The document discusses maintenance of standby generators to minimize downtime and operating costs while maximizing engine life. It emphasizes establishing a preventative maintenance program including daily, weekly, and periodic checks of key systems like fuel, oil, coolant, and batteries. Specific maintenance tasks are outlined to inspect components, monitor levels, and address issues like contamination. The importance of fuel, oil, coolant, and battery quality is stressed to avoid wear and failures.
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
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
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
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.