diesel engine PM

1. KPC Training Center

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

8. Walk -Around Inspection :

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 Cat’s 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°C [50°F]- Ambient Temperature
1280- Cold Cranking Amperes
Above 0 to 32°C [-18 to 0°F]- Ambient Temperature
1800- Cold Cranking Amperes

26. Batteries (Specific Gravity)
Battery State of Charge Specific Gravity (at 27°C [80°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
• ‫زمان‬ ‫در‬ ‫موتور‬ ‫عملکرد‬ ‫از‬ ‫اطمینان‬ ‫و‬ ‫پایداری‬‫اضطرار‬ 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
• ‫راندمان‬ ‫افزایش‬
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°C [140°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