7 steps to proper maintenance of diesel generator

The preventive maintenance tips for the diesel generator that guarantees uninterrupted power
supply that is innocuous and consistent for all the needs intended for. They include the following
aspects:

Routine General Inspection

During the running of the diesel generator, the exhaust system, fuel system, DC electrical
system and engine require close monitoring for any leaks that can cause hazardous
occurrences. As with any internal combustion engine, proper maintenance is essential. Diesels
are no exception, and the most important maintenance is oil changes at every 100 hours of
operation for a long and trouble-free life assurance.
Lubrication Service
The engine oil must be checked while shutting down the generator at regular intervals using a
dipstick.Allow the oil in the upper portions of the engine to drain back into the crankcase and
follow the engine manufacturer’s recommendations for API oil classification and oil viscosity.
Keep the oil level as near as possible to the full mark on the dipstick by adding the same quality
and brand of oil.
The oil and filter must also be changed at acclaimed time intervals. Check with the engine
manufacturer for procedures for draining the oil and replacing the oil filter and their disposal is to
be done appropriately to avoid environmental damage or liability.
Cooling System
Check the coolant level during shutdown periods at the specified interval. Remove the radiator
cap after allowing the engine to cool, and, if necessary, add coolant until the level is about 3/4
in. Heavy-duty diesel engines require a balanced coolant mixture of water, antifreeze, and
coolant additives. Inspect the exterior of the radiator for obstructions, and remove all dirt or
foreign material with a soft brush or cloth with caution to avoid damaging the fins. If available,
use low-pressure compressed air or a stream of water in the opposite direction of normal air
flow to clean the radiator.
Fuel System
Diesel is subject to contamination and corrosion within a period of one year, and therefore
regular generator set exercise is highly recommended to use up stored fuel before it degrades.
The fuel filters should be drained at the designated intervals due to the water vapor that
accumulates and condenses in the fuel tank. Regular testing and fuel polishing may be required
if the fuel is not used and replaced in three to six months. Preventive maintenance should
include a regular general inspection that includes checking the coolant level, oil level, fuel
system, and starting system. The charge-air cooler piping and hoses should be inspected
regularly for leaks, holes, cracks,dirt and debris that may be blocking the fins or loose
connections.
Testing Batteries
Weak or undercharged starting batteries are a common cause of standby power system
failures. The battery must be kept fully charged and well-maintained to avoid dwindling by
regular testing and inspection to know the current status of the battery and avoid any start-up
hitches of the generator. They must also be cleaned; and the specific gravity and electrolyte
levels of the battery checked frequently.
• Testing batteries: Merely checking the output voltage of the batteries is not indicative of their
ability to deliver adequate starting power. As batteries age, their internal resistance to current
flow goes up, and the only accurate measure of terminal voltage must be done under load. On
some generators, this indicative test is performed automatically each time the generator is
started. On other generator sets, use a manual battery load tester to attest the condition of each
starting battery.
• Cleaning batteries: Keep the batteries clean by wiping them with a damp cloth whenever dirt
appears excessive. If corrosion is present around the terminals, remove the battery cables and
wash the terminals with a solution of baking soda and water (¼ lb baking soda to 1 quart of
water). Be careful to prevent the solution from entering the battery cells, and flush the batteries
with clean water when finished. After replacing the connections, coat the terminals with a light
application of petroleum jelly.
• Checking specific gravity: In open-cell lead-acid batteries, use a battery hydrometer to check
the specific gravity of the electrolyte in each battery cell. A fully charged battery will have a
specific gravity of 1.260. Charge the battery if the specific gravity reading is below 1.215.
• Checking electrolyte level: In open-cell lead-acid batteries, verify the level of the electrolyte at
least every 200 hr of operation. If low, fill the battery cells to the bottom of the filler neck with
distilled water.
Routine Engine Exercise
Regular exercising keeps the engine parts lubricated and thwart oxidation of electrical contacts,
uses up fuel before it deteriorate, and helps to provide reliable engine starting. Engine exercise
is recommended to be executed at least once a month for a minimum of 30 min. loaded to no
less than one-third of the nameplate rating.
Keep your Generator Clean
Oil drips and other issues are easy to spot and take care of when the engine is nice and clean.
Visual inspection can guarantee that hoses and belts are in good condition. Frequent checks
can keep wasps and other nuisances from nesting in your equipment.
The more a generator is used and relied on, the more it needs to be taken care of. However, a
generator set that is rarely used might not need a lot of care.