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Diesel Generator Maintenance Schedule

Use this checklist to ensure proper maintenance of your diesel generator.

Cylinder Liner ▼

  • Dismantle all cylinder liners
  • Honing of the Cylinder liners is to be carried out.
  • Record of measurement is to be carried out.

Piston and Piston Ring ▼

  • Withdraw all the pistons for inspection and overhauling.
  • De-carbonization of pistons is to be carried out.
  • All piston and oil scraper ring grooves are to be cleaned and inspected for wear with the help of testing mandrel in order to assess the acceptable tolerance.
  • All the piston and scraper rings are to be replaced before installing the pistons.
  • While mounting the pistons, it is to be confirmed that the piston ring positions are offsetting the ring joint 180° to each other and the spring joint of the scraper ring is also fitted 180° offset to ring joint.
  • All the plugs are to be opened up and new Glue (Loctite 2701) to be applied after cleaning the holes and plugs with Loctite 7063. Plugs are to be tightened with 100Nm torque.
  • Ultrasonic test of piston pins to be carried out by external agency.
  • Retaining rings of all the pistons to be changed.

Connecting Rod ▼

  • Inspected and measured big-end bore diameter. (Readings enclosed).
  • Small end bearings are to be inspected. The clearance between the piston pin and bush, clearances to be checked and Readings to be enclosed.
  • Visual inspection of all the CR bolts and nuts to be carried out for any marked abnormality.
  • All the machining holes blank screws to be checked for tightness.

Cylinder Heads ▼

  • All cylinder heads are to be removed and cleaned.
  • Inspect all inlet and exhaust Valve spindles and to be machined/replaced as per the observation.
  • Check the valve rotators rotation before stopping engine for rotation and change the defective Robocap/ repair the with replacement of springs, balls & pressure plates depending upon the condition.
  • Carry out overhauling of all the safety valves & check & adjust the opening pressure to 175 bars.
  • Inspected Indicator valves.
  • Inspect the Valve seats. Replace /machine the valve seats as per observation.
  • Pressure testing of all the cylinder heads to be carried out.
  • All the Water guide jackets to be removed, cleaned, inspected and fitted back with new O rings.
  • Inspect & replace the nipples.
  • Nuts for cylinder heads are to be tightened with prescribed torque.

Camshaft and Camshaft Bearings ▼

  • Inspect all gear wheels bolt and connection carried out for any abnormality as per work card card no. 507-01.00.
  • Bearing clearances are to measured and recorded.
  • Checked the condition of cams.
  • Check the lubrication of camshaft for the flow of lube oil from all the bearings and spray pipe nozzles. Oil jet should be hitting at gearwheel right at meshing point.
  • Check the tightness of all screws, nuts and bolts including locking devices.
  • Inspect all pushrods.
  • Adjust inlet 0.4mm and exhaust valve 0.9mm clearance.

Operating Gear for Inlet valves, Exhaust Valves and Fuel Injection Pumps ▼

  • Roller Guide for Valve Gear: For any marks or score due to seizure, deformation on spherical stud, surface of rollers for any mark or deformation, and free play between the rollers and the bush and the pin.
  • Valve Gear-Valve Bridge springs and Push rods: All the valve bridge springs, Rocker arm brackets and push rods are to be inspected for any abnormality.
  • Roller Guide for fuel injection pumps: All the roller guides are to be inspected for any marks or score due to seizure and found ok, surface of rollers for any marks and deformation, and free play between rollers, bush and pin.
  • Check the lubrication of all the operating gears.

Governor ▼

  • Check the governor drive.
  • Change the governor oil after flushing the governor properly.
  • Check the linkages and foundation bolts tightness.
  • Governor to be overhauled by external agency.

Crankshaft and Main Bearings ▼

  • All the crankpins are to be inspected.
  • Main bearing alignment is to be checked (autolog). Crankshaft deflection and to be re-aligned. Readings to be enclosed.
  • Change all the main Bearing Shells including guide bearing.
  • Re-tightening of counter weight to be carried out at the prescribed torque of 300 Nm.
  • Re-tightening of main and guide bearing cap to be carried out at the prescribed torque of 900 bars.
  • Cleaning of crank pins has been to be carried out and check for any abnormal scoring marks.

Turbochargers ▼

  • Removed both the cartridges.
  • Removed the nozzle rings.
  • Changed the nozzle rings.
  • TC Cartridge is to be dismantled completely for change of bushes and labyrinth seal.
  • Assemble back the cartridges.
  • Check the clearances and the clearances measured are to be enclosed.
  • Cleaning of the CAC is to be carried out.
  • Pressure test of the CAC is to be carried out.
  • The air intake filter room inertia louvers are cleaned and replace the oil.

Engine Frame and Bed Plate ▼

  • Re-tightening of Holding down bolts is to be carried out.
  • Re-tightening of bolts between engine and base frame is to be carried out.
  • Overhauling of safety covers is to be carried out.
  • Change the ‘O’ rings of all the cam shaft inspection doors and CC doors.
  • Re-tightening and height measurement of all the conical (AVM) bolts is to be carried out.

Fuel Oil System and Injection System ▼

  • Check the Fuel injection valves and adjust for opening pressure/Change the nozzles. Inspect and change thrust spindles & springs.
  • ‘O’ rings off all the fuel valves are to be changed.
  • Check all the fuel high pressure pipes. Change the ‘O’ rings.
  • Check the nominal height of all the FIP and readings are to be enclosed.
  • Nozzle cooling pump is to be overhauled and following jobs has been carried out: Replaced seal and bearings, Replaced coupling, Overhaul the Motor.

Lube Oil System ▼

  • Remove the engine driven Lube oil Pump for inspection and change the bushes.
  • Replace all the Lube oil filters.
  • Clean the LOC.
  • Centrifugal filter is to be cleaned. Change the Kit of PRV (Centrifugal Filter).
  • Pre-lube oil pump is to be overhauled and carry out u/m jobs: Motor overhauled, Replaced pump seal, Replaced coupling.

Cooling Water System ▼

  • Remove & overhaul LT water pump.
  • Clean the PHE.
  • Check the thermostatic elements for 82°C stamping and change if required.
  • Remove, inspect and change the ‘O’ ring of LT water thermostat.
  • Change all the cooling water nipples in exhaust manifold if required.

Exhaust System ▼

  • Remove and clean the complete exhaust manifold and change the Intermediate pieces if found eroded with cold corrosion.

Compressed Air System ▼

  • Air starting motor to be overhauled. Change the O/h kit.
  • Main air starting valve to be overhauled and replace the kit.
  • Overhaul and replace the PRV kit.

Alternator ▼

  • Cleaning and change of bearing grease to be carried out by customer.

Miscellaneous ▼

  • Fuel pump index at Governor Index 0 is to be recorded.
  • Turning gear has to be overhauled. Change the bearing of motor and mechanical turning gear.
  • Safety shutdown switches and analogue switches functional test has to be carried out.
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