Walkaround Inspection for Diesel Generators

Let’s start from the cooling system and step-by-step we will go around the generator set.

Now I’m going to explain you the Radiator. It is the largest component in the generator unit.There are two indicators for coolant level,  one is an electronic indicator and other one is a physical indicator.  You can see that if the coolant level is below the required level; you must fill up the coolant. There are two indicators which are attached to the top tank. One is side glass where coolant level is indicated and in parallel to that you can see the electronic sensor. When the coolant level drops , it will send the signal to the control panel.Then control panel will emit the light and it will give an indicator of the coolant level being low. Further operator also can see the coolant level; if it is below the required level, he must fill it up. Operator has to reach the top of radiator and open the coolant tank lid and fill up coolant up to the required level.

Now I’m going to explain the radiator area. Radiator has three cores.

One is radiator jacket water core. One is separate circuit after cooler core. One is fuel cooler core. These three coolers are cooled by the radiator fan. The fan is behind the radiator, which is driven by the belt. Belts are connected to the crank shaft pully.  We have to make sure all these radiator cores are passed through the air. If it is carbonatized ; if it is accumulated by the dust , the air density will not passed through the radiator core. Hence the radiator cooling system will not cool the jacket water or after cooler system.  It will effect your engine efficiency,  and it will lead to raise the jacket water cooling system and after cooler temperature.  This will de-rate the engine and lead to shutting down the engine.

In the meantime you have to see the fan belt tension also. Because fan efficiency will depend on the  fan belt tension. Apart from that  need to check the fan belt has cracked, worn out, or pully has worn out all these things we have to see. If you found anything wrong;  any crack , any breakdown or just about to crack, it has to be notified and  entered to the documentation and should be informed to relevant person. Now I'm going to explain you the radiator bottom line area. This is also very important place because if you found any leakages, damages or cracks, immediately you have to notify, document it  and inform the relevant personal. If the radiator bottom tank is leaking and  it is neglected these leakages, there will be a huge problem during operation. Further to that, now in this water pump there is a component call V-Whole where radiator coolant could leak form the seal here. If you neglected this there could be damages to engine due to coolant water entering to the oil sump. It will create further problems. We have to notify this situation and inform relevant personnel to take necessary actions.

Now another thing is crank shaft damper.  This is called crank shaft damper. Behind the damper there is a crank seal. If the crank seal is leaking, you have to notify and inform the relevant personal to take necessary action to avoid such leakages by replacing the crank seal.

Now I am going to explain you these two lines assemblies. Cooling line assembly.

These are the jacket water Coolant line; return line to the radiator top tank. You can see there are two clamps. These clamps are put it together with the seals. If there's any internal damage there in the seal, there could be a water pop up from outside here. If you notice this, you have to document all these failures and immediately we must take the precautionary measures in order to avoid such leakages. Apart from that, you can see square type box is there. This is called jacket water regulator housing. Sometimes you will find out the gaskets area, ceiling areas are leaking here wet or some coolant are coming out.

That means red color is pop up out, that you have to notice and you have to type tight up this bolt. Otherwise you have to replace the gasket in the proper time beyond the damage. Another line also, regulator line is there, here. When the regulator is open once it is keep the constant, jacket water temperature, 78 degrees Celsius . Then this valve will open and it will bypass the, all the radiator Coolant to the jacket water here in. This is the circuit. These, there are seals are coming over here. These seals you have to concern. If there are any leakages occurring at the coolant joints, then you have to take the precautionary measures in order to avoid such things.

Now we will move to the fuel system. Fuel system starts from here, initially the water separators are there.

It is employed here before the transfer pump. You can see there is a nob. These, these are the drains. If there's a water, you can see the water you can indicate here. So you have to drain the water from here. That is a maintenance department’s job. And you have to see whether this area is wet or not. That is an important thing. This should be fully dry. There shouldn't be any wet area. Then the transfer pump, it comes to the intake. It is the suction. This is the trans pump. It is fitted behind the oil pump.

It is oil pump driven transfer pump. Then there are two lines you can see afterwards. These two lines will go there, these are the supply lines.  And you can see these supply lines are going over there. This is the written valve here. Once it is beyond the 110 PSI, this valve will release the pressure. It is the gallery pressure. 110 PSI is the gallery pressure. These are B series engine 3,500 B series engine. That's why it reaches 110 PSI during cranking. Otherwise, it will fail to start. Now this return line will come and it goes to the fuel cooler. You can see here, I'm indicating the line.

It is going the fuel cooler in. Then it'll come out, fuel cooler out and it goes to the fuel tank return line. Now why I’m explaining you this much, because you have to see like this connection, all the connection, this connection, some certain hours could leak, start to leak. Then this is very hazardous area also. So you have to notify all leakages and you have to rectify all leakages. Then you have. Inform to the concern, according to your workaround inspection. And next is part of the fuel system. I will explain new high pressure line area. These are the high pressure line area, all the injection line area. These are the fuel pressurized to the gallery.

