Every day, the world becomes more complicated. Our non-essential requirements are gradually becoming critical requirements. This category includes generators. Having a generator for residential use was once a luxury. However, a lot has changed since then. It is no longer a luxury. Having a generator for your home is now a requirement. Therefore, you would have to get into the swing of utilizing generators quite quickly. But having a generator would only give you a short-term benefit if you do not maintain it. Right maintenance of generators is, however, critical. Through this article, you would be able to know about the maintenance of diesel generators.
Importance of Safety Practices
Before telling you about the maintenance of diesel generators, we thought of telling you how important safety practices are when it comes to using a generator. It is critical that you adhere to all safety guidelines and standards. You must ensure that you are correctly operating your generator. You might find yourself in a perilous scenario if you utilize a generator incorrectly.
Carbon monoxide poisoning is caused by engine exhaust. Even if you don’t smell the motor fumes, you might be exposed to carbon monoxide. When running a generator, if you get queasy, dizzy, or weak, get some fresh air as quickly as possible. If you are having severe symptoms, you should get medical attention immediately. Carbon monoxide alarms should be placed with batteries. Take the required measures after reading the manufacturer’s instructions. Electric shock and electrocution, as well as fire, are all potential hazards. As a result, you must exercise caution when utilizing generators. It is just as crucial to understanding those safeguards as it is to understand why we need generators.
Generators should be placed outdoors, away from any buildings. When a generator is used in an enclosed or partially enclosed structure, dangerously high levels of carbon monoxide are produced, which can be fatal. To prevent emissions from entering your home, company, or neighbor’s, keep generators outdoors and at least 15 feet away from open windows. In addition, you must keep the generator dry. Make sure your hands are dry and you’re working on a dry surface beneath an open, canopy-like structure before approaching the generator. Do not use the generator if it is raining or moist outside. We advise you to get to know more about this by reading further.
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What do we mean by Diesel Generator Maintenance?
Proper diesel generator maintenance is essential for ensuring that your equipment lasts for many years. In order to do so, you must examine the following critical elements.
Diesel Generator General Inspection
It is common knowledge that when the diesel generator is running, the exhaust system, fuel system, DC electrical system, and engine must all be closely monitored for any leakage that might result in dangerous situations. Proper maintenance, like with an internal combustion engine, is critical. There are suggested standard service and oil replacement times based on the generator manufacturer. However, we recognize that some applications may demand faster maintenance, which is why after-sales support should be excellent.
Generator Log Book: Generator Maintenance Log Paperback – June 15, 2017
This generator logbook would be so useful to you in terms of maintaining your generator. Having a log book like this can make your work easier than you think it would. So, we thought of recommending this logbook to you for your use.
What are the Maintenance Practices that you must adhere to?
Broadly, there are a few maintenance practices that you must adhere to when it comes to the maintenance of diesel generators. In this section, we are going to focus on them. First, let us get to know what they are.
- Lubrication service
- Cooling system
- Fuel system
- Testing batteries
- Routine engine checkup
No doubt, we are so sure that you would like to know more about each of the above about the maintenance of diesel generators. We are going to tell you all about them in detail now.
1. Lubrication system
Using a dipstick, check the engine oil while shutting down the generator at regular intervals. You must also allow the oil in the top regions of the engine to drain back into the crankcase and adhere to the engine manufacturer’s API oil classification and viscosity requirements. Not only that, but you should add the same grade and brand of oil to keep the oil level as close to the full mark on the dipstick as feasible.
The oil and filter, as well as the oil, must be replaced at predetermined intervals. It’s critical to double-check with the engine manufacturer on how to drain the oil and replace the oil filter, as well as how to dispose of them. By following these standard practices correctly, we can prevent causing environmental harm or responsibility.
To keep your engine running, you must use the most trustworthy, highest quality oils, lubricants, and coolants available. According to the majority of manufacturer data, purchasing lubricants that meet the Original Equipment Manufacturers (OEM) generic lubricant standards is strongly recommended.
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2. Cooling system
Closed circulation liquid cooling mode with its own fan is used by the gensets with medium and high standard configurations. The water pump, the waterway between the engine cylinder block and the cylinder head, thermostat, bypass pipe between the thermostat body and the water pump, water tank radiator, pipeline and hose, and lubricating oil cooler make up the cooling system circulation loop.
While there are expansion tanks and remote tanks, such as the remote tank installation position is relatively high, you should add the transition tank to prevent the heat exchanger from meeting any damage due to excessive internal pressure in medium and high non-standard configuration gensets. such as split water tank-type units, water tank radiator should be replaced by the heat exchanger, while there are expansion tank and remote tank, such as the remote tank installation position is relatively high, the transition tank should be added to prevent the heat exchanger from being damaged due to excessive internal pressure.
In addition, at the user’s request, it is possible to install a coolant filtering system separately to medium and high generator sets. The device serves two purposes. One is it filters out all pollutants in the coolant, preventing scale development in the cooling system. And the other is it improves the coolant’s corrosion protection.
To minimize cooling performance loss owing to precipitation in the cooling system, you must replenish the coolant at least once every six months. Another reason to replace the coolant is to prevent the producing set from corroding, as rust reduces the efficiency of the additive and disables the water temperature sensor over time.
