits => These reduce the life of cylinder liners and rings Fuels that are a heavier grade engine knock, trouble starting, and black exhaust smoke. Low cetane numbers
  • 24. Symptoms... Clogged and slimy filters Dark, hazy fuel Sludge build up in tanks Loss of power and RPM Excess smoke Corroded, pitted injectors Foul odor
  • 25. Battery capacity (minimum recommended cold cranking amps): K50 Generator-Drive Above 10属C [50属F]- Ambient Temperature 1280- Cold Cranking Amperes Above 0 to 32属C [-18 to 0属F]- Ambient Temperature 1800- Cold Cranking Amperes
  • 26. Batteries (Specific Gravity) Battery State of Charge Specific Gravity (at 27属C [80属F]) 100% 1.260 to 1.280 75% 1.230 to 1.250 50% 1.200 to 1.220 25% 1.170 to 1.190 DISCHARGED 1.110 to 1.130
  • 33. Genset Services Key points 慍悋 惆惘 惠惘 惺擧惘惆 悋慍 悋愀悋 拆悋惆悋惘悋惷愀惘悋惘 Standby Power Fast Start (NFPA 110 3 times start) Rated Speed (Voltage , Freq.) Take a load Battery Fuel Oil Water heater
  • 34. Genset Services Key points 惘悋惆悋 悋慍悋愆 Installation ( Cooling, Room Design, Fan, Exhaust)
  • 35. Engine Difficult to Start or Will Not Start (No Exhaust Smoke) Fuel level is low in the tank Battery charge low Fuel shutoff valve(s) closed Fuel filter or fuel suction line is restricted Air intake system restriction is above specification Exhaust system restriction is not within specification Fuel is waxing due to cold weather
  • 36. Engine Difficult to Start or Will Not Start (Exhaust Smoke) Fuel quality is poor Air intake system restriction Exhaust system restriction Engine cranking speed is too slow Overhead adjustments are not correct
  • 37. Engine Will Not Crank or Cranks Slowly (Electric Starter) Battery cables or connections are loose or corroded (excessive resistance) Lubricating oil does not meet specifications Battery capacity is below specification or Battery voltage is low Battery temperature is below specification Crankshaft rotation is impaired
  • 38. Combustion chamber temperatures drop so low the fuel will not burn completely. carbon to clog the injector spray holes and piston rings and can cause valves to stick.
  • 39. If the engine coolant temperature becomes too low, 60属C [140属F] , raw fuel from incomplete combustion , will wash the lubricating oil off the cylinder walls and dilute the crankcase oil; all moving parts of the engine will not receive the correct amount of lubrication.
  • 40. Thanks for your Attention