Diesel Generator Warning

1. Do not charge a frozen battery, this may cause an explosion.

2. Ensure the generator set room is properly ventilated.
3. Keep the room, the floor and the generator set clean. When spills of fuel, oil, battery,
electrolyte or coolant occur, they should be cleaned up immediately.
4. Never store flammable liquids near the engine.
5. Store oily rags in covered metal containers.
6. Do not smoke or allow sparks, flames or other sources of ignition around fuel or
batteries. Fuel vapours are explosive. Hydrogen gas generated by charging batteries is
also explosive.
7. Avoid refilling the fuel tank while the engine is running.
8. Do not attempt to operate the generator set with any known leaks in the fuel system.
9. Do not use aerosol types of starting aids such as ether. Using these types of items could
result in an explosion and personal injury.
10. While the generator set is running do not attempt to reach under or around the guards
for any reason.
11. Keep hands, arms, long hair, loose clothing and jewellery away from pulleys, belts and
other moving parts. Some moving parts can not be seen clearly when the set is running.
12. Keep access doors on enclosures, if equipped, closed and locked when not required to
be open.
13. Avoid contact with hot oil, hot coolant, hot exhaust gases, hot surfaces, sharp edges and
corners.
14. Ear protection must be worn when operating or working around an operating generator
set.
 Troubleshooting of Diesel Generator

Primary Cause of Failure and/or poor performance

S.No. Issue to Trouble Shoot
1 Generator Fails to Start
2 Generator Fails to Start
3 Shutdown due to Low Oil
Pressure
4 Shutdown due to High
Temperature
5 Generator Set Poor
Performance
6 Generator does not Carry Full
Load
Primary Cause Remedy
Battery Status Faulty battery or charger-Test battery
charger & replace if necessary
No Fuel Check fuel level, if OK check fuel
delivery & quality, consider fuel
polishing
Oil Level too Low Check dipstick, & ensure oil top off part
of planned maintenance program(PMP)
Low Coolant Level Coolant levels should be checked &
Coolant check part of PMP
Filtration System Clogging fuel & air filters will retard
performance, change & change hours
in PMP
Carbonization Lightly run engine build up carbon, full
load and have Load bank testing service

Unit will not Start due to battery-80% of generator’s failures to start are due to
faults in the set’s battery. Weak or low charged batteries are a common
occurrence. Even a well-charged, well-maintained lead-acid battery will
deteriorate over time. Batteries must be replaced when they no longer hold a
proper charge. Battery charger system and alternators should be checked weekly
on sets used for standby and emergency applications, and at least monthly on
other applications.
Unit will not Start due to Fuel- Lack of fuel or low quality fuel are often reasons
generator-set engines fail to start or to give rated power. Fuel quality should be
checked as part of any planned maintenance visit. Technicians working on diesel-
fueled units will check if water or other contaminations are in the fuel or in the
unit’s filtration or delivery systems. Having no fuel in diesel and gaseous units
could be due to lack of storage capacity or poor delivery form the on-site storage.
Failure due to Low Oil Pressure- We recommend that the oil level for prime
power sets be checked daily and maintained as closely as possible to the dipstick
‘full’ mark. The most accurate readings are taken ten minutes after running the
unit under load and shutting down.
High Temperature failure-Low coolant levels due to cooling system leaks are the
most common reason engines fail because of overheating.
Filters leading to reduced Performance- The air, oil & fuel filter elements must be
changed per manufacturer’s recommendations or whenever necessary due to site
or operating conditions. Any blockage will restrict flow and result in reduced
performance. Air & oil filter blockages also contribute to excessive engine wear.
Will not Carry full Load- Regular testing under full load will identify issues that
could prevent the generator from taking its rated load. Standby/ emergency
installation should be regularly exercised for 30 minutes with a minimum 30
percent electrical load at least once a month. For critical standby applications, this
is often increased to once a week. Fuel quality can also be an issue for poor
performance.
CONCLUSION:
Practicing regular, planned maintenance by a qualified technician will play a
critical role in reducing or eliminating future problems, minimizing potential
failures and maximizing availability and reliability. It is most important that the
technician diagnoses and correctly identifies the cause of a part or component
failure, rather than simply replacing a failed part or component, to reduce the
likelihood of a repeat failure.