Operation and Maintenance of Generator Sets

Generator sets should be inspected regularly after a period of operation. Remote units should be inspected every 6–8 hours, and standby units should be inspected again after shutdown. Inspection areas may include lubricant levels, air filter clogging indicators, coolant levels, radiators and external ventilation, engine drive belt assemblies, and fuel supply. Every 50 hours of operation, drain the accumulated water from the oil-water separator and check the electrolyte level of the starter battery; for new units, inspect the valve clearances and fuel injectors after 200–300 hours of operation. Every 400 hours of operation, inspect and adjust the drive belts, replacing them if necessary. Check and clean debris from the radiator and sludge from the fuel tank; replace the lubricating oil and oil filter every 600 hours of operation or at least every 12 months; the frequency of lubricating oil changes varies depending on oil quality, fuel sulfur content, and the generator set’s oil consumption rate. Every 800 hours of operation, replace the oil-water separator and fuel filter; check the turbocharger for leaks; check the intake manifold for leaks; and inspect and clean the fuel lines; Adjust valve clearances every 1,200 operating hours; replace the air filter and coolant every 2,000 operating hours, and thoroughly clean the radiator fins and radiator water passages; inspect the fuel injectors every 2,400 operating hours, thoroughly inspect and clean the turbocharger, and thoroughly inspect the engine components.