Presented by

Jobayer Ahsan,
Senior Service Engineer
Date : 31/01/2017
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Contents:
 Generator Rating Definitions
 Engine Parts Identification
 Air Induction & Ventilation System
 Exhaust System
 Cooling System
 Fuel System
 Lubricating system
 Crankcase Breather System
 Internal Mechanical Feature
 Preventive Maintenance and Health Check of Generator.
 Safety for Troubleshooting.
 Question and Answer.

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 Background

 Generator is a machine that converts mechanical energy

into electrical energy.

 Engine is a device that converts thermal energy into

mechanical energy. Engine can be run with different kind of
fuel such as diesel, gas etc.

 Alternator is a electromechanical device. It coverts

mechanical energy into electrical energy in the form of
alternating current.

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 Ratings Definitions

Prime Power: Power available at variable load with a

load factor not exceed 80% of the Prime power rating.
Overload of 10% is permitted for 1 hour in every 12 hours
operation.
Standby (maximum): Power available at variable load
in the event of a mains power network failure up to a
maximum of 500 hours per year of which up to 300 hours
may be continuous No overload is permitted.

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Perkins Engine parts identification
Turbocharger
Air Filter Air Induction Pipe

Fuel Solenoid

Intake Manifold

Damper Pulley

Self Stator
Oil Sump
Oil Filters

Oil Cooler Fuel Filter Charging Alternator

Air Induction System
 Air Induction System
• Engine Mounted Air Filters 4012
• Medium Duty paper element type

• Filtration 98% of all particles greater than 10um (micron) in SAE (Society of
Automotive Engineers) fine test dust

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Ventilation System

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Ventilation System

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Ventilation System

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Ventilation System

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 Ventilation System

• Outlet/Inlet Sizes
• The outlet opening should have a free flow area approximately 25% larger
than the radiator matrix

– Recommended engine room is maintained at a maximum temperature

of 38oC.
– If ambient temperature exceeds 38oC, then a temperature rise of no
more then 8oC above ambient should be maintained

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Exhaust Systems
Exhaust Systems

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Exhaust Systems

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 Exhaust System
• Exhaust System Installation
– The exhaust system should avoid touching or passing
close to ;

• Lube oil and fuel filters, fuel tank and LP/HP fuel systems

• Radiator, oil sump and air cleaner/filter

• Engine wiring and sensors

– Keep weight off the turbocharger and exhaust outlet elbow by supporting
the exhaust system
– Provide flexibility between the engine outlet and exhaust system
– Exhaust pipe connections must be leak free

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 Exhaust System
• Back Pressure
– The exhaust system will produce a certain resistance to the flow of exhaust
gases

– The back pressure for the total system must be kept within the limit of
each engine maximum :-

Maximum Allowable Maximum Allowable

Exhaust Back Pressure Exhaust Back Pressure
at 1500rpm (kPa) at 1800rpm (kPa)

All 4012-46 5.0 5.0

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 Exhaust System

• Back Pressure Calculation

– Back pressure of a proposed exhaust system can be calculated by using
:-

– P = L x Q2 x 1187 x 109
D5.33
• P = Back pressure (mmHg)
• Q = Gas flow (kg/s)
• L = Total equivalent length * straight pipe (M)
• D = Pipe diameter (mm)

• Back pressure losses through silencer(s) must be added to the above to

obtain total system losses

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Exhaust System
• Effects of Excessive Exhaust Back Pressure
– Too high a back pressure leads to:
• Loss of power: approx. 0.5% decrease for each 3.3kPa above maximum
level
• Poor fuel economy: fuel consumption increases by approx. 0.5% for
each 3.3kPa above maximum level
• High combustion temperature: 2.5% increase in exhaust gas
temperature for each 3.3kPa above maximum level
• These conditions produce over-heating and excessive smoke from the
installation, and reduce the lives of the valve heads and valve seats

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Cooling Systems
Cooling Systems

