Maintenance Instruction V03

Orient Energy Systems (Private) Limited
Respected Customer, (Pages 1 to 18)
After Good Installation & operation, Maintenance is

one key to diesel generator set reliability
Customer’s Training or instruction for Good Operation:
1. Cleanliness is very important; always keep the Gen set and surrounding area
clean.
2. Before start up checks should be made in which oil level, coolant level and
fuel level.
3. Start the Gen set, check for any un-usual noises and leaks, monitor & record
the parameter like Oil pressure, water temperature, RPM and voltages output.
4. Put the load gradually after having the Water temperature around 35°C
5. Load (amps) should be balanced on all three phases and run the set >35% up
to 80% of Gen set capacity keeping in view of altitude and local ambient
temperature tendency. Please avoid to run Gen set under load.
6. Log Sheet should be maintained for recording the above mentioned
parameters or as per any of specific application.
7. At the time switching off, always switched off the load first and run the Gen set
for at least 5minutes to cool down the Engine temperatures.
8. Always operate the Gen set via its controller given start/stop button or
switches instead of Emergency push button because it’s built for only in
emergency cases.
9. In case of non-availability of static battery charger, always exercise twice in a
week for 15mintues to keep the Batteries healthy.
Maintenance instructions for Operators:
1. Daily, Weekly & Monthly checks should be performed and recorded via log
book.
2. First Maintenance will be performed after 50hours or one month after initial
startup or commissioning.
3. Next Maintenance will be performed after every 250hours or 6months as per
Engine family via manufacturer recommendation.
4. Maintenance should be done via qualified or trained technician.
Periodic Maintenance
The periodic maintenance procedures should be performed at whichever interval

occurs first. At each scheduled maintenance interval, perform all previous
maintenance checks that are due for scheduled maintenance.
The tabular data that follows gives the recommended service intervals for a
generator set on Standby service. If the generator set will be subjected to Prime
usage or extreme operating conditions, the service intervals should be reduced
accordingly.
1|Page
Some of the factors that can affect the maintenance schedule are:
• Use for continuous duty (prime power)

• Extremes in ambient temperature
• Exposure to elements
• Exposure to salt water
• Exposure to windblown dust or sand
Consult with an authorized distributor if the generator set will be subjected to any
extreme operating conditions and determine if extra protection or a reduction in
service intervals is needed.
Use the running time meter to keep an accurate log of all service performed for
warranty support. Perform all service at the time period indicated, or after the
number of operating hours indicated, whichever comes first.
Maintenance Service time:

