Title: Maintenance of Small Diesel Generating Sets
Objective
To understand and perform regular maintenance tasks on a small diesel generator to ensure
optimal performance and longevity.
Apparatus Required
1. Diesel generator (2–5 kVA capacity)
2. Tools: Spanners, screwdrivers, oil filter wrench, and cleaning brushes
3. Consumables: Diesel, engine oil, coolant, and grease
4. Multimeter or clamp meter
5. Safety gear: Gloves, goggles, and earplugs
Theory
A diesel generator requires regular maintenance to function efficiently and reliably. Proper
upkeep involves inspecting and servicing the engine, alternator, control panel, and other
components. Neglecting maintenance can lead to reduced performance, higher fuel
consumption, and costly repairs.
Key Aspects of Maintenance:
1. Preventive Maintenance: Routine checks and servicing to prevent issues.
2. Predictive Maintenance: Monitoring generator performance to predict potential
failures.
3. Corrective Maintenance: Addressing specific faults or breakdowns.
Maintenance Schedule:
Task Frequency
Check oil level Daily before starting
Inspect fuel system Weekly
Clean air filter Monthly
Replace engine oil Every 100–150 hours
Inspect alternator Annually
Procedure
1. Pre-Maintenance Checks:
o Place the generator on a flat surface in a ventilated area.
o Ensure the generator is off and cool before starting maintenance.
o Disconnect the battery to avoid accidental starts.
2. Engine Maintenance:
a. Oil Check and Replacement:
o Use the dipstick to check the oil level.
o Drain the old oil using the drain plug.
o Refill with fresh oil of recommended grade (e.g., SAE 15W-40).
b. Air Filter Cleaning/Replacement:
o Remove the air filter and inspect for dust and debris.
o Clean it with compressed air or replace if damaged.
c. Fuel System Check:
o Inspect fuel lines for leaks or cracks.
o Clean the fuel filter and sediment bowl.
o Drain water or impurities from the fuel tank, if necessary.
3. Cooling System Maintenance:
o Check coolant levels and top up with the recommended coolant.
o Inspect radiator fins for blockages and clean if needed.
4. Alternator Maintenance:
o Inspect alternator belts for wear or slack and adjust tension if required.
o Check electrical connections for corrosion or looseness.
5. Battery Maintenance:
o Clean battery terminals and apply petroleum jelly to prevent corrosion.
o Check the electrolyte level (if applicable) and refill with distilled water.
6. Control Panel Maintenance:
o Ensure switches and gauges are functioning correctly.
o Tighten any loose connections.
7. Final Inspection:
o Verify that all components are properly assembled.
o Test-run the generator under no-load and load conditions to ensure smooth
operation.
Observations
Component Observation Action Taken
Engine oil Low; replaced Refilled with SAE 15W-40
Air filter Dusty; cleaned Reinstalled
Fuel system No leaks observed No action required
Alternator belt Slightly loose Adjusted tension
Precautions
1. Always use genuine spare parts and recommended consumables.
2. Follow the manufacturer's guidelines for service intervals.
3. Ensure the generator is off and cool before performing any maintenance.
4. Dispose of used oil and filters responsibly.
Conclusion
Regular maintenance of a diesel generator is crucial to ensure efficient operation and extend
its lifespan. This practical demonstrated the necessary steps for maintaining critical
components and highlighted the importance of adhering to a maintenance schedule.
