Whatever sector you’re involved in, if you’re using a diesel industrial generator, you’ll no doubt already be enjoying the benefits, from cost-effectiveness and energy efficiency to high levels of safety and reliability. These machines are also typically very low maintenance.
However, as with any other machinery, regular servicing and attention will ensure your generator always works when you need it most. Unfortunately, all too often, diesel generators used to supply power in emergencies are neglected until there is a power cut.
And, like human beings, generators need a frequent workout! If your unit is on standby all the time, remember it needs to go from a “cold” start to fully functional in a matter of seconds. But if engine parts are kept well lubricated, and fluid lines unblocked, damaging oxidation of electrical contacts is avoided, and stress on parts reduced, so that the engine will start more reliably.
Therefore it’s good practice to run your generator in loaded mode every month, for at least half an hour.
Here are some other important aspects of generator maintenance:
- Regular checking of the exhaust system
- Attention to the fuel supply lines
- Caring for the machine’s electrical system
- Frequent monitoring of all fuel levels, coolant temperatures and oil pressure
- Oil changes and servicing of the fuel and cooling mechanisms.
At the same time, there are number of things to with your machine that you should be on the constant lookout for, including:
- Vibration
- Excess smoke from the exhaust
- Increased fuel or oil consumption
- Misfires
- Loss of power
Battery Maintenance
There are often two sets of lead-acid batteries – the power storage units and the starting batteries.
When standby power systems fail, one of the most common reasons is that batteries are undercharged or weak. But, even when well-maintained and charged, over time there can be deterioration. As batteries age, their own resistance to current flow rises.
So when a battery can no longer sustain a proper charge, it must be replaced. Regular generator services and inspection will avoid starting and power problems caused by premature battery failure.
But just checking the batteries’ output voltage will not tell you whether they can provide sufficient standby or starting power. Only testing under load will accurately assess terminal voltage.
Keep batteries rust-free and clean. If corrosion gets into the terminal area, the battery cables must be taken out and the terminals cleaned with a water and baking soda solution. Coat with a light cover of petroleum jelly after replacing the connections.
Equally, you will also need to check the battery electrolyte’s specific gravity with a hydrometer. In a fully charged unit this will be 1.260. Check the electrolyte level for every 200 operational hours, and top up as required using distilled water.
Finally it should be stressed that all maintenance and servicing work must be done by qualified technical staff, and ideally the jobs should be outsourced to specialists. Good diesel generator suppliers can advise – or may include servicing and maintenance as part of the package.
