Proper diesel generator maintenance is key to ensuring that your unit will continue to operate for many years to come, and the following points are important.
1. Routine general inspection diesel generator maintenance
While the diesel generator is in operation, the exhaust system, fuel system, electrical system DC and engine must be closely monitored for leaks that can cause dangerous incidents. As with any internal combustion engine, proper maintenance is essential. According to Georgia Scott of Constant Power Solutions, one of the leading manufacturers of generators and power generation equipment in the United Kingdom, standard maintenance and oil changes are recommended after 500 hours of operation, but some applications require shorter maintenance periods, so customer service should be top-notch. For better diesel generator maintenance, check it every two weeks if possible, but at least once a month. The alternator, regulators, AVR and entire sensor system also need to be checked regularly, as well as the wiring harnesses for integrity. A thorough diagnosis will allow the alternator to run smoothly and ensure that it is available the moment you need it.
2. Lubrication Service is essential for diesel generator maintenance
The engine oil must be checked periodically with a dipstick when the generator is off. Drain the oil into the crankcase in the upper areas of the engine and follow the engine manufacturer’s recommendations for API oil classification and oil viscosity. Keep the oil level as close as possible to the full mark on the dipstick by topping up with oil of the same quality and brand.
The oil and filter must also be changed at the specified intervals. Check with the engine manufacturer for procedures for draining the oil and replacing the oil filter, which must be disposed of properly to avoid environmental damage or liability.
Still, it pays to use the most reliable and highest quality oils, lubricants and coolants to keep your engine running. That’s why, according to Jim Girard of Lubriplate in Newark NJ in the U.S., it’s highly advisable to buy lubricants that meet the original equipment manufacturer’s (OEM) general lubricant specifications.
3. Cooling System as part of maintenance of your generator
Check the coolant level at the specified intervals during downtime. Remove the radiator cap after allowing the engine to cool and add coolant as needed until the level is approximately 3/4 inch. Also remember to check the coolant filters and change them as needed. Heavy-duty diesel engines require a balanced coolant mixture of water, antifreeze and coolant additives. Inspect the outside of the radiator for blockages and remove any debris or foreign material with a soft brush or cloth, being careful not to damage the cooling fins. Flushing the radiator is also an important maintenance procedure for diesel generators to prevent overheating or high temperatures on the engine. If available, use low pressure compressed air or a jet of water against the normal direction of flow to clean the radiator.
4. Check the Fuel System during maintenance of your generator
Diesel fuel is subject to contamination and corrosion within a year, so regular operation of the genset is strongly recommended to consume the stored fuel before it decomposes. The fuel filters should be drained at the scheduled intervals due to the water vapor that accumulates and condenses in the fuel tank.
If the fuel is not used and replaced in three to six months, periodic testing and polishing of the fuel may be required. Preventive maintenance should include a regular general inspection that includes checking the coolant level, oil level, fuel system and starting system. The intercooler piping and hoses should be checked regularly for leaks, holes, cracks, dirt and debris that could block the cooling fins, or loose connections.
According to the marketing department of Italy’s Visa SpA, one of the world’s leading suppliers of gensets specializing in the design, production, sale and rental of gensets, some engines used in emergency gensets have experienced some diesel fuel problems.
“While the engine maintains its mechanical properties, there may be problems related to the quality of diesel fuel. The chemical composition of diesel fuel has changed in recent years; some percentage of biodiesel at low or high temperatures releases contaminants, while some percentage of biodiesel at warm temperatures mixed with water (condensation) can be the cradle for bacteria to multiply. In addition, the reduction in sulfur content reduces lubrication, which eventually leads to clogging of the fuel injection pumps”.
“When buying a genset, it is also important to know that a wide range of optional accessories is available, which allows to extend the maintenance intervals and ensure the quality of power supply throughout the life of the genset. In the mobile genset sector, for example, Visa SpA offers fuel-water separator filters that give customers the peace of mind they need when engine failure is out of the question, or fuel tank inspection points.”
Clarizza Cortez of Adpower, one of the leading suppliers of diesel and gas generators in the Middle East and North Africa, also mentions that due to poor fuel quality, water separator fuel filters and additional filtration systems are installed in most countries to protect the sensitive fuel injection system, and advises customers to replace the elements in time to avoid such failures.
