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THEORETICAL CONCEPTS OF CONSUMABLES

REPLACEMENT
MODULE 2.5
DISTRIBUTORS TRAINING
Themes

01: Description of safety conditions

02: Maintenance and troubleshooting

03: Consumables identification

04: Consumables operation mode

05: Consumables replacement mode

06: Maintenance intervals

MODULE 2.5. | Theoretical concepts of consumables replacement |

01: Description of safety
conditions

MODULE 2.5. | Theoretical concepts of consumables replacement |

 01: Description of safety
conditions
Before any intervention it is necessary to
ensure that:
 The generator is blocked from startup.

 This is possible by doing the following:

 Set the controller in STOP mode

 Pushing the emergency STOP button

 Disconnect the battery switch

 Disconnect the negative terminal of the battery

MODULE 2.5. | Theoretical concepts of consumables replacement |

 01: Description of safety
conditions
 Some of the warning symbols that can be found on a generator:

MODULE 2.5. | Theoretical concepts of consumables replacement |

 01: Description of safety
conditions
 Warning!!!
 It is important that no attempt is made to work on the engine without the necessary knowledge
and experience of the various tools and instruments;
 All maintenance tools and equipment must be in good condition;
 Personal protective equipment must be used in accordance with the work to be performed;
 The manufacturer's instructions must be followed and the safety information must be observed;
 Before dismantling, it must be ensured that the systems concerned are drained and/or
depressurized;
 After disassembly, protect any openings in the engine against dirt.

MODULE 2.5. | Theoretical concepts of consumables replacement |

02: Maintenance and
troubleshooting

MODULE 2.5. | Theoretical concepts of consumables replacement |

 02: Maintenance and
troubleshooting

 During the preventive maintenance you must:

 Visually inspect the generator set for leaks, cleaning status, loose elements, changes and conservation
status;
 Check engine oil, fuel and coolant levels as well as battery status and possible alarms on the controller;
 If everything is normal, put the generator in Manual mode and start it up. Allow it to work about 10/15
minutes and stop it;
 Put the generator in safe mode and run the maintenance;
 After the maintenance is finished, it is necessary to start the generator in order to verify that it is in
good working condition

MODULE 2.5. | Theoretical concepts of consumables replacement |

 02: Maintenance and
troubleshooting

 Sometimes generators have difficulty starting or have alarms on the controllers that do not
allow them to function normally.
 When this happens it is essential to start with the simplest checks:
 Alarms on the controller: The controller is the brain of the installation, so if there is any
irregularity that it can detect, it will transmit information about the possible problem.
 Fuel system level and condition: Sometimes when the fuel level in the tank is very low and the
fuel sensor is defective, the circuit can catch air, so it is necessary to remove the air. Also, when fuel
quality is inadequate due to prolonged storage without use, it may also cause damage to the fuel
circuit, especially the injection pump.

MODULE 2.5. | Theoretical concepts of consumables replacement |

 02: Maintenance and
troubleshooting

 Battery condition and charge: The battery contacts must be clean and in good
condition and the electrolyte level must be adequate to fully cover the inner plates. Measure
the battery charge with the negative terminal off (be aware that the batteries may have a
normal voltage value, but their ampere rating is too low to start with the generator).

 Wiring condition: In the event of intermittent malfunctions, the cause may be in the
wiring that is degraded and the contact is not being effected effectively. Electric wires and
plugs should be drawn with moderate force to try to figure out if there is any weakening
connection.

MODULE 2.5. | Theoretical concepts of consumables replacement |

03: Consumables
identification

MODULE 2.5. | Theoretical concepts of consumables replacement |

 03: Consumables
identification

 The type of consumables to be replaced on a maintenance are:

 Fuel filters: Depending on the type of engine, in the fuel circuit we can find:
 Separating filters have the function of separating the water that may be present in the fuel
by decanting.
 Prefilters have the function of fuel filtration for larger particles.
 Main filters is where final fuel filtering occurs before it enters the injection pump.
 Oil filters: Usually these types of filters are easy to identify as they have no tubular connections.
In this type of filters is where the filtration of solid residues present in the lubricating oil occurs.
Particular care must be taken during replacement as the oil is at an high temperature.

