It doesn’t matter if your generator is used for permanent use or as a backup in case of necessity, in any case, generator service and maintenance guarantees the correct operation of your generator.
In this article, we will review the important points about generator service and maintenance.
Preventive generator service and maintenance methods for best performance
فهرست مطالب
Service and maintenance of generators plays an important role in maximum reliability, minimizing repairs and reducing long-term costs.
By following standard generator service and maintenance procedures and generator-specific manufacturer recommendations, you can ensure that your generator is ready to go when you need it most.
As with any mechanical device, service and maintenance are very important to ensure that the generator starts and runs when needed. A good maintenance program is essential to the operation of any power generation system.
Due to the durability of generators, service and maintenance are mostly preventive in nature. Generator preventive maintenance usually includes the following operations:
General inspection
When the generator is run for preventive service and maintenance purposes, the engineer must be on the lookout for mechanical problems that could create unsafe or dangerous conditions.
There are items that must be inspected regularly to maintain safe and reliable operation:
– Exhaust system
The entire exhaust system, including the exhaust manifold, muffler, and tailpipe, should be checked.
All fittings, welds, gaskets and fittings should be checked for leaks and ensure that the outlet pipes do not overheat the surrounding areas. Also, any leaks should be repaired immediately.
– Fuel system
Fuel supply lines, return lines, filters and fittings should be checked for cracks or wear.
It must be ensured that the lines do not wear with anything that will not eventually lead to internal breakage.
Also, any leaks should be repaired or the line route changed to prevent wear.
– Air intake system
The turbocharger (if applicable) and associated components should be checked.
After checking, the elements of the air cleaner filter should be cleaned or replaced based on the environmental conditions in which the generator works.
DC power system
Primary battery terminals should be checked for clean and tight connections. Loose or corroded connections create resistance that can prevent the generator from starting.
– Engine
Fluid levels, oil pressure and coolant temperature should be checked regularly.
Look for changes in engine performance, sound, or appearance that indicate service or repair is needed.
Watch out for fire, vibration, excessive exhaust smoke, loss of power, or increased oil or fuel consumption.
Lubrication service
When the engine is turned off, the engine oil level should be checked.
To get an accurate reading on the engine dipstick, shut off the engine and wait approximately 10 minutes for the oil from the top of the engine to drain into the crankcase.
The engine manufacturer’s recommendations for API oil classification and oil viscosity should be followed.
Note that it is better to keep the oil level as close as possible to the “full” mark on the dipstick by adding the same quality and brand of oil.
Also, oil and filter should be changed at recommended intervals. Used oil and filters must be disposed of properly to avoid environmental damage or liability.
Cooling system service
The coolant level should be checked when the engine is off.
After allowing the engine to cool, the radiator cap is removed and, if necessary, coolant is added until its level is about 2 cm below the bottom sealing surface of the radiator cap.
It should be considered that heavy duty diesel engines require a balanced cooling mixture of water, antifreeze and cooling additives.
The outer part of the radiator is checked for the presence of obstacles, and with a brush or soft cloth, all dirt and foreign materials are cleaned, and for this purpose, care must be taken to avoid damaging the fins.
If possible, low-pressure compressed air or water flow in the opposite direction of the normal air flow is used to clean the radiator.
By making sure that the hot coolant comes out of the outlet hose, the performance of the coolant heater can be checked.
Fuel system service
Diesel fuel filters must be drained at intervals specified by the manufacturer. The water vapor that accumulates and condenses in the fuel tank should also be periodically drained from the tank along with any existing deposits.
Air intake service
Air charging pipes and hoses should be regularly checked for leaks, holes, cracks or loose connections, and hose clamps should be tightened if necessary.
We also inspect the charge air cooler for dirt and debris that may clog the blades, as well as cracks, holes or other damage.
Engine air intake components should be checked at the required intervals.
The amount of time it takes to clean or replace air cleaner filter elements is primarily determined by the conditions under which the generator set operates.
Air cleaners usually contain a paper cartridge filter element that can be cleaned and reused if not damaged.
Battery starter service and testing
Weak or undercharged batteries are the most common cause of standby generator failure.
Even when fully charged, lead-acid batteries deteriorate over time and must be replaced periodically when they are no longer adequately charged.
Only a regular inspection and load test program can prevent generator starting problems.
– Battery test
Just checking the output voltage of the batteries does not indicate their ability to provide adequate starting power. As batteries age, their internal resistance to current increases, and only accurate terminal voltage measurement should be done under load.
A handheld battery load tester is used to check the condition of any starter battery.
-Cleaning the batteries
Batteries should be cleaned whenever excessive dirt builds up.
If there is corrosion around the terminals, the battery cables are removed and the terminals are cleaned.
– Checking the specific weight
A battery hydrometer is used to check the specific gravity of the electrolyte in each battery cell.
A fully charged battery will have a weight of 1.260. If the specific gravity is below 1.215, the batteries should be charged.
– Checking the electrolyte level
The electrolyte level in the batteries should be checked regularly and the battery cells should be filled with distilled water.
