Introduction

What is generator?
Generator is a machine used to produce electric power. The name by itself states generation
i.e., electric generation. Generator is organized in three main components. These are: -

a. Engine – which converts heat energy to rotary mechanical energy using diesel fuels
by combustion system
b. Alternator – having two main group coils converts rotating mechanical energy to
electrical energy
c. Control unit – a device responsible from start to continuous running actuating,
monitoring and control in order to perform safely and properly of the engine and
alternator.

This is the general description of generator so the training will discuss the detail of the
above machine for operation, utilization and maintenance of this machine. According the
next chapters will be seen in detail based on perking’s manufacturing principles.

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 Chapter one

1. Engine (Perkins)
An engine is a machine manufacture to convert heat energy to rotary mechanical energy. To
perform this engine is constructed in three main components and five systems. To see in
detail.
1. 1 engine main components
1.cylinder head
2. Engine block
3. Oil Jump
a. Cylinder head- the compartments lied on top of the engine which hold the intake and
exhaust values with their operating accessories like Roker arms, value spring , guide cooling
water lines, lubricating oil lines and other access and is attached to the engine block by bolts
got be tightened at specified torque and gasket known as cylinder head gasket which helps
to seal the combustion pressure created at cylinders.
b. Engine block – is the main compartment which holds the two compartments and where the
combustion is performed. It is the place the piston moves up and down the place the crank
shaft is placed, the pressure the comfort and other all system perfuming parts are available.
c. Oil jump – this the the compartment where oil is filled and the bottom cover to protect the
engine.
All the compartments are made of different type metallic alloys.
1.2 engine systems
1.Internal combustion (fuel system)
This is the main system designed to run the engine. As mentioned above engine convers
heat energy to rotary mechanical energy. This phenomenon is all about the combustion
system. Combustion system is diesel fuel system is performed as follows
First air should be entered to cylinder through air cleaner -> turbo charger -> intake
monitored-> intake value to be opened by the order of firing order by com shaft.
Then -> compression of the air took place at cylinder at values closed status.
Mean work -> fuel is asked from fuel tank by primary pump -> to filters -> to injection pump
-> high pressure line -> to injectors -> spar eyed (vaporized form) to cylinder
It is this time the power stroke or combustion takes place.

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Then -> burned fuel ( fuel gas) pushed out through exhaust value -> exhaust manifold ->
turbo charger -> exhaust pipe
Known combustion heat energy is converted to mechanical rotary energy in four strokes
The strokes are in take -> compression -> power -> exhaust
These four strokes are performed according to the firing order set by the manufacturers so
the power stroke is the time where fuel is combustion to create high power heat energy
which in turn pushes down the piston down ward to start vertical movement then
converted to rotary motion at the crank shaft.

Starting and charging system

Indore to start running an engine there must have another stating support in order to start
combustion as stated above in our contexts we are to mention electrolytic battery. Engine
should rotate first to start running for this purpose a device called starter motor is fitted at
the flywheel side of the engine which is toothed circular part of the engine and DC electric
supply is applied to the starter motor in order to rotate it and a pinion gear placed at the
starter pushed forwards to engage to fly wheel and since the starter is rotating the engine
also starts rotation. To perform the abode process start command for starter motor and fuel
control device should be initiated from the control device should be imitated from the
control unit. Through control relays and fuses fitted the control system. The starter motor
has solenoid relay to actuate the motor by connecting power terminals and pull fork which
pushes the pinion gear
In the new engine the crank time is set in the program of the controller
While doing these the battery is expected to get weak in power so therefore system
charging system will then recharge the battery to get at powerful state for the next starting
and controlling systems. To do this there is a device known as alternator (dynamo) with self-
voltage regulator fitted at front of the engine coupled with belt to crank shaft to get
rotation. This alternator has two coils a) starter b) rotor and bridge rectifier in order to
convert the AC power generator at starter to dc power to fit the battery.
The regulator regulates the excitation voltage entered to the rotor coil through carbon
brushes comparing the voltage of the battery supply to the required maximum value.

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 3.cooling system even through there are two types of cooling systems we ae to deal with
the water cooling systems.
Cooling system is the basic system for engine to run for long time may be the running after 5
minutes. In our context the water filled at radiator and engine water jackets has to rotate
respectively. To perform these there is a w after pump which help to rotate the water or
exchange from radiator to engine and is accomplished with the help of the thermostat
indoor to use the water in the required temperature range to keep water at radirotr for
period of time in order to fit cool. And the radiator cap having pressure and vacuumed
valves are decisive cooling controlling devices
The fan fitted in front of the engine is also the main part of cooling system which cools
down water by supplying air from atmosphere through the radiator fins.

4. Lubrication system
Lubrication is preventing friction using lubricating oils. Lubrication is the system prevents
engine failures duet to the following cases
- wear and tear due to metal to metal vertical and rotary motions.
- Overheating due to frictions
- Inefficiency due to dirt in engine internal parts
So oil is the one needs series attention because the engine can automatically out of use if
there is a problem in lubrication system.
How is oil circulating? There are parts and lines help for oil circulation. to see this
There is: -
 Oil jump for holding oil
 Strainer for suction and filtering bop sized dirt and materials
 Oil pump – the component to suck and deliver pressurized oil to all parts and circulate
 Oil filter – component to filter and deliver clean oil to system
 Oil lines (pipe) and on component pass through lines particularly in vertical and rotary
moving parts.