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Schematic of Typical Cooling System

outlet hose
Self venting thermostat housing

Draw down pipe

inlet hose

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Cooling System

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Cooling System

 Blocked Open Thermostats

 Always block thermostat open to 11.5mm
 Use an 18mm long spacer tube

 Drill wax capsule to disable thermostat

 Do not run without thermostat

 Inaccurate coolant restriction
 Inoperative bypass blanking will damage
engine

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 Cooling System

• Effects of air in water

 Local boiling
 Excessive coolant loss
 Drop of water pump performance
 Cavitations
 High metal temperatures
 Total cooling system failure
 Engine failure

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Cylinder Liner Cavitations
Coolant
Vapour
Liner Leak
bubbles

Cavitations Erosion

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 High Water Temperature Sensor (HWT)
Temperature Switch

If either of below condition found HWT to be declared faulty

1.Abnormal value show at Control panel display /Malfunctioning
2.Value fixed at a certain temperature.
3.Generator shutdown by showing high engine temperature / High coolant
temperature with in 30 sec of Generator start .

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Fuel Systems
 Fuel System

• The purpose of the fuel system is to ensure:

– An ample supply of clean fuel

– There is no water or air in the fuel system

– The fuel is at the correct pressure

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 Fuel System
• Fuel Filtration

Fuel Lift Pump

Fuel Filter

Hand Priming Pump

• Filtration to 10 microns

• Hand priming pump part of fuel lift pump

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Fuel System

Fuel Filter

Water
Separator

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Fuel System

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Fuel Injector

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 Fuel System
• Fuel Temperature
– Effect engine performance and emissions if fuel inlet temperature is
too high

– Fuel inlet temperature should not exceed 58oC

– Minimum fuel tank size to be 14,000 Litres,

– 14,000 Litres will allow 8 hours continuous running at Prime Power

Rating
• Low Pressure Fuel Pipes
– Material - Galvanized pipe, fittings or tanks must not be used

– M.S pipe must be used.

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Fuel System

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Fuel System
Lubricating Systems
 Lubricating Oil Recommendations
Lubricating Oil Specification
Viscosity
Perkins Engines Company Ltd recommend the use of SAE 15W/40 multi-grade oil for all engines
o o
that work in ambient temperatures above -10 C (14 F)
o o
This engine is intended for use only in temperatures above - 10 C (14 F)
Only oils which meet a minimum spec. API CG-4,CH4 or better, are to be used in this engine

Oil Top -up and Change Intervals

The usable oil shall be sufficient to allow at least 24 hours operation at Prime rating without adding
oil
The oil change interval is 500 hours for Prime duty, and 500 hours or 12 moths for Standby duty
(Oil and Fuel Filter Elements must also be replaced at this time)
Higher than recommended levels of Sulphur content in the fuel will require more frequent oil drain
periods

Oil Control
Oil consumption is not to exceed 0.1% of the fuel used
An increase in oil consumption to 0.5% of fuel used would require investigation
Lubricating Oil System

• Oil Filtration
• Disposable canister fitted with by-pass, full flow type
Oil Filler

Dipstick

• Filtration to 40 microns

• Use only lubricating oils which meet or exceed API CG4

Oil Filters
• Oil cooler is an integral part of the engine

• Oil Filler and Dipstick are mounted on B Bank only

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Oil Flow When Engine Oil is Hot

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Lubricating Oil System

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 Low Oil Pressure Sensor (LOP)
Oil pressure Switch

If either of below condition found LOP to be declared faulty

1.Value Malfunctioning
2.Value fixed at a certain level
3.Generator shutdown by showing low oil pressure .
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Crankcase Breather Systems
Crankcase Breather System

• Breather
– Check breather exit position, the point of exit of the breather should
be directed away from the engine air intake and cooling group
Fumes would deposit oil on radiator matrix and particles
of dust in the airflow would stick, resulting in radiator
and fan performance fall.

