Diesel Generators: Preventative maintenance is key to cost saving – Part One

Diesel Generators: Preventative maintenance is key to cost saving – Part One

By Jack Ward, MD of Powermode

If you are the owner of a diesel generator – whether it’s used for prime or backup power – you’ll be aware that the quality and frequency of preventative maintenance is important when it comes to service reliability.

In fact, monitoring and maintenance regimes are also keys to cost saving because the need for expensive emergency repairs will be minimised. More importantly, your well-maintained generator will work to full capacity every time it’s called upon to do duty.

I don’t have to stress how important it is for a standby power system to work first time, every time when a crippling power outage hits without warning.

Unfortunately, when it comes to regular servicing and maintenance, many critical procedures are overlooked on a day-to-day basis, particularly by owners of standby generator plants who often ignore them until they are desperately needed in an emergency.

Why is this? I believe it’s because there is no ‘driver behind the wheel’ when a generator is running, able to give mechanics a ‘heads-up’ when a problem becomes apparent.

This is why regular inspections are vital. First, study the technical data provided by the manufacturers. Then begin with the exhaust system, including the manifold, exhaust pipe and silencer. Look for leaks at all connections and joints, including welds. ‘Blow-by’ can cause fires.

Inspect the fuel supply lines, return lines, filters and fittings for cracks or abrasions. Ensure that the lines are not in contact with any object that could cause an eventual wear-through breakage. Repair any leaks or change the fuel line’s routing to eliminate wear.

Regular inspections must include the monitoring of all fluid levels, oil pressure and coolant temperatures. Most engine problems give an early warning. Look and listen for misfires, vibration, excessive exhaust smoke, loss of power or increases in oil or fuel consumption.

Checking the oil level (when the engine is NOT running) is a simple procedure. Oil should be changed every 12 months – no matter how much running has been done. Follow the engine manufacturer’s recommendations for API (American Petroleum Institute) oil classification and oil viscosity. When the oil is changed, also change the oil filter – and remember to dispose of it responsibly to avoid environmental contamination.

One of the most important tasks is to check the coolant level daily and top up if necessary. Diesel engines require a balanced coolant mixture of water, antifreeze and coolant additives.

At the same time, inspect the exterior of the radiator for obstructions and remove dirt or foreign material. If available, use low pressure compressed air or a stream of water in the opposite direction to normal air flow to clean the radiator. Change the coolant filter every 12 months and also drain, flush and refill the cooling system. Check that the radiator fan belt is not frayed, cracked or lacks the correct tension.

In my next blog, I’ll delve even deeper into the challenges of diesel generator maintenance and look at other important areas to inspect, monitor, maintain and repair when necessary - all in the quest to save money and boost efficiency.

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