Following three tables are as per Cummins Recommendations.
Table 1 Periodic Maintenance Schedule
Perform maintenance tasks as specified using Daily or Hourly periods
– whichever occurs first
MAINTENANCE ITEMS
Daily or 8 Wkly or 6 M or 12 M or 12 M or 2000 2Yrs. or
Hours 50 Hrs. 250 Hrs. 250 Hrs. 1500 hrs. Hrs. 6000 Hrs.
Operator
Task Task Service Technician Task
Air Intake Maintenance Schedule
Check air cleaner restriction indicator
(where fitted): If the service indicator
shows red, replace air cleaner ■
elements and reset the air cleaner
service indicator.
Check air intake system for leaks:
Visually inspect the air intake system
for signs of wear or damage. Check
■
audibly when the generator set is
running. To replace, contact your
authorized distributor.
Clean air cleaner housing. ■
Control Maintenance Schedule
Check operation of Control Panel:
Check display (the system will perform
a control panel test on initial ■
activation). To replace, contact your
2|Page
Check operation of Emergency Stop
Button: With the generator set
running, press the Emergency Stop ■
button. Check all systems, before
resetting the fault.
Cooling Maintenance Schedule
Check coolant level of radiator(s)
(water jacket & LTA): If low, top up to
coolant system specifications level, ■
with Cummins recommended coolant
mix.
Check cooling fan blades: Visually
inspect the fan blades through the
guarding for signs of wear or damage. ■
To replace, contact your authorized
distributor.
Check drive belt, condition and
tension: Visually check belt for
evidence of wear or slippage. To ■
replace, contact your authorized
distributor.
Check coolant lines and radiator hoses
for leaks, wear, and cracks: Visually
check for leaks, worn or damages ■ ■
hoses. To replace, contact your
Check radiator air flow: Visually inspect
the radiator through the guarding for
blockage, build up of debris, signs of ■
wear or damage. To clean or replace,
contact your authorized distributor.
Clean radiator cores. ■1 ■
Check aftercooler cores. ■
Check water pump. ■
Lubricate fan shaft bearings ■
Change coolant filter. ■
Check coolant heater. ■
Fan drive idler arm and fan belt
■
tensioner check.
Replace cooling system coolant. ■
■1 – Cleaning schedule may be reduced depending on operating conditions/environment. Contact your
ENGINE MAINTENANCE
Check fuel lines and hoses: Visually
check for leaks, worn or damages
■1
hoses. To replace, contact your
3|Page
Check engine oil level: If low, top up to
engine specifications level, with ■
recommended oil.
Drain water from fuel system primary
filter/water separator: Drain one cup,
or more, of fuel to remove water and ■
sediment. See procedure in this
chapter.
Crankcase breather tube/collector.
Check for condensed oil. Drain and
■
dispose of in accordance with local
legislation.
Check charge alternator: Check visually
and audibly when the generator set is
■
Check engine oil make‐up system: If
low, top up to indicated level, with ■
Cummins recommended oil.
Check engine coolant heater: Check
coolant heater has power and is
■
Replace lubricating oil and filters. ■
Check engine ground. Clean as
■
necessary.
Replace water separator element. ■ ■
Replace fuel system secondary filter. ■ ■
Check engine mounts. ■
Check starting motor. ■
Check turbocharger. ■
Check Charging Alternator ■
Engine oil heater check. ■
Engine steam clean. ■
■1 – Check before starting and again with the generator set running.
Exhaust Maintenance Schedule
Check all exhaust components, and
hardware (fittings, clamps, fasteners,
etc.): Visually inspect the exhaust
system for signs of wear or damage. ■
Check audibly when the generator set
is running. To replace, contact your
Check exhaust condensation trap:
Drain condensation into a suitable
■
container. Dispose of fluids in
accordance with local legislation.
4|Page
Table 2
Generator Set Maintenance Schedule
Perform maintenance tasks as specified using Daily or Hourly periods –
whichever occurs first
MAINTENANCE ITEMS
Daily or 8 Weekly or 6 Mths or 12 Mths or 12 Mths or 2000 2 Yrs. or
Hours 50 Hours 250 Hrs. 250 Hrs. 1500 Hrs. Hrs. 6000Hrs.
Operator
Task Service Technician Task
Task
Check fuel level in tank: If
low, add fuel (A full tank ■
reduces condensation.)
Check bedframe/enclosure
fluid containment (where
fitted): Drain as necessary.
Clean all contaminated ■
areas. Dispose of fluids in
accordance with local
legislation.
Inspect Engine/Alternator ■2
Flexible Rubber Coupling
Check generator set
Visually check enclosure (if
fitted), walk around
inspection of generator set.
Make sure no inlets/outlets
are covered/restricted,
■
service access doors are
operational and safety
systems are in place and
operational. To replace
damaged parts, contact
your authorized distributor.
Check batteries: Check
connections are secure and ■ ■
battery area is free from
tools and other items.
Check battery electrolyte
■1
level.
Check electrical
connections (battery,
■ ■
starter motor and
alternator connections).
■1 Lead acid battery's only ■2 For P80 Alternator regrease the alternator bearings every 1000 t0 1500 hours /
6 months
5|Page
Table 3 ALTERNATOR SERVICE SCHEDULE
SERVICE ACTIVITY Type SERVICE LEVEL
30,000 hrs / 5 years
Alternator running
10,000 hrs / 2 years
250 hrs / 0.5 year
Post Commission
1000 hrs / 1 year
Commission
Replace
Inspect
Level 1
Level 2
Level 3
Clean
System
Test
X = required * = if necessary
Alternator rating X X X

