A PRACTICAL GUIDE FOR MAINTENANCE

OFFICERS

BY—

K.SUDHEER(DME, MIE) , SDE (E), MYSORE.

 INTRODUCTION

SIGNIFICANCE OF MAINTENANCE

DUE TO THE ESSENTIAL NATURE OF SERVICES IN THE TELECOM

INDUSTRY, CAPTIVE POWER GENERATION IS AN INEVITABLE PART OF OUR
INFRASTRUCTURE AND THE COMPANY IS SPENDING HANDSOME AMOUNT
TOWARDS RUNNING AND MAINTAINING THE ENGINE-ALTERNATOR SETS
EVERY YEAR. THIS NECESSITATES SYSTEMATIC PERIODICAL
MAITENANCE TO AVOID THE FOLLOWING ILL EFFECTS.

DECLINE IN EXPLOITATION
BY AMC
EFFICIENCY AGENCIES

WASTAGE OF POOR HEAVY

OVERHAULING
FUEL MAINTENANCE COSTS

DECLINE IN PREMATURE/
ACCIDENTAL
RELIABILITY FAILURES
 SYSTEMS OF AN ENGINE

1. FUEL SYSTEM: PRE-FILTER, MICRO FILTER, FEED PUMP,

FUEL INJECTION PUMP, GOVERNOR,
INJECTORS.

2. COOLING SYSTEM: RADIATOR, WATER PUMP, THERMOSTATIC

VALVE, AFTER COOLER, OIL COOLER /
BLOWER WITH FINS.

3. LUBRICATING SYSTEM: OIL PUMP, OIL FILTER, OIL DUCTS, OIL

COOLER.

4. MECHANICAL SYSTEM: PISTONS, CONNECTING RODS, BEARINGS,

VALVES, CRANK SHAFT, FLY WHEEL,
COUPLING.

5. ELECTRICAL SYSTEM: BATTERY, CHARGING ALTERNATOR/

DYNAMO, STARTING MOTOR, CUTOUTS,
WIRINGS AND TRIPPINGS WITH SENSORS.
TYPES OF ENGINES USED BY BSNL

KVA MAKE MODEL HP

7.5 KOEL TA 2 SR. II 12

15 KOEL HA 394 26
GREAVES 2 YWA MK V 23.6
GREAVES 2 YWA MK VI 26
30 KOEL HA 494 43

40 KOEL HA 494 TC 56
GREAVES 4 YDA MK II 56.1
100/125 KOEL SL 9088 TA 154
GREAVES 6YDX MK-III 156
200/ CUMMINS NTA-743G 310
250 KOEL 6 SL 8800 TA 310
GREAVES TA 2232 V12 357
 ROUTINE MAINTENANCE SCHEDULE
DAILY: CHECK OIL LEVEL, WATER LEVEL, FUEL LEVEL, DYNAMO
CHARGING, OIL PRESSURE, HOT AIR VENTILATION ETC.

125 HOURS: ELECTROLYTE LEVEL IN BATTERY, STATIC BATTERY

CHARGER FUSES, BELT CONDITION AND TENSION, BATTERY
TERMINALS CLEANING & TIGHTING ETC

250 HOURS: DRAIN AND CHANGE ENGINE OIL (SAE 20-40W), CHANGE OIL
FILTER ELEMENT, FUEL FILTER ELEMENTS, AIR FILTER OIL
(For bath type filters), CLEAN THE CYLINDER FINS, ADJUST BELT
TENSION, BATTERY ELECTROLYTE, CHECK TRIPPINGS, CLEAN
THE E/A SET ETC. (PLEASE NOTE THAT DUE TO
ADVANCEMENTS IN OIL TECHNOLOGY, MANY COMPANIES
ARE ALLOWING UP TO 400 / 500 HRS RUNNING BETWEEN OIL
CHANGES, SUBJECTED TO RECOMMENDED OIL BEING USED)

1200 HOURS:ADJUST THE TAPPET GAPS, HEAD BOLT TORQUE, REPLACE

BELTS, CLEAN DIESEL TANK, CHANGE THE RADIATOR WATER
AND ADD COOLANT, CHECK THERMOSTAT ELEMENT ETC.

