Maintenance of Diesel Generator Sets in Summer

With the arrival of summer, temperatures rise and electricity demand increases accordingly. For many businesses and households, diesel generator sets have become indispensable backup power sources. However, summer-specific climatic conditions such as high temperatures, humidity, and thunderstorms pose many challenges to generator operation. To ensure diesel generator sets operate stably and safely in summer and to extend their service life, the following is a detailed maintenance and care guide.

In hot summer months, the frequency of diesel generator set usage increases significantly, and its stable operation is crucial for ensuring power supply. To ensure that the generator can work safely and efficiently in high-temperature environments, pre-startup checks are essential.

Before starting the diesel generator set, first check whether the circulating cooling water in the tank is sufficient. Cooling water is key for heat dissipation in the generator set. If the tank is low on water, the heat generated by the unit cannot be effectively dissipated, leading to potential malfunctions. If the cooling water is insufficient, purified water should be added in time. Purified water ensures the cooling system remains clean and operates efficiently, preventing impurities from clogging the cooling channels.

The engine room is an important space for the operation of the diesel generator set, and its safety is crucial. During the hot and humid summer, the engine room should maintain good ventilation to ensure smooth airflow. Dust and dirt in the ventilation ducts should be regularly cleaned to keep the ducts unobstructed. In addition, flammable and explosive items such as gasoline, paint, fireworks, and firecrackers are strictly prohibited in the engine room. These items are prone to cause fires in high-temperature environments, posing serious threats to the generator set and surrounding areas.

The generator set should not operate in direct sunlight or high-temperature environments. During summer, direct sunlight can rapidly raise the temperature of the generator's body, increasing the load on the cooling system and potentially causing malfunctions. Therefore, avoid placing the generator set under direct sunlight as much as possible. Sunshades or shade structures can be used to block sunlight and reduce the surface temperature of the generator.

Once all pre-startup checks have been completed properly, the generator enters the operational phase. However, starting the generator is only the first step. Management and maintenance during operation are equally important.

Summer is the thunderstorm season, and lightning strikes can cause serious damage to generator sets. To ensure safety, on-site lightning protection measures must be implemented. All mechanical equipment and ongoing construction should follow grounding regulations during installation and use. The generator set should be equipped with protective grounding, ensuring good electrical grounding. Grounding devices should be inspected regularly to ensure connections are firm and grounding resistance meets the requirements. This effectively prevents lightning from damaging the generator set and ensures safe operation.

Continuous operation of diesel generator sets in high-temperature summer conditions can lead to overheating, affecting service life. Therefore, it is recommended that after 5 hours of continuous operation, the generator should be stopped for half an hour to allow it to rest. This is because the diesel engine operates under high-speed compression, and prolonged high-temperature operation can damage the cylinder block. Reasonable scheduling of runtime can effectively reduce the unit temperature and extend its service life.

High summer temperatures cause fuel to evaporate easily. Users should regularly check fuel levels and replenish engine oil and diesel in time. Additionally, fuel and oil meeting specifications should be used, avoiding low-quality products. Low-quality oil may reduce engine performance or even damage the engine. Regularly checking the quality and quantity of fuel and oil ensures normal operation of the generator set and improves work efficiency.

During high summer temperatures, controlling the temperature in the engine room is particularly important. The normal working environment temperature of the generator should not exceed 50°C. If the engine room temperature is too high, it may cause the generator to shut down. In this case, measures such as opening all doors and windows or replacing hot water in the radiator with cold water can be taken to lower the temperature. Maintaining the engine room temperature within a reasonable range ensures stable operation and prevents faults caused by high temperatures.

Regular maintenance is a key factor in ensuring long-term reliable operation of the generator set. It can promptly identify potential problems, prevent minor faults from developing into major accidents, and effectively extend the service life of the generator set while improving operational efficiency.