Bedplate arrangement X X
Coupling arrangement X X * X
Environmental conditions and cleanliness X X X X X X
Ambient temperature (inside & outside) X X X X X X
Alternator
Complete machine ‐damage, loose parts & X X X X X X

earth bonds
Guards, screens, warning and safety labels X X X X X X
Maintenance access X X
Electrical nominal operating conditions & X X X X X X X
excitation
Vibration* X X X X X X X
Condition of Windings X X X X X
Insulation resistance of all windings (PI test X X * * X X
Windings
for MV)
Insulation resistance of rotor, exciter and
X X X
PMG
Temperature sensors X X X X X X X
Customer settings for temperature sensors X X
Condition of bearings X X X
Grease exhaust X X X X X
Bearings
Grease in re‐greasable bearing(s) X X every 4000 to 4500 hours / 6 months
Sealed bearing(s) X every 4000 to 4500 hours
Re‐greasable & sealed bearing(s) X * X
Temperature sensors X X X X X X X
Customer settings for temperature sensors X X
All alternator/customer connections and
X X X X X
Ter. Box cabling
Initial AVR & PFC set up X X X
AVR & PFC settings X X X X X X
Controls X X X X X
Customer connection of auxiliaries
&
Function of auxiliaries X X X X X X
Auxiliari
es Synchronization settings X X
Synchronization X X X X X X X
Anti‐condensation heater X * X
6|Page
Diodes and varistors X X X X X
Rectifier
Diodes and varistors X X
Air inlet temperature X X X X X X
Cooling Air flow (rate & direction) X X X
Condition of fan X X X X X X
* For stand‐alone alternator only.
Preventive maintenance
Because of the durability of diesel engines, most maintenance is preventive in nature.
Preventive diesel engine maintenance consists of the following operations:
A. General inspection
B. Lubrication Service
C. Cooling system Service
D. Fuel system Service
E. Air Intake System Service
F. Servicing and testing starting batteries
A. General inspection
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 ASAP.
B. Lubrication Services for 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.
For accurate readings on the engine’s dipstick, shut off the engine and wait approximately 10
minutes to allow the oil in the upper portions of the engine to drain back into the crankcase.
Keep the oil level as near as possible to the “full” mark on the dipstick by adding the same
quality and brand of oil.
Cummins Inc. recommends the use of a high quality, diesel oil such as Valvoline premium
blue or Valvoline premium blue extreme life.
7|Page
Question: Why Oil consumed?

Yes, normally the engine oil must have consumed sputtering
• To adhesion layer of oil on the cylinder wall,
• Piston rings scraper oil left in the cylinder wall in the high-temperature
gas under some burning With the exhaust together discharge
• There are some oil evaporates and is discharged into the crankcase.
(Approximately, 5% ~25% or with respect to Engine family & Manufacturer)
C. Cooling system service

Check the coolant level during off periods, Remove the radiator cap after allowing the engine
to cool and, if necessary, add coolant until the level is about 3/4-inch below the radiator cap
lower sealing surface. Heavy duty diesel engines require a balanced coolant mixture of water,
antifreeze and coolant additives. Use a coolant solution as 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.
By definition we think of cooling system has something that cools but actual has four functions
and must all work cohesiveness for the engine to survive
1. It absorb the unwanted heat generated by the engine