3600 HOURS:TOP OVERHAULING (SERVICING OF INLET/OUTLET PORTS

AND VALVES),PUMP- INJECTOR CALIBRATION,
DECARBONISING OF SILENCER AND PIPE, COUPLING
ALIGHMENT ETC

9000 HOURS: MAJOR OVERHAULING, TURBO CHARGER SERVICE,

VARNISHING AND BAKING OF ALTERNATOR WINDINGS IF
REQD, CHANGING ALTERNATOR BEARING ETC. [THIS IS FOR A
“WELL MAINTAINED” ENGINE. POOR MAINTENANCE, OVER
LOADING, POOR VENTILATION OR ACCIDENTAL SEIZURES ETC
MAY LEAD TO NEED FOR OVERHAULING EVEN WELL BEFORE
9000 Hrs]

CONSUMPTION SPECIFIC MAINTENANCE

1. A CLEAN AIR FILTER SUPPLIES SUFFICIENT OXYGEN TO BURN THE
ENTIRE FUEL INJECTED.
2. A CLEAN HEAD AND VALVES ENABLES COMPLETE SCAVENGING THE
EXHAUST GASES SO THAT COMPLETE FRESH AIR WILL BE SUCKED
TO THE CYLINDER TO BURN THE ENTIRE FUEL INJECTED.
3. A WELL-CALIBRATED PUMP AVOIDS SUPPLY OF EXCESS DIESEL.
4. A WELL-CALIBRATED INJECTOR ENSURES COMPLETE MIXING OF
DIESEL AS A MIST.
5. A CLEAN AFTERCOOLER ENSURES MORE MASS OF AIR ENTERING THE
CYLINDER TO BURN THE ENTIRE FUEL INJECTED (TURBO ENGINES).
6. A WELL-LUBRICATED ENGINE HAS LESSER FRICTIONAL HORSE
POWER LOSS.
 7. CORRECT RINGS AND BORE FIT ENSURES GOOD COMPRESSION AND
THUS GOOD COMBUSTION.

PROPERTIES OF LUBRICATING OIL

VISCOCITY: RESPONSIBLE FOR LOW FRICTION OF BEARINGS.

SPECIFIC HEAT: RESPONSIBLE FOR COOLING OF THE BEARINGS.
CHEMICAL STABILITY: RESPONSIBLE FOR LIFE OF OIL.
HIGH BOILING POINT: RESPONSIBLE FOR PREVENTION OF
EVAPORATIVE LOSS
LOW FREEZING POINT: PREVENTS SOLIDIFICATION IN WINTER.
OILINESS: RESPONSIBLE FOR CARRYING OF THE DUST PARTICLES.
DETERGENCY: RESPONSIBLE FOR CLEANING OF SCALES/ CARBON .

SINCE THE OIL LOSES ITS PROPERTIES DUE TO MOISTURE ABSORPTION

ETC., DURING COURSE OF TIME, IT HAS TO BE CHANGED ONCE IN A YEAR EVEN
IF THE RUNNING HOURS ARE LESS THAN 250/400/500 HRS (AS PER COMPANY
RECOMMENDATION) FOR BETTER ENGINE LIFE.

MANUFACTURERS’ RECOMMENDED HOURS OF OIL CHANGE (B-CHECK)

KOEL ‘HA’ SERIES 250 HRS

R1040 / R 1080 400 HRS (K-OIL)
SL 90 500 HRS (K-OIL)
GREAVES ALL MODELS 250 HRS
MAHINDRA 4335 GM (25 KVA) 500 HRS (VALVOLINE OIL)
ESCORTS G-30 ( 25 KVA) 300 HRS

NORMAL OIL CONSUMPTION: MAX 0.7% OF ACTUAL FUEL CONSUMPTION

[ DISPOSAL OF REMOVED OIL: SINCE THE REMOVED OIL POLLUTES THE SOIL,
IT MAY BE COLLECTED AND SENT FOR
RECYCLING AS PER POLLUTION NORMS. ]
OBSERVED FUEL CONSUMPTIONS IN EXCHANGES (ON ACTUAL LOAD)

