DOC NO.

SIL/IMPE/DGS/00/1 OF 6
Date 09.01.06

SIMPLEX INFRASTRUCTURES LIMITED

INSTRUCTION MANUAL FOR PLANT & EQUIPMENT

DIESEL GENERATORS

1.0 Machine Particulars

i).Manufacturer's Name & Address : __________________________

ii).Capacity : __________________________

iii).Model : __________________________

iv).Serial No. : __________________________

v).Engine No. : __________________________

vi)..Alternator No. & Make : __________________________

vii).F.I.P No. & Make : __________________________

viii).Name & Address Of Dealer : __________________________

__________________________
__________________________

ix).Date Of Purchase : __________________________

x).Date Of Installation : __________________________

xi).Registration No. : __________________________

xii).Insurance Policy No. : __________________________

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Date 09.01.06

SIMPLEX INFRASTRUCTURES LIMITED

2.0 Operation:

Diesel Generators are generally used to produce electrical power through an alternator driven by an
engine depending upon the capacity of the electric generating unit. Generators are placed on a high
raised platform mounted by AVM pads. The DG comprises of a panel box through which the flow of current &
electrical factors can be calculated. The capacity varies from 3.0 KV to 1250 KV. Now a days Diesel
Generators are kept inside a silent set accessories to avoid noise pollution.

3.0 Maintenance Schedule

3.1 Before Starting.

a) Check the dust indicator.
b) Check the engine oil level.
c) Check the coolant level.
d) Check & adjust the V-belt tension.
e) Check fuel level in fuel tank.
f) Check fuel tank element.
g) Check all the safety warning devices.
h) For air cool engine check blower.
i) Check any oil leakege.
j) Tighten water pump idler pully bolts.
k) Check power distribution wiring & connection.
l) Make sure AVM pads are tighten enough.
m) Check radiator for any external leakage.
n) Clean the silent panel mesh.
o) Check the turbo charger for any kind of leakage.

3.2 After Starting.

a) Check engine exhaust smoke colour.

b) Check all the gauges.
c) Check all the safety warning devices.
d) Check any abnormal sound in the Engine unit .
e) Check the electrical wiring system.
f) Check all the switches.
g) Check all the function of the governor.
h) Check any abnormal sound in the alternator.
i) Check the oil & water temperature.
j) Check the illumination of all lights & bulbs.
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Date 09.01.06

SIMPLEX INFRASTRUCTURES LIMITED

3.3 Maintenance: After every 250-300 running hours.

a) Clean the air filter element.

b) Replace the engine oil.
c) Replace the oil filter element.
d) Replace the fuel filter.
e) Wash the fuel tank strainer.
f) Check terminal bloch.
g) Clean the engine body.
h) Check the air cleaner
i) Clean the radiator.
j) Check all the auto electrical system.
k) Check coolant inhibitor.
l) Check heat exchanger zinc plugs.
m) Change the by-pass filter.
n) Clean fuel tank breather.
o) Clean/change crank case breather.
p) Check the output voltage.

3.4 After Monthly checking is completed.

i) Start the engine.

ii) Run at idle rating for 5 min.
iii) Check the oil pressure.
iv) Stop the engine and check the oil level after 15 min.
v) Note the date of servicing, the hour at which servicing is done and the next due
date.All in log book for the machine.
vi) In case any abnormality is being rectified it should also mentioned in the Log Book.

4.0 Safety:

a) The machine shall be run according to the norms & instruction indicated in the manual
to ensure personal safety of the operator and the site workers.

b) The machine can only be operated by specialized & trained operator .

c) The operator shall wear

i) Safety shoes.
Safety Helmets.
Safety Goggles.

d) Never operate the machine or carry out maintenance without any proper knowledge.
 e) Fire extinguisher should be kept.

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Date 09.01.06

SIMPLEX INFRASTRUCTURES LIMITED

f) Clean all the electrical points to avoid spark/fire.

g) Don't wear any loose fittings.

h) Before operation of machine make sure that all points of safety have been checked and
are in order.
i) Don't try to rectify any fault during running of machine .

j) After servicing the machine check & count the tool before starting the machine.

k) Make sure the rear of the vehicle is free from any obstacle or working personel.

I) The machine should be fenced around.

“Prevention is better than cure”

5.0 Maintenance schedule in sheets to follow.