One of the important issues for improving efficiency and optimizing the use of batteries for diesel generators is operating at the appropriate temperature. Accordingly, depending on its construction type, each battery must be placed at a specific temperature. For example, the optimal temperature for sealed lead-acid batteries is 20 to 30 degrees Celsius (or room temperature). If the ambient temperature exceeds this limit, excessive heat will generate a lot of gas inside the battery, eventually leading to valve operation and releasing oxygen and hydrogen gases resulting from the battery's reactions. Consequently, the water in the electrolyte decreases, or the battery swells due to high temperature. In both cases, the battery's lifespan is significantly reduced, leading to complete battery failure over the long term. Chemical reactions slow down significantly at low temperatures, resulting in inadequate efficiency and backup time according to battery standards. It's worth mentioning that all necessary tests for the battery, such as backup time, full charge and discharge cycles, must be performed at a constant temperature to ensure accuracy.
After the initial 150 to 200 hours of operation of the diesel generator, change the engine oil and the engine oil filter simultaneously. The oil change interval should not exceed 12 months if the diesel generator is used for emergencies. Use only the oil and lubricants recommended by the manufacturer. Note: Change the engine oil filter whenever the engine oil is changed. Cooling System Maintenance and Servicing Instructions for Diesel Generator: - Check the coolant level at specific intervals when the engine is off. After the engine has cooled down, remove the radiator cap and, if necessary, add radiator water until the level is about 1.5 centimeters below the top of the radiator. Heavy diesel engines require a mixture of cold water, antifreeze, and cooling additives. - Inspect the radiator's exterior and carefully remove any paint or foreign substances with a soft brush or cloth to prevent damage to the radiator fins. If available, use low-pressure compressed air or a water flow opposite to the natural air flow to clean the radiator. - When replacing the diesel generator engine coolant, use the same type that the engine manufacturer previously filled. Mixing different types of coolant can damage the engine. - A mixture of 40% antifreeze and 60% pure water protects the engine from freezing at temperatures up to -25 degrees Celsius. Mixing more than 50% antifreeze with water reduces the cooling effect and increases the diesel generator engine temperature. - Mix antifreeze and pure water in a separate plastic container before filling the diesel generator radiator with it. - Fill the diesel generator radiator slowly to allow air to escape the system.
1. Completely drain the cooling system of the diesel generator. 2. By attaching a hose of clean water to the coolant filling area, thoroughly flush it until no trace of deposits or contaminants is observed with the water exiting through the drain valve. 3. Fill the cooling system (radiator) with a mixture of 15 to 20 percent antifreeze and pure water (previously mixed together in a separate plastic container) and operate the diesel generator for 1 to 2 days with this mixture. 4. After this period, by opening the filling cap and the drain valve, quickly drain the system and then rinse it again with clean warm water until the water exiting the drain is completely clear. 5. Close the drain valve and fill the system with the appropriate mixture of antifreeze and pure water (previously mixed in a separate plastic container according to local conditions). Note: In areas where the water has a high mineral and sediment content, do not use this water for the radiator, as these minerals and sediments can cause blockages in the water tubes, return lines, and water pump, leading to engine overheating.
Throughout the year, diesel is exposed to contamination and corrosion, so it is recommended that standard generators regularly use stored fuels before they spoil. Fuel filters and diesel water separators must be drained at specified intervals due to the accumulation of water vapor in the fuel tank, and the diesel generator should be bled. Regular fuel tests may be conducted every three to six months if the fuel is not used and replaced if necessary. Preventive maintenance should have a regular general schedule, including checking coolant levels, oil levels, the fuel system, and the starting system. Plumbing and air hoses should be regularly inspected for leaks, holes, cracks, dirt, and debris, which may block radiator fins or loosen connections.
Low voltage or low consumption batteries commonly cause failure in
ready-to-use electrical systems. The battery must be fully charged and
well-maintained to prevent unnecessary testing and battery inspection to
prevent excessive generator start-ups. They must also be cleaned; the specific parameters
and the battery's electrolyte level are often checked.
Battery Testing: Merely checking the output voltage of the batteries does
not indicate their ability to provide adequate consumption power. The age of
the battery increases its internal resistance to current flow, and for accurate
measurement, the terminal voltage should be measured under load. In some
generators with a control board, this test is automatically performed whenever
the generator is started. In other generator sets, use a battery load tester to
determine the condition of each battery.
Cleaning the Battery: Whenever there is an excessive accumulation of dirt,
clean the batteries with damp cloths. If there is corrosion around the
terminals, remove the battery cables and wash the terminals with a solution of
baking soda and boiling water (1/4 kg of baking soda to 1 kg of boiling water).
Be careful not to let the solution enter the battery cells and rinse the
battery with clean water. After placing the connections, cover the terminals
with clear protective covers.
Specific Gravity Check: In lead-acid batteries, use a battery hydrometer to
check the specific gravity of the electrolyte in each battery cell. A fully
charged battery has a specific gravity of 1.260. If the specific gravity
reading is below 1.215, charge the battery.
Electrolyte Level Check: In lead-acid batteries, check the electrolyte
level in each cell every 200 hours of operation by opening the cell. If it is
low, fill the battery cells with distilled water.
When the engine is clean and well-maintained, ensure to guard against oil
leaks and other issues. Inspection can ensure that hoses and clamps are in good
condition. Protect the engine, equipment, and exhaust from nests of bees and
birds. Any generator that is used frequently requires more servicing. However,
a generator set that is rarely used may not need as much care.