2. Circulate that heat
3. Dissipate the heat
4. Control the heat
8|Page
Let’s take a moment to talk about all the components that actual make that happened;
1. The heat absorbed by the coolant itself and this means coolant must have good heat
absorbing and heat transferring capabilities. Glycol or Antifreeze mixed with 50/50%
with pure water has much superior heat transferring characteristics, either pure water
or pure glycol.
2. Coolant is continuously circulating with in the cooling system and this function is
performed by water pump. Interestingly enough typical water pump can circulate
between 11 to 15000gallons of water /hour and it’s critical that this pump functions
flawlessly.
3. Heat is dissipated or radiated and this takes place in radiator. The efficiency and
effectiveness of radiator is critical.
4. Finally, the cooling system controls the heat and this is done by the thermostats,
again imperatively that thermostat operates flawlessly.
9|Page
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OR
ES Compleat
It is already Mixed as per
required Ratios. (Complete
Mixture)
 A good coolant has properties that inhabit
things like liner pitting, reduce or eliminates
scale or corrosion which can affect things
like radiator, water pumps and thermostat.
 A good coolant also contains many other additives that protect specific engine component
based on their design and type of metal.
REAL™ Performance
 Lifetime coolant with service interval at 150,000 mi, 250 km, 4000 hrs.
 Provides antifreeze and antiboil protection
 Best liner pitting and corrosion protection
 Best aluminum and solder protection
 Compatible with gaskets, elastomers and other non-metallic in the engine
 Optimizes cooling system performance and water pump life
 Contains proprietary scale inhibitors
Coolant Testing
Field Maintenance Tools for Engine Coolants
Quik-Chek™ Coolant Quality Test Strips

With proper maintenance, Fleetguard ES Compleat™
coolant can last for the major overhaul life of the engine.
However, when poor quality make-up water is added to the
system or when minimum coolant maintenance is not
observed, pH levels can rise or fall to dangerous levels and
contaminants (Sulfate and Chloride) can rise to
unacceptable levels. When this occurs, coolants must be
drained and replaced immediately. To help customers
determine the quality of their coolants, Fleetguard has
developed revolutionary Quik-Chek™ Coolant Quality Test
Strips. In a matter of minutes the pH, Sulfate and Chloride levels in a coolant can be
determined. If results fall within acceptable limits, the coolant can be used until the next
service interval with confidence. The Quik-Chek™ Coolant Quality Test Strips are
available in bottles of 10 test strips (CC2718).
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Fuel system service 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 breakage. Repair any
leaks or alter line routing to eliminate wear immediately.
Diesel fuel is subject to contamination and deterioration over time, and one
reason for regular generator set exercise is to use up stored fuel over the
course of a year before it degrades. In additional to other fuel system service
recommended by the engine manufacturer, the fuel filters should be drained
at the interval. Water vapor accumulates and condenses in the fuel tank and
must also be periodically drained from the tank along with any sediment
present.
Don't Compromise on
 Quality of Fuel
 Cleaning of base tank & bulk storage tanks.
 Additional Water separators(filter) installation
 Periodic replacement of Fuel Filter its replacement also relates
to the quality of fuel
13 | P a g e
Today we like to draw your attention to the reasons of early clogging of Fuel filter
which is not the fuel filter quality issue but the contaminated fuel. Contaminated
particles as small as 4microns which is 12 times smaller than human hair and these
Particles invisibles to the human eye, can premature wear fuel injector, is not only
decreased engine performance and higher fuel consumption but could also lead to
costly damage and down time.
Today diesel engines operator are facing many fuel related challenges and first,
which is fuel quality.
Worldwide fuel chartered has stated that 50% of the diesel fuel dispensed around
the world, does not meet the international standard organization or ISO code for
cleanliness. Add to the fact that fleets off & on highway are challenged with fuel that
is transported, loaded & offloaded some time, several times and its delivery to the
actual equipment fuel tank, each time adding to the possibility of contaminations.
Therefore today challenge are:
 Fuel quality & cleanliness
 Fuel delivery & transfer
 Filter loading (filter actual loses efficiency overtime)
 Fuel pressure surges
 Filter vibration
All in all not a good combination for today engine therefore to overcome the situation,
Cummins recommends to install the additional Water separator between fuel tank
and engine. Please go through an article and at least solution.
Longer Life, Reduced Costs
All fuel filtration systems are engineered with precision to MEET customer demands for
longer life and improved performance. Fuel filters using proprietary StrataPore® multi-
layered media offer superior micron efficiencies, removing large particles, as well as the
14 | P a g e
smallest debris. Each StrataPore layer offers unique properties to extend fuel filter life
and improve performance.
The Most Technologically Advanced Fuel Filtration Systems

