Diesel Generator

A diesel generator is the combination of a diesel engine with an electric generator

(often an alternator) to generate electrical energy. This is a specific case of engine-
generator. A diesel compression-ignition engine often is designed to run on fuel
oil, but some types are adapted for other liquid fuels or natural gas.

They require less maintenance due to their durability, reliability and the sturdiness
characteristic and also they are considered cheaper to operate due to the low fuels
costs as compared to the other types of fuels such as gasoline and propane.

They can withstand heavy load for long hours and start off the power supply on
full load within minutes and must be regularly maintained to ensure they provide
quality power throughout their service life. The best generator maintenance
practice is following the maintenance schedule provided by the manufacturer of the
generator to ensure maximum service time for the generator and proper operation
when it is called upon to provide power.

Having a well-designed and well-maintained standby power system is the best

protection against utility power outages.For hospitals and other health-care
facilities they can be life-threatening. For businesses like data centers, the outages
can be enormously costly. Other critical facilities at risk include government
offices, police departments, fire stations, airports, and water/sewage treatment
plants.

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:
Diesel Generator 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. According to Georgia Scott of Constant Power
Solutions one of the leading Generator and Power Equipment Manufacturers in the
UK, standard servicing and oil change times are recommended at 500hrs, however
some applications may require shorter servicing times which is why after sales
services should be top notch.

1. 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.

Nevertheless, it pays to use the most dependable, highest quality oils, lubricants
and coolants to keep your engine working. Therefore, according to Jim Girard
of Lubriplate from Newark NJ, in the US, it is highly advisable to purchase
lubricants that comply with the Original Equipment Manufacturer’s (OEM) generic
lubricant specifications.
2. 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.

3. 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.

According to Marketing Department of the Italy-based Visa SpA one of the

world’s leading gensets suppliers, dedicated to design, production, sales and rental
of generating sets; some engines used in Stand-by generating set applications have
had a few issues concerning diesel fuel.
“While the engine maintains its mechanical properties, it can give rise to problems
related to the quality of diesel fuel. The chemical make-up of diesel fuel has
changed in recent years; a certain percentage of biodiesel at low or high
temperatures releases impurities, while a certain percentage of biodiesel at warm
temperatures mixed with water (condensation) can be the cradle of bacterial
proliferation. Besides, the reduction of Sulphur reduces lubrication, which
eventually blocks the fuel-injection pumps.”“Moreover, by purchasing a genset, it
is important to know that a wide range of optional accessories are available that
allow to extend maintenance intervals and ensure providing quality power
throughout the genset’s life. In the mobile range for example, Visa SpA offers fuel
water separator filters, giving the customers the reassurance required when engine
failure is not an option, or the fuel tank inspection points.”

Ms. Clarizza Cortez of Adpower one of the leading providers of Diesel and Gas
Generators in the Middle East and North Africa also mentions that, since the fuel
quality is bad in most countries, they install Water Separator Fuel Filters and
additional filtration system to protect the sensitive fuel injection system; and advise
the customers to replace the elements on time to avoid such breakdowns.

4. 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.

5. 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.
Most importantly, when it comes to engine maintenance, according to Peter
Whitfield of YorPower a leading independent UK diesel generator manufacturer, it
is recommended to do inspections regularly because preventative maintenance is
better than reactive maintenance. Nevertheless it is of utmost importance to follow
the designated service procedure and intervals.

6. Keep your Diesel 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.

7. Exhaust system inspection

In case there are leaks along the exhaust line which usually occurs at the
connection points, the welds and the gaskets; they should be repaired immediately
by a qualified technician.

Nevertheless according to Ms. Arlene of Maverick Generators in South Africa,

always make sure your units are serviced. Especially 24 hrs before using your
generators. “For standby generators for example you need to have your units
serviced 150hrs on average. However if the generator is used constantly the hours
go up much quicker and in more regular intervals,” she adds.

Furthermore, according to Ryan Mason of Lister Petter a manufacturer of internal

combustion engines from the UK, it is quite advantageous when you have
maintenance kits for different service intervals.
 Diesel Generator Maintenance Schedule

Maintenance Items Service Time

Daily Weekly Monthly 06 Month Yearly

Inspection 

Check Coolant Heater 

Check Coolant level 

Check Oil Level 

Check Fuel Level 

Check Charge Air Piping 

Check/Clean air cleaner 

Check Battery Charger 

Drain fuel filter 

Drain water from fuel tank 

Check Coolant Concentration 

Check Drive Belt tension 

Drain exhaust condensate 

Check starting batteries 

Change Oil & Filter 

Change coolant filter 

Clean crankcase breather 

Change air cleaner element 

Check Radiator hoses 

Change fuel filter 

Clean cooling system 

 MEDIKAY CARDIAC CENTER
Biomedical Engineering Department

Diesel Generator Maintenance Schedule

Sr.No Maintenance Items Service Time(Daily Basis )

1. Inspection 

2. Check Coolant Heater 

3. Check Coolant level 

4. Check Oil Level 

5. Check Fuel Level 

6. Check Charge Air Piping 

Service Time(Weekly Basis )

7. Check/Clean air cleaner 

8. Check Battery Charger 

9. Drain fuel filter 

10. Drain water from fuel tank 

Service Time(Monthly Basis )

11. Check Coolant Concentration 

12. Check Drive Belt tension 

13. Drain exhaust condensate 

14. Check starting batteries 

Service Time(Periodic Basis ) 04 or 06 Months

15. Change Oil & Filter

16. Change coolant filter

17. Clean crankcase breather

18. Change air cleaner element

19. Check Radiator hoses

20. Change fuel filter

Service Time(Yearly)

21. Clean cooling system 