110 PSI I told you earlier. So these are very important in these connectors. These connectors could leak anytime because, it develops a tremendous pressure, also 110 PSI is not a small pressure. So we have to look all these leakages, whether it is wet or not. These are identically. All the lines are same, but other side also same line assemblies are there. So these lines assemblies are very important. We have to see there are seals are there in between these, there are the seats are there. These seats, if damage, if we over tighten or any leakages are there, we have to see, we have concern and we have to report to the consent people, If you found anything wrong.

Now I am step into the lubrication system.

In the lubrication system, you can see this is the oil pump. It is mounted on this housing. Now this oil pump sucks the oil from here. This area is we have to see whether it is leaking or not because it has a seal and it is a very difficult area also to replace, when it leaks. Because you have to pull the oil pump completely out to do so. Now, this oil pump; It will suck and pump out oil here to this location. It'll come here from here, this line, and it goes to the oil cooler. Oil Cooler has two interconnected circuits; One is jacket water circuit, One is oil circuit. So the jacket water will cool the oil. So in between that, there are seals. You can see from here, gaskets are there here so many seals are there.  These seals, you have to check whether it is leaking or not. And the water line also connected over here. This also could leak. In this area, there shouldn't be any drop of water or coolant. Oil also shouldn't be dropped over here. If you notice any such visible leakages, you have to notify and inform the responsible personal to take actions. 

Now you see there are seals. These are relief value over here. All seals and gaskets are connected.

This should be concerned over here.

Then this circuit will go here. These are the line assemblies; oil line assembly. This is the filters area. These seals are coming over to this location. You have to see these are wet or not, or damaged; otherwise, it'll leak. You have to take proper action in order to avoid such leakages.

Now, I'm going to explain you the battery charging alternator.

I will show you that; this is called alternator. So, we have to see it is a belt driven. It is, you can see the beyond the guard internally; there's a belt. You have to check it properly. We can check it by the finger, all these things. If it is beyond the level or beyond the limit, then you have to adjust it properly.  This is the adjustment for that. But apart from that, you have to see all these areas also, whether it is properly connected,  connections are proper. Another thing also, behind this there's a regulator  also coming, and this, if there's any failure, this will indicate battery discharge.

If there's no any proper indication to charge it, then it'll indicate in the system. There's a failure on the alternator system charging system. That's all.  That's all in that case. And there are wires are there, you can see that there are connectors. You have to see properly these connectors is cracked. Wires are cracked because these  are so hot area. Some certain hours, some certain years, this wire could break off.  Then these things also, you have to look over there during your walk around inspection.

Now I am going to brief you about the air induction system; exhaust and the intake air.

These are the common lines for the, both turbos. In one side, there are two turbos. So one is there. One is here. See these lines. There are clamps. There are seals. We have to see whether there are air leakages, or some oil leakages are happening over here. These are turbo charges. This is exhaust side. Exhaust side has also exhaust gas emits that you can see from these clamps. In some occasions when the generator is running under load below 30% or below 40%, you can see black wet black oil is pouring out or popping up. That is called there's a sickness of the generator that is called Valve slobbery. That is not engine failure. That is a low load problem.  You have to apply the load at least 80%. Then one hour: one hour run, then it it'll be alright.

So these things you have to see: apart from that, you have to see that there are parameters here. You can see the sensors are there. The sensors are damaged or not here: you have to see. These the exhaust temperatures that will calculate by the ECM. Now same set of turbocharges will be there in the other side, in parallel to that.  And apart from that, you have to see that air indicator is there. Air indicator means if the air cleaner is clogged up, this will indicate in red color. So you have to push it and you have to see whether this is clearing or not.if it is not clearing, that means your air filter has to be changed. Air filter is completely clogged up. That means you will get the low power,  and you will get the black smoke and engine will debate.

Apart from that, you have to see the exhaust joints are here. These joints, you have to see weather there are leakages, exhaust emits or not. If improperly exhaust is leaking, then that means that gasket is damaged. That also you are to notify and inform to the concerned person. You can see the way I'm indicating from my finger. There's a housing; after cooler housing, After cooler is concealed inside the housing. So these are all together in between two set up turbos. That means in between four turbos, it is there. So it will subject to tremendous heat also. So we have to see whether there are any leakages is occurring from here from the lines. There are joint line also there. That also we have to see. and, if there's any leakages, so we have to take proper action. There are intake seals also over there, these seals are damaged or not, you have to verify, normally if it is exceeding recommended running hours this problem will create. Otherwise you have to notify, whether there is any leakage or not.

Now we have approached to the very important area.

