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2. Maintenance Procedures 13
2.1 Safety 13
2.1.1 General Precautions 13
2.1.2 Natural Gas Precautions 14
2.2 Daily Maintenance 16
2.2.1 Daily Check List 16
2.3 Weekly Maintenance 17
2.3.1 Weekly Check Lists 17
2.4 Monthly Maintenance (Code 0) 19
2.4.1 Monthly Check Lists 19
2.5 3 x Monthly / 500h Maintenance (Code 5) 21
2.5.1 3 x Monthly / 500h Check Lists 21
2.6 6 x Monthly / 1000h Maintenance (Code 10) 23
2.6.1 6 x Monthly / 1000h Check Lists 23
2.7 12 x Monthly / 2000h Maintenance (Code 20) 25
2.7.1 12 x Monthly / 2000h Check Lists 25
2.8 24 x Monthly / 6000h Maintenance (Code 60) 27
2.8.1 24 x Monthly / 6000h Check Lists 27

Operation & Maintenance Manual Vol 1
Part 5 - Maintenance
Page 11

Maintenance Page 12 . BLANK PAGE Operation & Maintenance Manual Vol 1 Part 5 .

WARNING High voltages are present. even when the genset is not running. The following pages include suggested routines for maintaining the overall genset and its equipment in prime condition.2. Maintenance Procedures FOR ENGINE & ALTERNATOR MAINTENANCE. REFER TO THE ENGINE MANUAL AND THE ALTERNATOR MANUAL (VOL 2). Maintenance intervals are shown in elapsed time/running hours. refer to Part 5.1. 2. Start the routine again past the 24-monthly/6000h period. particularly in confined areas. Do not open any terminal box covers without first isolating the high voltage supply. Keep terminal box covers in place during Troubleshooting. always immobilise the genset as detailed in Part 4. Remember that over-familiarity with potentially dangerous equipment can and often does result in serious injury or death. should be carried out by two engineers working together. If the lifting of engine components is planned. 2. REFER ALSO TO THE SAFETY ADVICE GIVEN BELOW AND OVERLEAF. but read and understand them all before carrying out any maintenance. and ‘codes’ are included to comply with the codes provided in the engine manual. exercise extreme caution and wear the necessary personal protective equipment as detailed in Part 1 of this volume.1 General Precautions Some maintenance work.1 Safety The following text is provided for your safety.Maintenance Page 13 . WARNING Before carrying out genset maintenance. WARNING When carrying out maintenance inspections with the engine running. Section 1 for component weights. Continued Operation & Maintenance Manual Vol 1 Part 5 . Then each maintenance item can be ticked off as it is carried out. Maintenance is performed on a rolling basis. A number of warnings and cautions are included. therefore it is suggested that you photocopy the pages from ‘Daily Maintenance’ onward. Section 1.

Contact Cummins Power Generation if you require details or copies of UK regulations. Failure to observe this precaution may result in personal injury.1. WARNING If coolant is not released from engine when engine cooling system is drained. Caution Never steam clean the Alternator. On Non-UK installations. • SHUT DOWN THE GENSET (S) BY FULLY SHUTTING THE GAS TRAIN SHUT-OFF VALVE (S). • ALERT THE EMERGENCY SERVICES AND LOCAL GAS SUPPLIER. Operation & Maintenance Manual Vol 1 Part 5 . • FULLY SHUT OFF ALL EXTERNAL GAS SUPPLY VALVES TO THE GENSET. WARNING Do not remove a cooling system pressure cap when system is hot. 2.2 Natural Gas Precautions If servicing is required on natural gas pipes or components. • EVACUATE ALL PERSONS FROM THE PLANT ROOM IMMEDIATELY AND VENTILATE BUILDING. Caution Do not add cold coolant to a hot engine. Section 1 for General Safety Notes. comply with all local and national gas regulations. as this may cause damage. Refer to the BRITISH GAS CODE OF PRACTICE IM / 17 before working on UK installations. DANGER IF A GAS LEAK IS SUSPECTED: • DO NOT OPERATE ANY ELECTRICAL EQUIPMENT OR SWITCHES IN THE PLANT ROOM WHICH CAN CAUSE SPARKS. take steps to waterproof the Alternator. Allow engine to cool below 500C before adding coolant. first.Maintenance Page 14 . Ensure that engine circuits are fully drained via the two drain plugs located on the engine (Refer to the Engine Manual). refer to the Safety section in Part 5. If steam cleaning the Engine. Only Competent Persons are to work on natural gas equipment. hot coolant may be released when engine components are removed. WARNING Avoid contact with hot exhaust components.