 keep an accurate log of all services performed. This log also will be important for warranty support. The Table shows a typical diesel engine maintenance schedule for generator sets.
When the generator set is running, operators need to be alert for mechanical problems that could create unsafe or hazardous conditions. Following are several areas that should be inspected frequently to maintain safe and reliable operation.
• Exhaust system: With the generator set operating, inspect the entire exhaust system, including the exhaust manifold, muffler, and exhaust pipe. Check for leaks at all connections, welds, gaskets, and joints — and make sure that the exhaust pipes are not heating surrounding areas excessively. Repair any leaks immediately. Check for excessive smoke upon starting: It can indicate possible performance and air quality issues that may require immediate attention.
• Fuel system: With the generator set operating, inspect the fuel supply lines, return lines, filters, and fittings for cracks or abrasions. Make sure the lines are not rubbing against anything that could cause an eventual failure. Repair any leaks or alter line routing to eliminate wear immediately.
• DC electrical system: Check the terminals on the starting batteries to make sure the connections are clean and tight. Loose or corroded connections create resistance, which can hinder starting.
• Engine: Monitor fluid levels, oil pressure, and coolant temperatures frequently. Most engine problems give an early warning. Look and listen for changes in engine performance, sound, or appearance that will indicate that service or repair is needed. Be alert for misfires, vibration, excessive exhaust smoke, decreases in power, or increases in oil or fuel consumption.
• Control system: Inspect the control system regularly, and make sure it is logging data properly during engine exercise. Be sure to return the control system back to normal automatic standby (AUTO) when testing and maintenance are completed.
Check the engine oil level when the engine is shut down at the interval specified in the Table. For accurate readings on the engine’s dipstick, shut off the engine and wait approximately 10 min. to allow the oil in the upper portions of the engine to drain back into the crankcase. Follow the engine manufacturer’s recommendations for API oil classification and oil viscosity. Keep the oil level as near as possible to the “full” mark on the dipstick by adding the same quality and brand of oil.
Change the oil and filter at the intervals recommended in the Table. Check with the engine manufacturer for procedures for draining the oil and replacing the oil filter. Used oil and filters must be disposed of properly to avoid environmental damage or liability.
Cooling system service
Check the coolant level during shutdown periods at the interval specified in the Table. Remove the radiator cap after allowing the engine to cool, and, if necessary, add coolant until the level is about 3/4 in. below the radiator cap’s lower sealing surface. Heavy-duty diesel engines require a balanced coolant mixture of water, antifreeze, and coolant additives. Use the coolant solution recommended by the engine manufacturer.
Inspect the exterior of the radiator for obstructions, and remove all dirt or foreign material with a soft brush or cloth. Use care to avoid damaging the fins. If available, use low-pressure compressed air or a stream of water in the opposite direction of normal air flow to clean the radiator. Check the operation of the coolant heater by verifying that hot coolant is being discharged from the outlet hose.
Fuel system service
Diesel is subject to contamination and deterioration over time, and one reason for regular generator set exercise is to use up stored fuel before it degrades. In addition to other fuel system service recommended by the engine manufacturer, the fuel filters should be drained at the interval indicated in the Table. Water vapor accumulates and condenses in the fuel tank — and also must be periodically drained from the tank along with any sediment pres