Capacity in kVA Liters / Hour

7.5 1.2 to 1.8
15 2.2 to 3.0
30 2.5 to 3.5
40 3.5 to 4.75
60 5.0 to 8.0
100 12.0 to 14.0
200 28.0 to 38.0
 LOG BOOK-PARAMETERS TO BE OBSERVED AND NOTED REGULARLY

DATE KEB OIL E/A HOURS HOUR OIL

FAIL RESTORE /WATER START STOP RUN METER PRESSURE
LEVEL TIME TIME Hr/ Min READING
2.3.12 8.45 10.00 OK 9.00 10.00 1.0 1598.5 5.5
3.3.12 12.00 14.00 OK 12.30 14.00 1.30 1560.0 5.0

BATTERY CHARGING DIESEL DIESEL OPERATOR REMARKS

FROM FROM LEVEL CONSUMED INITIALS / REPAIRS
DYNAMO CHARGER Ltrs
OK OK 210
OK OK 204 6.0

DIESEL ACCOUNTING:
AT THE MONTH END, THE DIESEL ACCOUNT TO BE TOTALLED IN THE LOG BOOK
AS BELOW:

1. OPENING BALANCE (LTS)

2. TOTAL DIESEL FILLED DURING MONTH (LTS)
3. CLOSING BALANCE (LTS)
4. DIESEL CONSUMED = 1+2-3 ABOVE.
5. TOTAL HRS RUN
6. HOURLY CONSUMPTION= 4 / 5 ABOVE ( LTS/HR)

NOTES:
1. ENGINE IS TO BE RUN MINIMUM 10-15 MINUTES DAILY WITH LOAD TO
ENSURE PROPER WORKING CONDITION.
2. CHECKING OF OIL AND WATER LEVELS DIALY TO AVOID SEIZURES.
3. OBSERVING OF BATTERY CHARGING FROM DYNAMO / CHARGER TO
AVOID STARTING TROUBLES.
4. KEEP MINIMUM 1" DIESEL LEVEL ABOVE THE VALVE IN THE TANK TO
AVOID STARTNG TROUBLE DUE TO AIR BLOCK.
5. OIL PRESSURE LESS THAN 2 kg/cm2 TO BE REPORTED IMMEDIATELY.
6. TURBOCHARGED ENGINES SHOULD BE RUN AT ‘NO LOAD’ FOR 2-3
MINUTES WHILE STARTING AND STOPPING TO AVOID TURBO FAILURE DUE
TO “OIL LAG”.
7. ENSURE PROPER VENTILATION OF THE ENGIE ROOM TO AVOID
OVERHEATING AND SEIZURE OF ENGINE
PARAMETERS TO BE INSPECTED BY THE JTO / SDE

A. IF ALL THE RUNNING PARAMETERS ENTERED IN THE LOG BOOK

AND UPDATING OF THE LOG BOOK BY OPERATOR AND INITIAL IT
FOR HAVING VERIFIED.

B. VERIFY THE FUEL CONSUMPTION AND ACCOUNTING OF DIESEL

C. RUN THE ENGINE AND OBSERVE FOR ANY ABNORMALITY.

D. ENSURE PROPER VENTILATION FOR HOT AIR EXHAUST AND

FRESH AIR INTAKE.

E. CHECK WHETHER BATTERY IS GETTING CHARGED FROM

DYNAMO AND BATTERY CHARGER.

F. CHECK FOR SYMPROMS LIKE BLACK SMOKE, SLACK BELTS,

BEARING NOISE, OVERHEATING OF WATER, INCREASE IN OIL
TEMPERATURE, BATTERY CONDITION ETC.

G. INSIST FOR PROPER UPKEEPING OF THE ENGINE ROOM AND

CLEARING OF DEBRIS.