Due to high summer temperatures, the cooling system of diesel generators is particularly important. Users should regularly check whether the cooling water is sufficient and ensure that its temperature does not exceed the specified value. In addition, the cooling system should be regularly checked for leaks or other faults. If problems are detected, they should be dealt with in a timely manner to ensure the normal operation of the cooling system. Regular cleaning of scale and debris in the cooling system can improve cooling efficiency and extend its service life.

Summer air contains more dust and impurities, so it is very important to regularly clean or replace air filters. Air filters are used to filter air entering the engine, preventing dust and impurities from entering the engine. If the air filter is blocked, the engine may draw in impurities, affecting performance and service life. Regular cleaning or replacement ensures the engine receives clean air, maintaining its performance and longevity.

Diesel generator sets have various wear parts, such as valves, fuel injectors, and filters. The normal operation of these parts is critical to the generator's performance. Therefore, they should be cleaned or replaced regularly based on wear levels. Parameters such as valve clearance, injection pressure, and fuel supply timing should be regularly adjusted to ensure the generator set remains in good working condition. Timely replacement of heavily worn parts can prevent faults and extend the generator's service life.

During normal operation, high temperatures in multiple components can cause carbon deposits to form on valves and other parts. These deposits can affect engine performance, increase fuel consumption, and even cause engine faults. Therefore, carbon deposits should be cleaned in a timely manner. For backup generators, cleaning intervals may be extended. For generators in regular use, cleaning every 4–6 months is recommended. Regular cleaning of carbon deposits helps maintain good engine performance and improve work efficiency.

Proper installation and reasonable usage are the foundation for safe and efficient generator operation. Improper installation or unreasonable use may prevent normal operation and even lead to safety accidents, regardless of pre-checks and maintenance.

The installation site of the diesel generator set should be well-ventilated. The Yuchai generator end should have sufficient air intake, and the Yuchai diesel engine end should have a good exhaust outlet. The exhaust outlet area must be 2–3 times larger than the radiator area. This ensures sufficient airflow during operation and prevents faults caused by poor heat dissipation. The surrounding area should be kept clean, avoiding items that produce acidic, alkaline, or other corrosive gases or vapors, which could corrode the generator set.

When using diesel generator sets indoors, exhaust ducts must be routed outdoors. The duct diameter must be equal to or larger than the muffler outlet, and the number of elbows should not exceed five. Pipes should be inclined downward by 5–10 degrees to prevent rainwater entry. For vertical exhaust pipes, rainproof devices must be installed to prevent water from entering the generator. Proper exhaust duct installation reduces indoor pollution and improves generator efficiency.

The generator casing must have reliable protective grounding. For generators requiring neutral point direct grounding, professional electricians must perform the neutral grounding and install lightning protection devices. Do not use mains grounding for direct neutral point grounding, to avoid safety accidents. Proper installation of grounding and lightning protection devices effectively prevents lightning strikes and electric leakage, ensuring the safety of equipment and personnel.

The bidirectional switch between the generator and mains must be very reliable to prevent backfeeding. The wiring reliability of plastic-cased bidirectional switches must be verified and approved by the local power authority before energizing. Correct bidirectional switch setup ensures safe switching between the generator and mains and prevents accidents caused by operational errors.

Summer is a peak electricity season and a period of increased diesel generator usage. To ensure stable and safe operation and extend the generator's service life, users must conduct thorough pre-startup checks, follow operational guidelines during use, and perform regular maintenance. Through proper cooling system maintenance, air filter cleaning, fuel and oil management, inspection and replacement of wear parts, and carbon deposit cleaning, generator performance can be effectively ensured. Additionally, proper installation site selection, exhaust duct setup, grounding and lightning protection installation, and correct bidirectional switch configuration are crucial for safe operation. In high-temperature weather, particular attention should be paid to engine room temperature control and summer preparation following winter maintenance. Only by comprehensively addressing these measures can diesel generator sets operate stably in hot summer conditions, providing reliable power support to users.