Like other common mechanical equipment, diesel generator sets also require daily maintenance and upkeep. The following 9 tips can help you extend the service life of diesel generators and make the operation process smoother.
1. Routine general inspection
During the operation of diesel generator sets, any potential leakage that may cause dangerous accidents needs to be monitored, including the monitoring of exhaust systems, fuel systems, DC electrical systems, and AC generators. The diesel generator set will generate vibration during operation, and over time, it is likely to cause bolts or other parts of the body to loosen or even fall off. It is necessary to regularly check for any looseness or detachment as mentioned above.
2. Check the lubrication system
The lubrication system of diesel generator sets is very important. It plays a role in lubricating, cooling, and cleaning the moving parts of diesel generator sets, while also serving as a seal to prevent surface rust of certain components. Before starting the engine, it is usually necessary to use a dipstick to check the engine oil level. The oil level should be as close to the full mark as possible. The oil and filter need to be replaced regularly. 500 operating hours is the recommended standard maintenance and oil change time, but some special occasions may require shorter or longer maintenance time. If oil needs to be added or replaced, try to add oil of the same quality and brand as much as possible. It is best to purchase lubricating oil that meets OEM specifications.
3. Check the cooling system
Regularly check the coolant level when the equipment is not running (when the engine is cooling). When the engine cools down, remove the radiator cap and check if the radiator is full. Coolants can be water, antifreeze, or other coolant additives, or their mixtures. Check the outside of the radiator for any obstacles every day, remove any dirt or foreign objects, to avoid damaging the radiator.
4. Check the fuel system
Diesel can be contaminated and corroded within a year, so it is strongly recommended to run the generator set regularly to use up stored fuel before it degrades. Due to the accumulation and condensation of water vapor in the fuel tank, the fuel filter should be drained at specified time intervals. If fuel is not used or replaced within three to six months, regular testing and fuel polishing may be required. Preventive maintenance should include regular comprehensive inspections, including checking the coolant level, oil level, fuel system, and starting system. Regular inspections should be conducted on the pipes and hoses of the charge air cooler for leaks, holes, cracks, dirt, and debris that may clog the heat sink or loosen the connection. If necessary, replace the fuel filter and oil-water separator during maintenance.
5. Check the battery
Low battery power or insufficient charging during startup is a common cause of backup power system failure. The battery must be kept fully charged and well maintained to avoid regular testing and inspection to understand the current state of the battery and to avoid any startup faults of the generator. They must also be clean; And regularly check the specific gravity and electrolyte level of the battery, and check whether the terminals are oxidized or loose.
6. Regular engine exercises
Regular operation can keep engine components lubricated and prevent oxidation of electrical contacts, deplete fuel before it deteriorates, and help provide reliable engine start-up. It is recommended to run the engine at least once a month, for at least 30 minutes each time, with a load not less than one-third of the nameplate rated value.
7. Check the exhaust system
If there is any leakage in the exhaust pipeline, which usually occurs at the connection points, welds, and gaskets, it should be repaired immediately by qualified technicians. Always ensure that your equipment is repaired, especially 24 hours before using the generator. For backup generators, you need to have diesel generators serve an average of 150 hours. However, if the generator is frequently used, the time will increase faster and the intervals will be more regular.
8. Check the wires
Check if the electrical wiring of each part of the entire generator set is loose or detached, such as the wiring inside the control cabinet, terminal load wiring, partial wiring with the engine body, emergency stop devices, etc.
9. Keep the diesel generator clean
Diesel generators should be kept clean. When the engine is clean and tidy, oil droplets and other issues are easily detected and addressed. Visual inspection can ensure that the hoses and belts are in good condition. Regular inspections can prevent wasps and other distractions from building nests in your device. The more generators you use and rely on, the more you need to maintain them.