H. CONDITION OF THE EARTH AND INSIST FOR WATERING. ( 2 NOS

NEUTRAL AND 2 NOS BODY EARTH- FOR 3 PHASE ENGINE)

I. RUN THE ENGINE ATLEAST 30 MINS WITH LOAD IN 3 DAYS EVEN

IF KEB POWER DID NOT FAIL.
RECOMMENDED BATTERY CAPACITY FOR VARIOUS CAPACITY ENGINES

ENGINE HP BATTERY Ah NO. OF PLATES

20-32 88 13
38-49 120 17
50-69 130 19
70-120 150 21
154-345 2x180 25

COMMON FAULTS OBSERVED

I . ENGINES
FAULT CAUSES REASONS
1. LOW BATTERY 1. POOR BATTERY CONDITION
2. DYNAMO FAIL
STARTING 3. NO ELECTROLYTE
TROUBLE. 4. CHARGE LAMP LEFT ‘ON’
2. AIR BLOCK 1. LOW DIESEL LEVEL IN TANK
2. LOOSE BANJO CONNECTIONS
3. CLOSED DIESEL VALVE
3. DIESEL BLOCK 1. CLOGGED DIESEL FILTER
2. CLOGGED BABY FILTER
3. CLOGGED INJECTOR
4. FAULTY PUMP/GOVERNOR
4. STARTING MOTOR 1. UNSKILLED OPERATOR
FAIL 2. ARC’ED CUT OUT TERMINAL
5. ELECTRICAL 1. LOOSE CONTACT
2. FUSE BLOWN
OIL LEAKS ‘O’ RINGS / GASKETS 1. LACK OF VENTILATION
FAIL 2. INFERIOR SPARES & BAD
FIXING
DYNAMO FAIL DYNAMO BEARING 1. OVER TENSION OF BELT
(TA 2 ENGINES 7.5 (M/S AUTOLEC) 2. WRONG DESIGN
KVA) DYNAMO ARMATURE 1. BATTERY / CUTOUT FAULTY
(M/S AUTOLEC)
EXHAUST LEAK BROKEN FLEXIBLE 1. MISALIGNMENT
(7.5 KVA & 15 KVA 2. EXCESS VIBRATION OF
ENGINES) SMALL ENGINES
BLOWER FAIL 1. BELT FAIL 1. PULLEY MISALIGNMENT
2. DAMAGED BEARING
2. BEARING FAIL 1. EXCESSIVE BELT TENSION
OVER HEATING 1. LACK OF 1. CLOSING OF SHUTTER/
VENTILATION WINDOWS
2. RADIATOR FAIL 2. CLOGGED RADIATOR
3. BELT FAIL 3. WATER PUMP BEARING FAIL
OIL TRACES IN LEAK OF OIL TO 1. LEAK IN OIL COOLER
WATER WATER
WATER TRACES IN LEAK OF WATER TO 1. FAULTY HEAD GASKET/
OIL SUMP CYLINDER BARREL ‘O’ RINGS
EXCESS OIL LEAKS GASKETS AND ‘O’ RINGS LEAKS
CONSUMPTION BURNING WITH WORN OUT OIL RINGS
DIESEL WORN OUT T/C BUSHES
WORN OUT VALVE GUIDES
LOW OIL 1. MAJOR 1. EXCESSIVE WEAR OF
PRESSURE BEARINGS
2. MINOR 1. FAULTY PRESSURE GUAGE
2. CLOGGED OIL FILTER
3. WRONG SETTING AT
GALLERY
COUPLING FAIL RUBBER ELEMENT 1. WRONG DESIGN OF 6 HOLE
COUPLING
2. ALIGNMENT FAULT

II . ALTERNATORS

FAULT CAUSES REMEDY

NO VOLTAGE 1. LOSS OF RESIDUAL FLUSH THE FIELD WITH 12 V
BUILD-UP MAGNETISM DC FOR 2-3 SECONDS
2. AVR FAIL 1. CHECK THE FUSE
2. AVR REPLACEMENT
3. SHIFT THE AVR TO PANEL
3. RR ASSEMBLY 1. DIODES REPLACEMENT
4. BRUSH FAIL 1. REPLACEMENT
VOLTAGE AVR MIS SETTING SET STABILITY ON AVR
FLUCTUATION LOOSE CONTACTS ATTEND LOOSE CONTACTS
BURNT WINDING OVERLOAD/IMBALANCE REWINDING
RUBBING OF ROTOR REPLACE BEARINGS
RODENT ENTRY PROVIDE WIRE SCREENS
 MAJOR OVERHAULING OF ENGINES.