As the industry leader, Cummins Filtration has always remained a step ahead of market
needs by introducing innovative fuel filtration systems. Recent technological advances
include:
• Fleetguard Fuel Filters featuring NanoNet® Advanced Filtration Media

With extensive field-testing over a three-year development cycle, NanoNet advanced
filtration media is the latest in the Fleetguard fuel product lineup. Engineered to deliver
unmatched protection and superior uptime for customers using revolutionary
manufacturing technology, NanoNet media is a major leap FORWARD over competitive
media in several ways. The first of its kind for fuel filtration, NanoNet has the capability
for increased filtration efficiency while also extending filter life beyond the capacities of
conventional premium fuel filter media available on the commercial market today.
Trapping 98.7 percent of all particles as small as 4 microns (12 times smaller than the
smallest particle visible to the human eye) means that NanoNet is ten times more
effective at hard particle removal than the next best competitive product—Fleetguard’s
own StrataPore media.
• Fuel Pro®, Diesel Pro® & Industrial Pro™ Remote Mount Diesel Fuel Filtration
System
Cummins Filtration's unique "Seeing is Believing®" filter clear cover technology lets you
see the fuel filter and shows when the filter needs changing. Fuel level is low on a new
filter and as it is used the fuel level rises to show how much filter life remains. You know
when NOT to change your Fuel Pro® filter, Diesel Pro® filter, and Industrial Pro™ filter
thus reducing filtration costs, reducing maintenance costs, and much more. They can be
used with conventional Diesel fuel, JP-5, JP-8, and Jet-A fuel. Available SINGLE housing
units are rated for fuel flows up to 200 GPH (757 LPH), 180 GPH (681 LPH), 90 GPH (341
LPH), and 60 GPH (230 LPH) providing best-in-class filtration and fuel/water separation.
FH239 Series Industrial PRO® ALL in One Fuel/Water Separator

With NanoNet ™
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With the best fuel processor available today to protect your valuable equipment.
Causation: Don’t fill diesel in base tanks while the Gen set or engine in
operation; it can mix all the sediments and water which can create wear & tear
in fuel pump, nozzles/injectors and symptom can be low frequency, low power
or early chocking of fuel filters. Therefore base tank or storage day tank
should be cleaned once in two year. Can be varied as per diesel quality
These contaminations can be from the supplier, means like dirty drums,
buckets or by diesel handler.
16 | P a g e
D. Air Intake System:
The charge-air piping and hoses should be inspected daily for leaks, holes, cracks or loose
connections. Tighten the hose clamps as necessary. Also, inspect the charge-air cooler for dirt
and debris that may be blocking the fins. Check for cracks, holes or other damage.
The engine air intake components should be checked. The frequency of cleaning or replacing air
cleaner filter elements is primarily determined by the conditions in which the generator set
operates. Air cleaners typically contain a paper cartridge filter element which can be cleaned and
reused if not damaged.
Cleaning of Air filter Element with pressure Air is strictly prohibited.
For every gallon of fuel the typical diesel engine burns, it’s require about 1500gallons of air and that is
Clean Air.
Following are the air filter servicing guidelines will go long way to ensuring long engine life.
 Ensure correct replacement air filter on hand before starting.

