6 Precautions for Daily Maintenance of Generators

May 17, 2023

Routine maintenance of generators can not only reduce the maintenance cost, but also extend the service life of generators. There are various types of generators in use today, such as synchronous generators, rechargeable alternators, series generators and exciter generators. No matter what model of generator, maintenance is basically the same. Daily maintenance should be carried out during or after work. Proper generator maintenance ensures that your equipment will stay running for years to come, and these key points are critical. Preventive maintenance techniques for diesel generators ensure uninterrupted, harmless and consistent power supply for all expected needs. They include the following aspects.


Routine general inspection

The exhaust system, fuel system, DC electrical system and engine must be closely monitored during the operation of a diesel generator and, as with any internal combustion engine, proper maintenance is essential. Diesel generators are no exception, requiring an oil change once they have reached 500 hours of operation to ensure a long, trouble-free life, but some applications may require shorter maintenance times, with checks every two weeks or at least monthly, as well as regular checks on the integrity of the alternator, controller, AVR and complete sensor system, as well as wiring and harness. To better maintain diesel generators.


/photo/genset-dieselgenerator/editor/diesel generator


Cooling system service

Coolant level must be checked when engine is shut down. Allow the engine to cool, remove the radiator cap, and add coolant until the liquid level is about 2 cm below the sealing surface under the radiator cap. Heavy-duty diesel engines require a balanced coolant mixture of water, antifreeze and coolant additives. Check the outside of the radiator for obstructions and remove all dirt or foreign objects with a soft brush or cloth. Exercise caution to avoid damaging the heat sink. If possible, use low pressure compressed air or water flowing in the opposite direction of the normal flow to clean the radiator. Check coolant heater operation by verifying hot coolant discharge from outlet hose.


fuel system

Diesel generators are vulnerable to pollution and corrosion within a year, so it is strongly recommended to operate the generator set periodically to burn off stored fuel before it descends. The fuel filter should be drained periodically as water vapor accumulates and condenses in the tank.

If the diesel has not been used and replaced within three to six months, regular testing and cleaning of the fuel may be required. As part of preventive maintenance, routine routine inspections should include checking coolant levels, oil levels, fuel systems, and starting systems. Check booster air cooler pipes and hoses regularly for leaks, holes, cracks, dirt, and debris that could clog heat sinks or loose connections.

Although the engine retains its mechanical properties, it is vulnerable to diesel fuel quality problems. In recent years, the chemical composition of diesel oil has changed; At low or high temperatures, a certain percentage of biodiesel releases pollutants, while at warm temperatures, a certain percentage of biodiesel mixed with water (condensation) may become a breeding ground for bacteria. In addition, reducing sulfur reduces lubrication and ultimately leads to clogging of the fuel injection pump.


/photo/genset-dieselgenerator/editor/diesel generator

Repair and test the starter battery

A low starting battery charge or insufficient charge is the most common cause of backup power system failure. Even if the batteries are kept fully charged and maintained regularly, lead-acid start batteries degrade over time and must be replaced regularly when they no longer hold the proper charge. Only regular inspection and testing under load can prevent generator startup problems.

Test the battery: Simply checking the output voltage of the battery does not indicate that they are capable of providing sufficient starting power. As batteries age, their internal resistance to current increases, and the only accurate measurement of voltage must be made under load. Use a manual battery load tester to verify the condition of each starting battery.

Clean the battery: When there is too much dirt, wipe the battery with a damp cloth to keep the battery clean. If corrosion occurs around the terminals, remove the battery cable and clean the terminals.

Check gravity: Use a battery hydrometer to check the gravity of the electrolyte in each cell. A fully charged battery has a specific gravity of 1.260. If the specific gravity reading is below 1.215, charge the battery.

Check the electrolyte level: Check the electrolyte level in the battery periodically. If low, fill the battery with distilled water to the bottom of the filling port.


Keep diesel generators clean

When the engine is clean and tidy, oil drips and other faults are easy to identify and fix. Hoses and belts can be visually inspected to ensure that they are in good working order. Checking your equipment regularly will prevent wasps and other annoyances from nesting in it. The more a generator is used and relied upon, the more maintenance it requires. On the other hand, infrequently used generator sets may not require much attention.

Conventional generator engine exercises

A continuously standby generator set must be able to go from cold start to full operation in a matter of seconds. This puts a heavy burden on engine parts. However, regular exercise keeps engine parts lubricated, prevents oxidation of electrical contacts, runs out of fuel before it deteriorates, and generally helps provide reliable engine starting. Run the generator set at least once a month for at least 30 minutes each time, with load if allowed on site. Accurately record all observations, performance and operational parameters, and corrective actions taken for future reference.