This is called oil, sump area. This is a large area, the oil sump is here. So very important thing is oil level. We have to see there's a dip stick is here, We have to see the oil level from here. First of all you have to clean up your dip stick. Then you have dip it inside the oil sump, then you see the proper level. You have to see the level like. Don't look like this. You have to look like this. Then you have to see the engine running level and engine stop level. While running it is one level while stop another level. Then if there's oil is less, if it is beyond the required level, you have to pull the filling cap over here and fill the oil in proper grade recommended by the manufacturer.

So apart from that, as a part of that, your concerned also, you have to see that if there are any oil leaks are there, in the gasket area. There are no gasket these are liquid gasket is put, so some occasions after some certain number of hours, it could leak from that area. So that also very important. These gasket also there, these things also, we have to consider during your work around inspection.

Now we have come to the flywheel end area.

That means engine backside. There's a flywheel over here; behind the flywheel, there's a seal; that is called crank seal. So you have to see whether there are any oil leakages from here. That means that crank seal is leaking. that you have to see, why it is leaking also, you have to see. I will explain you when we go to the other side, then after that you have to see the fan is damaged or not. Sometimes cooling fans are damaged, Fan pins are damaged, eroded or rusted. then only if there you have found any abnormal things, then you notify and take to the concerned person for proper action.

Now we have come to the generator area. This has a heater. You can see this because there's a heater is fixed in the alternator side, in order to eliminate the condensation and moisture, because winding built up the moisture and the condensation it'll cause the low voltage also. That is called space heaters. We call space heaters. The space heaters has fixed all together inside. So you cannot see it; it is not visible. It is a concealed one. So we have to see whether it is working or not. If you see, you can feel that whether it's working or not, and it'll indicate in the system, what is the space heater temperature also, if you don't found anything; anyway, indicator will alarm you that your heat spacer will fail. When It is not working; moisture will built up, then your voltage will become zero or voltage become low.

Now we are in the left side of the engine while viewing from flywheel end.

So now I'm going to explain you the after cooler circuit, after cooler circuit has a separate after cooler pump, that is called separate after cool circuit. So it has waterline here, it'll go in here. Then here temperature; it picks up the temperature from the sensor. Then after goes through the after cooler it'll return from here, there's a regulator here also. Now, the important thing is why the after cooler is required; after cooler pump separate circuit is required in order to, improve the density of the intake or induction air. Then in order to burn the more fuel, and more efficiency to the engine.

So now very important thing is while walk around inspection, you will see these all leakages, if there's happening or not, any apparent leakages are there, immediately you have to notify and you have document also, you have to inform to the concern person to take proper action. Now I have come to the engine breather section. You can see there are four breathers. These are 3512/3516, normally the four breathers are comingNow you see the line assemblies. The breathers are fitted, However it will develop the pressure inside the engine during the operation, that pressure has to be exposed, It has to be discharged. If it is clocked, what will happen; there are leakages will emerge. First of all, the leakages will happen over here, in these clips and everything, and this will become hardened also.

Another worst thing is this will start to leak in all the gasket because of the high crank pressure. And another thing what happen is both the crank seal will burst. because of the high crank pressure. But in this system, this technology B series technology high crank pressure has a sender It is indicated; it'll indicate in the system. If there's any high crank pressure is built up, it'll show you, there's a system, high crank pressure is available. So you have to rectify the problem. You have to see the breathers.

Now we have come to the electrical side; electrical starting system.

You can see the isolation switch is here. Now the isolation switch is already connected. It is on. If you turn to the left side, it'll isolate the power completely. Then it'll black out the entire system and no power will be delivered to the system and starter motors. During your inspection, you have to see these wires are connected, and any loose connections are there. You have to check that full test, you have to see. And there are two twin starter motors are there crank motors These all connection has to be checked properly. then up to the, the bridge wire and all this thing, and this connection control box; everything has to be checked.

If you find any loosen connection of wires, you need to fix it as it could be a bigger disaster. It could ignite the Wires harness, because wires will overheat. and these wire harnesses are very costly and also it is not available. You have to see very carefully all these wire harness, because after some hours, this will become hard. Then it'll get short circuited also, Then we will come to the battery. The battery is also important; at the right time you have to check. There are caps and you have to open and see the battery levels are there or not; with the liquid electrolytic level are correct or not. Then if it is not correct, you have to fill out. Then every once in a month, you have to check the batteries.

During the walk around inspection, you have to see all the batteries, whether electrolytic are there or not. Then, if you found anything wrong; battery, crack or battery damage, you may change the battery. You have to see the batteries placed on a proper place, it must be kept on the wooden platform. If you are not keeping it in a wooden platform, then it will be a disaster for battery in long term. then if you found anything, this lugs have shorted or spark or, melt out, then you have to report immediately to concern person in order to repair or replace the battery.