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Routine maintenance

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List of Possible causes
1 Battery capacity low.
2 Bad electrical connections.
3 Fault in starter motor.
4 Wrong grade of lubricating oil.
5 Starter motor turns engine too slowly.
6 Fuel tank empty.
7 Fault in stop control.
8 Restriction in a fuel pipe.
9 Fault in fuel lift pump.
10 Dirty fuel filter element.
11 Restriction in air induction system.
12 Air in fuel system.
13 Fault in fuel injectors or fuel injectors of an incorrect type.
14 Cold start system used incorrectly.
15 Fault in cold start system.
16 Restriction in fuel tank vent.
17 Wrong type or grade of fuel used.
18 Restricted movement of engine speed control (not applicable to 2800 series engines).
19 Restriction in exhaust pipe.
20 Engine temperature is too high.
21 Engine temperature is too low.
22 Incorrect valve tip clearances.
23 Too much oil or oil of the wrong type is used in wet type air cleaner, if one is fitted.
24 Not enough lubricating oil in sump.
25 Defective gauge.
26 Dirty lubricating oil filter element.
27 Fan damaged.
28 Fault in engine mounting or flywheel housing.
29 Too much lubricating oil in sump.
30 Restriction in air or water passages of radiator.
31 Restriction in breather pipe.
32 Insufficient coolant in system.
33 Vacuum pipe leak or fault in exhauster (not applicable to 2800 series engines).
34 Fault in fuel injection pump.
35 Broken drive on fuel injection pump.
36 Timing of fuel injection pump incorrect.
37 Valve timing is incorrect.
38 Bad compression.
39 Cylinder head gasket leaks.
40 Valves are not free.
41 Wrong high-pressure pipes (not applicable to 2800 series engines).
42 Worn cylinder bores.
43 Leakage between valves and seats.
44 Piston rings are not free or they are worn or broken.
45 Valve stems and/or guides are worn.
46 Crankshaft bearings are worn or damaged.
47 Lubricating oil pump is worn.
48 Relief valve does not close.
49 Relief valve does not open.
50 Relief valve spring is broken.
51 Fault in suction pipe of lubricating oil pump.
52 Piston is damaged.
53 Piston height is incorrect.
54 Flywheel housing or flywheel is not aligned correctly.
55 Fault in thermostat or thermostat is of an incorrect type.

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56 Restriction in coolant passages.
57 Fault in water pump.
58 Valve stem seal is damaged.
59 Restriction in sump strainer.
60 Valve spring is broken.
61 Turbocharger impeller is damaged or dirty.
62 Lubricating oil seal of turbocharger leaks.
63 Induction system leaks.
64 Turbocharger impeller is damaged or dirty.
65 Drive belt for water pump is loose.
66 Induction system leaks (turbocharged engines).
67 Faulty engine management system

Troubleshooting (Based on system)

Troubleshooting (Based on system)

Based on plant control (DSE)

Based on PC suite software

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 Chapter Two

Alternator
Alternator is the electrical part of the generator used to generate electrical energy
converting from the rotary mechanical energy from engine and using and excitation electric
from itself through the AVR.

The alternator has the following parts:

1. Stator Coil – in recent cases used to produce the A.C type electric coils are set in
different pole number patter in order to produce at specific frequently level AC
electric. It’s the rotating magnetic flux on rotor over the pled stator coils i.e.
electromagnetic induction theory. Or inducing electric from elector magnetized
rotary part. The output voltage is controlled by the automatic voltage regulatory to
the sated required value.
2. Rotor coil – the part connected to engine to receive rotary motion and the part
having the excitation coil and rectifier to convert the AC power induced AC power at
the excitation to DC power that enter the rotary coil to produce electro magnet.
3. AVR and Excitation
The AVR is electric device used to control the output voltage off the generator
receiving input and reference voltage and current from the stator. AVR starts
supplying pc power to excitatory stator coil to induce electromagnet from the
residually produced violated output and improved to required value by supplying
and controlling the excitation generator.
Excitation is the process used to induce electrum magnet at the main rotor coil small
amount of electric power to produce big amount of electric power
4. Current transformer and voltage measurements
Current transformer is device used to measure electric load amount by reducing the
current to the measurable ratio. This is because current is measured in putting meter

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in series which makes difficult to hold the capacity. Voltage is measured directly by
the controller

Trouble shooting

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 Chapter Three
Control Units
Control units are devices used to start control and stop the generator systems individually or
totally or show an alarm for taking care to operate the machine in safe and reliable manner.

a. Generator has plant control unit for all models and additional engine control
module(ECM) for commercial engines.
Plant control unit
For this training deep see electronic controller
The DSE generator controller is a device used to control, start and stop the generator
DSE has control input for engine, generator and communication with ECM.
According to the engine running system DSE can control by direct sensor controllers
from engine or by CAN communication with ECM to receive engine data but
alternator is controlled here for both systems.
The DSE is so the plant controller b/c it controls the whole systems in the generator
The plant controller has two main control (monitoring) systems:
- Status monitoring
- Device configuration

Status monitoring helps operators and professionals to observe the engine and alternator
running status. In this page the following are reviewed:

1. Generator status
2. Engine status
3. Events
4. Input status
5. Output status

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