Daily Maintenance and Key Considerations for Diesel Generator Sets

Daily Maintenance and Key Considerations for Diesel Generator Sets

As a critical backup or primary power source, the daily maintenance of diesel generator sets is essential to ensure reliability and extend service life. Below are detailed maintenance points and key considerations:

I. Daily Maintenance Tasks

Visual Inspection

Cleaning: Remove oil stains, dust, and debris from the unit’s surface to ensure proper ventilation (especially around the radiator and air intake/exhaust ports).

Fasteners: Check for loose bolts and electrical terminals to prevent detachment due to vibration.

Leaks: Inspect for fuel, oil, or coolant leaks (focus on pipe joints and gaskets).

Lubrication System

Oil Level Check: Measure 10 minutes after shutdown; the oil level should be between the dipstick marks (L~H).

Oil Quality Check: Replace if the oil appears black or has altered viscosity (indicating fuel/water contamination).

Replacement Interval: Typically every 250 operating hours or 6 months (whichever comes first). For new units, the first oil change is recommended at 50 hours.

Fuel System

Fuel Reserve: Ensure sufficient fuel in the tank to avoid shortages during emergency starts.

Filter Replacement: Replace primary and secondary filters every 500 hours. If idle for long periods, drain fuel to prevent gum deposits.

Water Separation: Regularly drain accumulated water from the fuel filter (especially in humid environments).

Cooling System

Coolant Level Check: When cold, the expansion tank level should be between MAX and MIN. Use antifreeze/corrosion-inhibited coolant.

Radiator Cleaning: Clean fins quarterly with compressed air or a soft brush to prevent clogging.

Belt Tension: Press the belt midway; 10-15mm deflection is normal. Replace if cracked or worn.

Battery Maintenance

Voltage Check: Static voltage ≥ 12.6V (12V system); charging voltage should be 13.8-14.4V.

Terminal Care: Apply petroleum jelly to prevent corrosion. Top up with distilled water (not acid) if electrolyte is low.

Charging: If unused for long periods, recharge every 2 weeks to prevent sulfation.

Air Filter

Cleaning: Blow out the filter element every 200 hours (from inside to outside). Replace if pressure drop is excessive.

Replacement Criteria: Change immediately if the filter media is damaged or cannot be cleaned (shorten intervals in dusty/desert conditions).

Operational Testing

No-Load Test: Start monthly and run for 10-15 minutes until coolant reaches 60°C+.

Load Test: Run quarterly at 30%+ load for 30 minutes to verify stability.

II. Key Considerations

Startup & Shutdown Procedures

Cold Starts: Preheat (glow plugs/intake heater) if temperature is <5°C to avoid hard starts.

Shutdown: After heavy loads, idle for 3-5 minutes before turning off to cool down.

Load Management

Sudden Loads: Avoid adding > 30% of rated power at once; increase gradually.

Phase Balance: Keep imbalance <10% to prevent overheating.

Environmental Adaptations

High Heat: Increase oil/coolant change frequency; monitor turbocharger temperature.

High Humidity: Check electrical insulation weekly; use moisture-resistant heaters.

Long-Term Storage

Rust Prevention: Drain fuel, add oil to cylinders, and manually rotate the crankshaft.

Moisture Control: Use desiccants and dust covers (ensure ventilation).

Safety Precautions

Ventilation: Ensure exhaust flow in enclosed spaces; keep CO <50ppm.

Fire Safety: Store fuel >5m away; keep ABC-class fire extinguishers nearby.

III. Maintenance Schedule (Reference)

IV. Common Warning Signs

Abnormal Noises: Knocking (bearing wear), screeching (belt slip).

Exhaust Smoke: Black (incomplete combustion), blue (burning oil), white (coolant leak).

Voltage Fluctuations: AVR or excitation system failure.

Systematic maintenance can prevent 80%+ unexpected failures. Maintain a logbook for oil changes, filter replacements, etc., and schedule professional servicing (e.g., injector calibration, valve adjustment) periodically.