– If possible the pipe work should be less than 5 meters long and should
be of equal or greater diameter than 50.8mm

– Crankcase pressure should not exceed 245Pa at full load

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Crankcase Breather System

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Crankcase Breather
System

Clean every 500 hours

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Internal Mechanical feature
Crankcase (In-Line 8 cylinder)

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Crankshaft

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Crankshaft

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Big End Main
Bearing Bearing

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Thrust washers (bearings)

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Connecting rods

Oil feed to small end bush

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Connecting rod - ‘Vee’ engines

Inner thrust face

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Piston & Piston Ring Assembly

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In-Line Piston Cooling Jet
Oil outlet

Oil inlet

‘O’ ring seal

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Cylinder Liner
View under top flange Cylinder Liner (Top view)

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Cylinder Heads
Section Through Head & Injector Sleeve

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 Valve Assemblies (4 Valves per
cylinder)
Inlet Valve
30° Seat

Collets

Exhaust Valve Valve Rotor In / Ex

45° Seat Improves service life
Minimises carbon deposits

Lower
Spring Seat
Inner Spring Outer Spring

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Turbocharger

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Coolant Pump

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Rocker Box (Fitted & Removed)
In-Line Engine Timing
Gears

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Gear Train
Pendulum Type Camshaft Gear
Coolant pump
Drive Gear
Position
Adjustable Idler Gear

Idler Gear
Compounder Gear Assembly
Fuel Transfer Pump

Crankshaft Pinion Gear

Oil Pump Drive Gear Position

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Flywheel Housing (Oil Transfer
Details)

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Operation & Maintenance
Maintenance Procedure of Generator
 Maintenance means efforts to upkeep and repair of the Generator.
 Maintenance may be divided in the following ways :
 Emergency maintenance
 Scheduled maintenance
Battery Replace

When Battery Cable Disconnect

Engine/ Alternator Clean
required Engine Air cleaner Element Clean/ Inspect
Fuel Injector Test/ Change
Fuel Systems Inspect

Tappet Clearance Check & Adjust

Breathing System Servicing
Every
All Filter Items & Lube Oil Replace /Fill
6Months All Protection Device Check
/500 hrs Radiator Check / Servicing
Fan Belts Tension Check/ Tight
The specific gravity & the pH value of the coolant Measure
 Every 250 service Hours/1 Year
1. Engine Air cleaner Element Replace

2. Water Separator (Primary fuel filter) Replace

3. Radiator water/coolant Replace

4. Water filter (if req

req)
) Replace

5. Alternator output terminal Check

6. All Electrical wiring/ connection Check

7. Battery load capacity Check

8. Lubricating oil and Oil filter Replace

9. Fuel filter Replace

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 Every 1000 Hours Service
1. Engine Valve clearance Check/ Adjust

2. Alternator AVR Connection Inspect/ Check

Every 2000 Hours Service

1. After cooler core Inspect
2. Alternator/ Alternator coupling Inspect
3. Engine Mounting Inspect
4. Turbo charger Inspect
5. Water Pump Inspect
6. Starting Motor Inspect

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Every 3000 Service Hours
1. Fuel Injector Test

Every 4000 service Hours/ 2 Years

1. After cooler / Clean/ Test
Charge cooler core

Every 5000 Service Hours

1. Top Overhauling

Every 10000 Service Hours

1. Major Top Overhauling

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Generator Set Operation
During Generator operation
Ensure the correctly load is being applied and removed
• Do Not overload the engine
• Do Not apply two much load at one time
• Do Not remove two much load at one time
Rectify / Report / Record Any Incidents of Shutdown Due to
• Over speed • Low oil pressure
• High coolant temperature • Low coolant level
• High / Low frequency
• High exhaust temperature

Rectify / Report / Record Any

• Oil leaks • Unusual noises
• Coolant leaks • Engine will not take load
• Any Smoke issues • Air leaks
• Exhaust leaks

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Some Common Problems
Sl. No. Problem Probable Causes
Battery capacity low.
Bad electrical connections.
The starter motor turns
1  Fault in starter motor.
the engine too slowly
 Wrong grade of lubricating oil

 Starter motor turns engine too slowly.

Fuel tank empty.
The engine does not Fault in stop control.
2
start Restriction in a fuel pipe.
Fault in fuel lift pump.

Lack of Residual magnetism

Check the connection of the sensing leads to
the AVR
No voltage at no load or Faulty rotating diode
3
start up
Short ckt on rotor winding

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Safety for Troubleshooting

Ensure that guards are fitted over exposed

or live electrical terminals.
Always wear protective boots when
working in hazardous area.
Do not wear loose clothing, ties, jewelers,
etc.
Always wear suitable overalls.
Be conscious to avoid any risk of getting
electric shock.
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Question ???
and
Answers ….

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Thank you

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