MODULE 2.5. | Theoretical concepts of consumables replacement |

 03: Consumables
identification

 Water filters: They are a type of filters that are usually installed in larger groups and are

rarer to find. These filters have the function of filtering the engine coolant. Particular

care must be taken during replacement, as the coolant is at high temperature.

 Air filters: These filters are located inside the black cylindrical cartridge(s) located at the

top of the engine. Its closure is made by quick couplings. When replacing these filters, it

is convenient to clean the inside of the cartridge.

MODULE 2.5. | Theoretical concepts of consumables replacement |

 03: Consumables
identification
 Lubricating oil: Depending on the type of engine, the amount of oil to be replaced will
be different. Proper oil should be recommended by the engine manufacturer. The oil
level on the dipstick should be between the minimum and maximum mark. Note that
after changing the oil and after starting the engine, the oil level will drop slightly, as
some oil will be stored in the oil filters.
 Coolant: The mixture of water and coolant should be in an approximate proportion of
50% -50%. The coolant should be of the brand recommended by the engine
manufacturer. The coolant should be drained at the lowest point of the refrigeration
circuit in order to remove as much as possible.

MODULE 2.5. | Theoretical concepts of consumables replacement |

 03: Consumables
identification

 Driving belt: Although this element is not replaced as often as the filters, it is also
considered a consumable element. There are engines that have more than one driving
belt. These belts have the purpose to drive the refrigeration fan and the battery charge
alternator, besides other existing equipments, depending on the engine.
 It’s important to check the condition and the tension of the belts regularly, if they are
loose or in poor condition, they will have to be tensioned or replaced sooner than
recommended by the maintenance schedule.

MODULE 2.5. | Theoretical concepts of consumables replacement |

 03: Consumables
identification

 Blow-by filters: These filters have the function to separate the condensable vapors

from the non condensable vapors that com from the crankcase.

 Inside the crankcase are produced vapors because of the oil heating and because of

some combustion gases that might pass through the piston rings.

 There are different types of crankcase filters, some of these are washable, others

don’t require a maintenance and others are replaceable.

MODULE 2.5. | Theoretical concepts of consumables replacement |

04: Consumables operation
mode

MODULE 2.5. | Theoretical concepts of consumables replacement |

 04: Consumables operation
mode
 Oil filters:

MODULE 2.5. | Theoretical concepts of consumables replacement |

 04: Consumables operation
mode
 Fuel filters:

MODULE 2.5. | Theoretical concepts of consumables replacement |

 04: Consumables operation
mode
 Air filters:

MODULE 2.5. | Theoretical concepts of consumables replacement |

 04: Consumables operation
mode
 Blow-by filters:

MODULE 2.5. | Theoretical concepts of consumables replacement |

05: Consumables
replacement mode

MODULE 2.5. | Theoretical concepts of consumables replacement |

 05: Consumables
replacement mode
 Working principle:

MODULE 2.5. | Theoretical concepts of consumables replacement |

06: Maintenance intervals

MODULE 2.5. | Theoretical concepts of consumables replacement |


 Example of maintenance intervals for Grupel engines:
Daily maintenance
Check oil level
Check coolant level
Check fuel level
Check for leaks
Check battery charge and electrolyte
Check condition of air filter
level
Check the integrity of all components
attached to the engine
Check the air filter clogging indicator
Check belt condition
06: Maintenance intervals
50 hours
Replace crankcase oil
Replace the oil filter(s)
Replace the fuel filter(s)
Check coolant condition
Check belt condition and
tension
250 hours
Check coolant condition
Check the radiator cleaning
condition
Replace crankcase oil
Replace the oil filter(s)
Replace the fuel filter(s)
Check belt condition and tension
500 hours 1000 hours Annually
Maintenance of the 250 hours Check the radiator cleaning
condition
Check the battery charge
Maintenance of the 250 hours Replace coolant
alternator condition
Check the condition of the
Replace crankcase oil
injectors
Check the condition of the Replace the oil filter(s)
turbocharger
Check the condition of the
Check intake and exhaust valve
sensors and the connection
clearances
cables of the engine sensors
Replace the air filter (if
necessary) Replace the fuel filter(s)
Check the radiator cleaning
condition Check belt condition and tension
Clean the terminals of the
battery
MODULE 2.5. | Theoretical concepts of consumables replacement |
Thank you