Diesel generators use the diesel engines with the electrical generator to produce electricity. Fuel oil is the most commonly used in diesel compression-ignition engines, and there are a few exceptions that use liquid fuel or natural gases. Even though diesel generators are durable, have sturdy characteristics, and provide cost-effective operations, they require maintenance to ensure their proper functioning. Here is a complete guide with tips and a checklist for maintaining the diesel generators.
Diesel generator
Diesel generators are crucial in every business for backup power, and engines are the core component of them. To run the diesel generator efficiently, it is necessary to have it maintained regularly. Engines, exhaust systems, fuel systems, and electrical systems require constant monitoring once the diesel generator is in use, as they can potentially lead to hazardous events. Of all the parts, internal combustion engines are to be maintained without fail. They are capable of withstanding heavy loads for prolonged durations, and due to this reason, diesel generators are to be maintained regularly.
Common Generator Issues
Over time, gradual deterioration of the diesel generator may occur due to several issues.
Leaks in Fuel Systems
Diesel generators are susceptible to contamination and degrade over time. Fuel, filters, pipes, and injection systems need to be checked constantly. Generators may experience fuel and coolant oil leaks; however, regular maintenance can prevent these issues.
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Fuel leaks can be a result of overfilling the base tank, often due to pump malfunctions or human error.
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Coolant leaks are commonly found in block heater hoses, which are subject to high temperatures.
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Oil leaks are frequently caused by wet stacking, which is the build-up of various substances in the exhaust system that resembles an oil leak.
Low coolant
Another major issue with generators is low coolant levels, which can trigger alarms or cause the generator to shut down to prevent overheating. Also, it can lead to engine overheating and cause extensive component damage, including the alternator, rotor, bearing, head gasket, and exhaust valves. In some cases, the cost of repairing these damaged parts may outweigh the expense of purchasing a new generator altogether. Frequent coolant additions could be an indication of a potential leak in the generator.
Generator failure
Inadequate battery maintenance and negligence in monitoring the battery charger condition and starter motor are the most common causes of generator failure. In cases where generators won’t operate even with plenty of fuel, it could be an indication of air stuck in the fuel system, a leak in the pipe line, or an issue with the check valves. A technician could assist you in finding the cause and resolving it.
Block Heater Wear
Block heaters warm the coolant, facilitating smooth flow through the engine block, heating it, and preventing oil thickening. This minimises generator wear and tear by maintaining stable cooling system temperatures. However, due to constant operation, block heaters will eventually require replacement.
Why should Diesel Generator Needs To Be Maintained?
Like any other engine, diesel generators wear and tyre over time and require constant maintenance. In situations where diesel generators are used as backup power, maintenance will ensure the generators are well equipped and ready to use in the event of an outage. Diesel generators are high priced and their regular upkeep will make it last for many years. It is advisable to get the diesel generator serviced after completing 500 hours of operation or every 6 months. In certain environmental conditions, this schedule might require adjustment. For instance, if the generator is situated in an area with high dust or sand content, air filters may become clogged sooner than the standard 500-hour interval, necessitating earlier cleaning.
Housekeeping Tips for Generator Maintenance
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Operate generators periodically to allow the internal fluids to activate the engine.
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Check for fuel levels regularly, as it is always better to detect any leaks or major contaminants prior to use.
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Visually inspect the batteries for any corrosion, which could prevent the generator from starting.
Diesel Generator Maintenance Guide
General Inspection
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Regular monitoring of exhaust, fuel, electrical, and engine systems is crucial for safety.
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Proper maintenance, including oil changes every 500 hours, is essential for a hassle-free diesel generator.
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Timely inspections of components like alternators, controllers, and sensors are necessary for overall integrity and functionality.
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After-sales services are crucial for optimal performance, especially in high-use scenarios
Lubrication Service
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Check engine oil regularly when the generator is powered off, using a dipstick.
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Maintain the oil level close to the full mark on the dipstick using the same grade and brand of oil.
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Replace oil and filters at specified intervals.
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For generators with high annual run hours, more frequent maintenance may be necessary.
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Follow the manufacturer's instructions for draining oil, replacing filters, and proper disposal to prevent environmental damage.
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Allow oil in the upper engine areas to drain back into the crankcase.
Cooling System
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Regularly check the coolant level during shutdown periods.
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After the engine cools, add coolant if needed, maintaining it at about 3/4 inch from the top.
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Check and replace coolant filters as required.
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Ensure a balanced coolant mixture of water, antifreeze, and additives for heavy-duty diesel engines
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Inspect the radiator exterior for damages and clear any dirt with a soft brush or cloth, being cautious of fin damage.
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Radiator flushing is crucial for preventing overheating and excessive engine temperatures.
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If available, use low-pressure compressed air or a reverse water flow for efficient radiator cleaning.
Fuel System
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Diesel fuels may degrade over time and could be a major reason for contamination.
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To prevent contamination and corrosion of diesel generators, regular exercises are recommended to burn up stored fuel before it degrades
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As water vapour condenses in the fuel tank, it's important to drain fuel filters at appropriate intervals
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Regularly inspect charge-air cooler piping and hoses for leaks, holes, cracks, dirt, and loose connections
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Changes in diesel fuel composition can lead to issues, including contaminants from biodiesel and reduced lubrication due to reduced sulphur.
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Routine maintenance should include checking the coolant level, oil level, fuel system, filters, and starting system.
Battery Testing
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Weak or undercharged starter batteries are a frequent cause of standby power system failures.
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Starter batteries must be kept fully charged and well-maintained to prevent degradation and ensure reliable generator start-up.
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Regular testing and inspection are necessary to assess the battery's condition and avoid start-up issues.
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Replace the batteries as they approach the end of their expected lifespan to prevent potential failures during critical moments.
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Measuring terminal voltage under load is the correct way to determine a battery's ability to provide starting power.
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For open-cell lead-acid batteries, check the electrolyte level at least every 200 hours of operation. Fill the low battery cells with distilled water in the filler neck.
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When the generator is not in use, always disconnect the batteries to prevent unnecessary discharge.
Regular Optimization
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Regular exercise of the engine should be performed to keep parts lubricated and to prevent oxidation of electrical contacts.
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Engine exercise is suggested every 15 to 25 days for a minimum of 30 minutes.
Cleaning
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A clean engine allows for easy identification and repair of issues such as oil drips and faults.
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Regular checks help ensure that hoses and belts are in good working condition.
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The level of maintenance required depends on how frequently the generator is used. The more you rely on your generator, the more care it demands.
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Avoid the misconception that rarely used generators don't require maintenance. Always adhere to the manufacturer's maintenance guidelines. They know what's best for your generator.
Exhaust System Inspection
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Identify and repair exhaust line leaks at connection points, welds, and gaskets immediately with the help of a technician to prevent issues.
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After approximately 500 hours of engine operation, service the air cleaner. It should have a filter element made of highly porous cardboard or a clogged signal to indicate when a replacement is needed.
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Part of air cleaner maintenance involves purging the primary filter element, which traps dust entering the air cleaner. In certain cases, the control filter element should be cleaned and replaced with the primary one.
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Ensure the fresh air intake and hot air discharge openings are not blocked to maintain proper airflow for the generator.
Load Testing
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Load testing is a comprehensive evaluation process that stimulates real-world conditions to assess how well generators handle various loads. Generators responses under different load levels are analysed.
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This is a critical aspect of diesel generators, as it indicates potential issues and ensures optimal performance during power outages or peak conditions.
Proper maintenance is essential to keeping diesel generators in good working condition and can save you a lot in the long run.