Diesel Generator Servicing Rules

Advice on extending the service life of diesel generator sets

If diesel generators are used incorrectly they fail quickly, and even when no serious breakdown has occurred yet, they need repair.

When the rules are broken, parts wear out and burn out quickly, so the equipment serves far less time than it should. It is therefore necessary to monitor the installation process carefully, carry out scheduled diagnostics on time, and repair the equipment immediately if a fault appears.

Common faults on diesel generators

During general diagnostics of diesel generators, service specialists often encounter problems that can be avoided by taking preventive measures or by carrying out urgent repairs.

These problems are:

1. the generator does not start
2. the generator stops during operation
3. oil consumption is above the normal level
4. the running engine produces heavy knocking
5. the exhaust gases take on an abnormal colour
6. the unit produces no voltage

Each of these faults has its own causes and corresponding ways of resolving them:

• The generator may fail to start because of a faulty fuel pump, the use of dirty or low-quality fuel, or failure of the starter or the cold-start device.
• Voltage problems arise from damage to the contactors and the regulator.
• The engine may stall if there is gas in the fuel, if the tank is empty, if the fuel filter is contaminated, and so on
• Excessive oil consumption occurs when the sealing of the oil system fails, or when poor-quality oil is used.
• The generator engine can produce heavy knocking noises if the injectors, valves, connecting rod bearings or piston rings have failed.
• The exhaust gases of a diesel generator may turn whitish-blue or black. This indicates that the air filter is heavily contaminated. If the colour is still abnormal after the filter has been replaced, check the injectors, the glow plugs, the relays and the electrical system.

To avoid the problems listed above, call a diagnostics and maintenance specialist immediately. Checking and repairing the unit yourself can damage the diesel generator even further, because every failure has many possible causes and many methods of elimination. It is therefore better to follow the scheduled inspection and maintenance plan.

Operating rules

When using a diesel generator set it is important to follow the operating rules; the unit will then serve throughout the whole warranty period and will run without failure for much longer.

The main recommendations are as follows:

1. Overloading the engine while it is running is not recommended.
2. Filling the fuel tank while the generator is running is not recommended; in exceptional cases it is possible using an automatic pump from another fuel tank, and not from another fuel container.
3. Changing the oil or filters and similar work must also not be carried out while the generator is switched on.
4. Only special fluids may be used as coolant, and under no circumstances water.
5. The generator must not be installed on bare ground; there must be a concrete or wooden platform with a perfectly level surface.
6. Every 250 h the oil and the oil, fuel and air filters must be changed, the exhaust gas must be checked, the unit must be tested under the appropriate load, and distilled water must be added to the batteries if necessary.

This is an incomplete list of the recommendations to take into account when servicing a diesel generator. If we take all of this into account, we will find it much easier to use the diesel generator as efficiently as possible and to ensure an uninterrupted supply of electricity whenever it is needed. If you have further questions, do not hesitate to contact us. Our team is always ready to help, whether with advice, consultation, sharing experience, or bringing in professional technicians and engineers to solve your tasks.