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Standards Cummins Genset Technical Maintenance-8

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C. Genset Maintenance (Class II)
(This is only available for experts.)
The Class II maintenance must be added to the following items besides the ones in the procession of the class I maintenance.
1. Wash the piston with its brake, the rocker set, piston and ring set, double bearing and examine the state of wearing and tearing.
2. Examine the rolling big end bearing and check inside and outside of them if they are loose.
3. Clarify the dirt or mud in the pipes of the coolant system.
4. Clarify the accumulated coal in the burning room of the cover gasket and in the exhausting pipelines.
5. Examine the state of wearing and tearing about the valve, valve pipelines and valve stand, push the rod and the rocker and then grind and regulate them.
6. Wash and examine the oil pump, oil cooler and their pipelines.
7. Examine the producing valve of the oil spraying cylinder plug complete set.
8. Examine and regulate the state of oil-sprayer, oil spraying pressure and atomizer.
9. Clarify the accumulated coal in the turbocharger rotor, and examine the state of wearing and tearing about the bearing and impeller. If necessary, repair or change it.
10. Examine if the connector bolt of the generator and diesel engine is loose or tooth-slip. If something problem, repair or change it.
11. Examine if the insulation packing is super heated and aging so as to hurt somebody. If there‟s some damage, repair it in time.
D. Genset Maintenance (Class III)
The Class III maintenance must be added to the overhauling besides the ones in the procession of the Class II maintenance.
12. List about How to Fix a Common Breakdown
Breakdown phenomenon/ Causes to the breakdown and settlements/ Failed to start / An attempted start/ Low or unsteady rotational speed/ Low voltage frequency or zero indication/ Additional installation without operation/ Non-transmission genset/ Low oil pressure/ Water temperature/ Hypervelocity (Over speed)/ Low oil level/ Battery warning/ Engine smoking/Different sounds from engine/ Causes/ Settlements
1) Abnormal circuit operation/ examine the electric causes or contact FDK Co.
2) Inadequate battery power/ examine and charge the battery, change it when necessary.
3) Battery joint is rotten or cable connector is loose./ Examine the connecting role which connects the cable, twist the nut tight and change the connectors and nuts which are rotten heavily.
4) Cable connecting in bad condition or breakdown from charger or battery/ Check the connector between charger and battery.
5) Breakdown from motor start/ Contact FDK Co. and ask for help.
6) Inadequate fuel in the engine cylinder/ Examine fuel tank and fill with oil.
7) Air within fuel pipeline/ Get rid of the air in the fuel system.
8) Fuel filter blocked up/ Change the fuel filter.
9) Abnormal fuel system operation/ Contact with fuel filter.
10) Air filter blocked up/ Change the air filter.
11) Over low ambient humidity/ Examine the oil viscosity and brand.
12) Abnormal governor/ Contact FDK Co. and ask for help.
13) Breakdown from the start circuit of control system/ Examine the starter of control system and stop the control circuit.
14) Low ambient humidity or under preheated engine/ Examine the engine‟s preheating system, operate the engine no load and make it reach the operation temperature.
15) Abnormal operation of AVR/DVR/ Contact FDK Co. and ask for help.
16) Over low hypervelocity of engine/ Examine the engine governor.
17) Breakdown from the indicating meters/ Examine the meters, change them when necessary.
18) Breakdown from the meters connection/ Examine backtrack of the meters‟ connection.
19) Overload/ Lower the load of genset.
20) Overload and tripping operation/ Lower the load of genset and survey if the ambient humidity is over height or not.
21) Short circuit or overload causes tripping operation/ Examine the genset exit installation and its backtrack.
22) Abnormal operation of additional installation/ Contact FDK Co. and ask for help.
23) Vanished power source/ Examine the power backtrack.
24) High oil level/ Drain off the unnecessary oil.
25) Lacking oil/ Add oil to oil tank and examine if there‟s leakage or not.
26) Oil filter blocked up/ Change the oil filter.
27) Abnormal load of oil pump operation/ Contact FDK Co. and ask for help.
28) Lacking cooling water/ Examine the water tank after the engine is cool and check if the coolant level is normal and if there‟ any leakage too. Add coolant if necessary.
29) Breakdown from pump/ Contact FDK Co. and ask for help.
30) Breakdown from sensor, control system and connecting lines/ Examine if the connecting lines are loose or cut off, which are of sensor, control system and connecting lines to the ground. Check if it is necessary to change the sensor.
31) Water tank/ intercooler blocked up or too dirty/ Examine and clarify the water tank/ intercooler and check if there‟s some impurity obstructs the airflow around the water tank.
32) Other possible breakdowns/ Contact FDK Co. and ask for help.

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