5. Test Batteries during maintenance of your generator
Weak or inadequately charged starting batteries are a common cause of emergency power system failures. The battery must be fully charged and well maintained to prevent degradation. This is done through regular testing and inspection to determine the current condition of the battery and prevent generator starting problems. It must also be cleaned and the specific gravity and electrolyte level of the battery checked regularly.
– Battery testing: Simply checking the output voltage of the batteries does not indicate their ability to provide adequate starting power. As batteries age, their internal resistance to current flow increases, and the only accurate measurement of terminal voltage must be made under load. On some generators, this test is automatically performed each time the generator is started. On other generators, the condition of each starting battery must be checked with a manual battery tester.
– Cleaning the Batteries: Keep the batteries clean by wiping them with a damp cloth if they appear excessively dirty. If corrosion is present around the terminals, remove the battery cables and wash the terminals with a solution of baking soda and water (¼ pound of baking soda to 1 gallon of water). Be careful not to let the solution get into the battery cells, and then rinse the batteries with clean water. After replacing the terminals, coat the terminals with a light coat of petroleum jelly.
– Check specific gravity: for open lead-acid batteries, use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. A fully charged battery has a specific gravity of 1.260. Charge the battery when the specific gravity value is below 1.215.
– Checking the electrolyte level: For open cell lead-acid batteries, check the electrolyte level at least every 200 hours of operation. If the level is too low, fill the battery cells to the bottom of the filler neck with distilled water. Always disconnect the generator batteries when not in use.
6. Routine diesel generator maintenance exercise
Regular exercise keeps engine parts lubricated and prevents oxidation of electrical contacts, uses up fuel before it is consumed, and contributes to reliable engine starting. It is recommended that the engine be exercised at least once a month for at least 30 minutes, with a load not less than one-third of nameplate capacity.
According to Peter Whitfield of YorPower, a leading independent UK manufacturer of diesel gensets, when it comes to engine maintenance, the most important thing is to carry out regular inspections, as preventive maintenance is better than reactive maintenance. Nevertheless, it is of utmost importance that the prescribed maintenance procedures and intervals are followed.
7. For Diesel generator maintenance cleanliness is key
Oil drips and other problems are easy to spot and fix if the engine is nice and clean. A visual inspection can ensure that hoses and belts are in good condition. Frequent inspections can prevent wasps and other pests from taking up residence in your unit.
The more a generator is used and the more you rely on it, the more you need to take care of it. However, a generator that is rarely used may not need as much care.
8. Exhaust system inspection for a diesel generator maintenance check
If leaks occur along the exhaust line, usually at the joints, welds and gaskets, they should be repaired immediately by a qualified technician. Make sure that all intake and exhaust ports are well covered.
However, according to Ms. Arlene of Maverick Generators in South Africa, you should always make sure your equipment is serviced. Especially 24 hours before using your generators. “For standby generators, for example, the units need to be serviced for an average of 150 hours. However, if the generator is in constant use, the number of hours increases much more quickly and at more regular intervals,” she adds.
According to Ryan Mason of Lister Petter, a UK-based manufacturer of internal combustion engines, it’s also very beneficial to have maintenance kits for different service intervals.
9. Servicing the air cleaner
The air filter should be serviced every 500 hours of engine operation with a filter cartridge made of special high-porosity cardboard or, if prescribed, with the contamination indicator. Maintenance of the air filter includes cleaning of the main filter element, which collects dust entering the air filter. Checking the clogging of the filter element indicates damage to the main filter parts (broken paper curtain, loosening bottoms). In such a case, it is necessary to clean the control filter element and reinsert the main filter. Also check the fresh air inlet and warm air outlet windows or ducts to make sure they are not closed or blocked.
10. Washing the engine breathers
The engine breathers should be cleaned with diesel fuel after every 2 000 engine operation hours. The diesel generator maintenance on breathers is done by removing the housings, taking the breathers from the cylinder heads cover caps, washing and purging them with compressed air. The breathers and their housings should then be put back in place.