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3. Fuel system
It is common knowledge that within a year, contamination and corrosion can occur in diesel. Thus, frequent generator set exercise is highly advisable to burn up stored fuel before it degrades. As a result of the water vapor that builds and condenses in the fuel tank, you should empty the fuel filters at the appropriate intervals.
If you do not use the fuel and replace it every three to six months, frequent testing and fuel cleaning may be necessary. A regular general examination, which includes checking the coolant level, oil level, fuel system, and starting system, is necessary in preventative maintenance. Inspect the charge-air cooler pipes and hoses for leaks, holes, cracks, dirt, and debris that may be obstructing the fins or loose connections on a frequent basis.
According to a study conducted by the world’s leading generator manufacturers, while the engine retains its mechanical qualities, it can cause difficulties with diesel fuel quality. It’s because diesel fuel’s chemical composition has altered in recent years. It is a fact that a specific amount of biodiesel emits contaminants at low and high temperatures. At high temperatures, a certain amount of biodiesel mixed with water (condensation) might be a breeding ground for bacteria. In addition, reducing Sulfur diminishes lubrication, which eventually causes the fuel injection pumps to become clogged.
It is vital to know that a variety of extra accessories are available, allowing you to lengthen maintenance intervals and ensuring that the genset continues to provide reliable power throughout its lifetime. Because most nations’ fuel quality is poor, they use Water Separator Fuel Filters and a secondary filtration system to safeguard the delicate fuel injection system. They also encourage users to replace the elements on a timely basis to avoid malfunctions.
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4. Maintenance batteries
Maintenance of batteries is also a very important thing to do when it comes to the maintenance of diesel generators. Weak or undercharged starting batteries have been found as a prevalent cause of standby power system failures. To avoid fading, the battery must be kept properly charged and well-maintained. It may be done by frequent testing and inspection to determine the current state of the battery and avoid any generator start-up issues. They must also be cleaned, and the battery’s specific gravity and electrolyte levels must be monitored on a regular basis.
Testing batteries
It is clear that simply testing the batteries’ output voltage is not a reliable indicator of their capacity to provide appropriate starting power. Furthermore, as batteries age, their internal resistance to current flow increases. And the only way to accurately measure terminal voltage is to do it when the battery is full. However, it is a fact that on certain generators, this suggestive test operates every time the generator is working. Other generator sets, on the other hand, will require the use of a manual battery load tester to verify the condition of each starting battery.
Cleaning batteries
Cleaning is necessary for proper equipment upkeep. As a result, the user must keep the batteries clean at all times. If there is dust on the batteries, you should wipe them off with a moist cloth. Remove the battery cables and wash the terminals with a baking soda and water solution (1/4 pound baking soda to 1-quart water) if corrosion is evident around the terminals. Make sure the solution does not get into the battery cells while you are doing this and then flush the batteries with clean water when you finish doing it. Coat the terminals with a thin coating of petroleum jelly after reinstalling the connections.
Checking specific gravity
It is a fact that in open-cell lead-acid batteries, the specific gravity of the electrolyte in each battery cell should be there under inspection using a battery hydrometer. A completely charged battery has a specific gravity of 1.260, as can be observed. If the specific gravity value is less than 1.215, you must charge the battery.
Checking electrolyte level
In open-cell lead-acid batteries, you should check the electrolyte level at least every 200 hours of operation. If it is low, fill the battery cells with pure water all the way to the bottom of the filler neck.
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5. Routing engine checkup
This is another very important step in the process of maintenance of diesel generators. In open-cell lead-acid batteries, you should check the electrolyte level at least every 200 hours of operation. If it is low, fill the battery cells with pure water to the bottom of the filler neck. Inspections should be done on a frequent basis. That is according to a top independent UK diesel generator manufacturer since proactive maintenance is preferable. It is also critical to adhere to the established servicing procedures and intervals.
Keep your diesel generator clean
When the engine is clean and tidy, oil drops and other faults are easier to identify and address. The visual examination helps ensure that hoses and belts are in excellent working order. But routine inspections can prevent wasps and other pests from nesting in your equipment. It is clear that the more you use a generator, the more care it requires. As a result, a generator set that is not in use much may not require as much attention.
Exhaust system inspection
Leaks along the exhaust pipe are more likely to occur at the connecting points, welds, and gaskets. So, you should fix them as soon as possible with the help of a competent specialist.
Most generator manufacturers recommend that you need to service your machines on a regular basis. It is extremely important to wait at least 24 hours before utilizing your generators. For a standby generator, for example, you should maintain your units every 150 hours on average. However, if you operate the generator continuously, the hours accumulate considerably more quickly and in more regular intervals. Additionally, having maintenance kits for various service intervals is really beneficial.
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Conclusion
In this article, we told you about the maintenance of diesel generators. We hope that you now have a very good idea about the maintenance of diesel generators. Perhaps, professionals like electricians and HVAC technicians may need generators a lot. If you are one of them, or even if not, nowadays, generators are surely necessary. If you’d like to know more about generators, you can try history of generators, early versions of generators, types of generators, why do we need generators?, general uses of generators, how a generator works, fuel types of generators, warranty of a generator, market availability of commercial generators, generator accessories, portable generators, market stats of generator industry, impact of Covid-19 on generator industry