SYMPTOMS OF AN OVERHAULING-DUE ENGINE.

LOW OIL PR. WORN OUT MAIN, CR & INTERMEDIATE

(<2 Kg/cm2) BEARINGS.

COMPRESSION LOSS DUE TO WEAR OF

DROP OF SPEED
RINGS AND BORE, GOVERNING AND
ON LOAD
FUEL INJECTION, CLOGGED VALVES.

RED HOT EXH. MIS FIRING OF FUEL, FAULTY VALVE

MANIFOLD SEATING.

BLACK
SMOKE WORNOUT RINGS AND BORE

COMPRESSION LOSS, BLOCKED

EXCESSIVE
VALVES, FUEL INJECTION PROBLEM
FUEL
CONSUMPTION

‘KIRLOSKAR’ RECOMMENDED PERIOD FOR MAJOR

OVERHAULING OF A ‘WELL MAINTAINED’ ENGINE = 9000 Hrs
OVERHAULING INSPECTION CHECK LIST
 VERIFY THE YEAR OF MANUFACTURE AND TOTAL HOURS RUN.
 VERIFY THE PREVIOUS REPAIRS / OVERHAULING HISTORY.
 VERIFY THE FUEL AND OIL CONSUMPTION FOR LAST TWO YEARS. A
STEADY INCREASE SHOWS GRADUAL DETERIORATION OF THE
ENGINE.
 VERIFY IF THE ENGINE FAILED DUE TO GRADUAL DETERIORATION OR
ACCIDENTAL FAILURE.
 ACCIDENTAL FAILURES CAN BE DUE TO
o ABSENCE OF OIL
o FAILURE OF OIL PUMP / DRIVE GEAR/BLOCK OF OIL STAINER
o FAILURE OF RADIATOR FAN SHAFT/ BELT / WATER PUMP/HOSES
o FAILURE OF BLOWER BEARING / SHAFT / BELT/BLOCK OF COOLING
FINS
o CLOSED WINDOWS / SHUTTERS OF ENGINE ROOM
o FAILURE OF CYLINDER BORE ‘O’ RINGS LEADING TO MIXING OF
WATER IN THE OIL SUMP.

 VERIFY THE CONDITION OF TURBO CHARGER. AXIAL PLAY OF THE SHAFT,

OIL SEEPAGE FROM THE BUSH LEADING TO TRACES OF OIL IN THE INLET
MANIFOLD ETC.
 VERIFY THE CONDITION OF ALTERNATOR. IF REQUIRED REPLACE
BEARINGS, VARNISH AND BAKE THE WINDINGS
 COLLECT AS MANY INFORMATION AS POSSIBLE FROM THE MAINTENANCE
STAFF REGARDING PERFORMANCE AND SYMPTOMS OF THE ENGINE.

 DECIDE THE DEGREE OF OVERHAULING REQUIRED BASED ON THE

ABOVE.
o TOP OVERHAULING: REPLACE VALVES, VALVE SEATS, VALVE
GUIDES, HEAD GASKETS AND RINGS,
PUMP-INJECTOR CALIBRATION.

o MEDIUM OVERHAULING: (REPEAT TOP OVERHAULING) +

REPLACE PISTONS, LINERS, CR BEARINGS
ETC.,

o MAJOR OVERHAULING: (REPEAT MEDIUM OVERHAULING)+

REPLACE MAIN BEARINGS, INTERMEDIATE
BEARINGS, THRUST WAHSERS ETC., CRANK
SHAFT GRINDING IF REQUIRED, TURBO
CHARGER SERVICE KIT.

ITEMS LIKE SERVICING OF RADIATOR, OIL COOLER, AFTER

COOLER, STARTING MOTOR, DYNAMO ETC., CAN BE ADDED WITH
ANY OF THE ABOVE THREE DENPENDING ON THEIR ACTUAL CONDITION.
K.SUDHEER (DME, MIE) , SDE (E), MYSORE.
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