 Remove the dirty air filter carefully to prevent trapped dirt from being dislodged and probability
entering the air intake housing.
 Thoroughly clean the air filter housing and components with damp rag and or a vacuum
cleaner if available. Make sure the seal or gasket contact surfaces are clean.
 Have the new replacement filter nearby to replace quickly, shorting the time to open air
cleaner is exposed to the environment. Ensure the Gasket of air filter sealing the housing
properly.
17 | P a g e
 Check for contact 100% of the gasket area, Appling a small amount of grease to the Gasket,
installing the filter and properly fastening all covers and then removing to inspect for square fit
can accomplish this.
 When the old filter has been removed, inspect it for uneven dirt pattern that are indicators of
dust leakage or sealing problems.
 Inspect all air system, duck works, especially between air filter and the engine. Insure that all
clamps and connections are tight and all piping is free of cracks and holes.
 Always replace the air filter with correct part number cross. Air filter element is shorter by a
fraction of an inch may make a positive and seal impossible and allow dirt into the engine.
 Use restriction indicator to term, when to change the air filter element. Otherwise change it at
the time of routine maintenance at 250~500 hours of operation. Never open air cleaner just to
look, don’t take chances and risk contamination the engine for frequent useless inspection.
Special note: Cummins Engine manufacturer & filtration discourage to clean the filter with pressurized
Air or any other means due to inadequate and incomplete process, non-availability of effective quality
measure to make sure filter is free of holes and leaks in both media and Gasket area.
E. Servicing and testing of Starting batteries
Weak or undercharged starting batteries are the most common cause of standby power system
failures. Even when kept fully charged and maintained, lead-acid starting batteries are subject to
deterioration over time and must be periodically replaced when they no longer hold a proper
charge. Only a regular schedule of inspection and testing under load can prevent generator
starting problems.
 Cleaning batteries: Keep the batteries clean by wiping them with a damp cloth whenever dirt
appears excessive. If corrosion is present around the terminals, remove the battery cables
and wash the terminals with a solution of baking soda and water (1/4-pound baking soda to
one quart of water). Be careful to prevent the solution from entering the battery cells, and
flush the batteries with clean water when done. After replacing the connections, coat the
terminals with a light application of petroleum jelly.
 Checking specific gravity: Use a battery hydrometer to check the specific gravity of the
electrolyte in each battery cell. A fully charged battery will have a specific gravity of 1.260.
Charge the battery if the specific gravity reading is below 1.215.
 Recommended Method of Removal/Installation of Batteries: before removal always push
the emergency push button than remove or install the Batteries, at the time of removal always
remove the negative cable from Battery than positive cable. At the time of installation, always
put the positive cable than the negative cable.
 Expected, Healthy Battery life is one year with Good Maintenance.
Notes:
1. These are General Instruction and for any of specific Maintenance, please consult relative
Operation & Maintenance Manual.
2. Being an Authorized distributor of Cummins diesel Engine & Generator Set
a. Genuine and legal parts, imported from Manufacturer the Cummins e.g., all
Consumables like Filters, Lube Oil (Valvoline premium blue, Only One Endorsed by
Cummins) & Grease etc. Engine Parts, Alternator Parts and Controller parts are
ready in our Stock.
b. We have qualified and Principal or Manufacturers certified Technicians for Service.
3. Non Genuine, Illegal, cheaper parts and service from unqualified persons will leads to heavy
cost in near future due to breakdown.
4. Here we like to recommend you, please have AMC contract with us which leads to trouble
free and smooth operation and long terms heavy cost will also be reduced. Peace of mind will
be there.
Waseem Iqbal
Assistant General Manager
Product Support Services  +92 3018496079  waseem.iqbal@orient-power.com
1 KM Defense Road, Off Raiwind Road Lahore –Pakistan
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Orient Energy Systems (Private) Limited

Respected Customer, (Pages 1 to 18)

After Good Installation & operation, Maintenance is

Maintenance instructions for Operators:

The periodic maintenance procedures should be performed at whichever interval

• Use for continuous duty (prime power)

Maintenance Service time:

Alternator rating X X X

Complete machine ‐damage, loose parts & X X X X X X

Preventive diesel engine maintenance consists of the following operations:

B. Lubrication Services for Engine:

Question: Why Oil consumed?

C. Cooling system service

1. It absorb the unwanted heat generated by the engine

Quik-Chek™ Coolant Quality Test Strips

The Most Technologically Advanced Fuel Filtration Systems

• Fleetguard Fuel Filters featuring NanoNet® Advanced Filtration Media

FH239 Series Industrial PRO® ALL in One Fuel/Water Separator

 Ensure correct replacement air filter on hand before starting.

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