EMILIO AGUINALDO COLLEGE - CAVITE CAMPUS

School of Engineering and Technology

Fundamental parts of Diesel Generator

and its
Preventive Maintenance

August 29, 2019

1:00pm – 4:00pm
OBJECTIVE:

a. To be familiar with the basic part of a Diesel Generator

b. Once identify, participants will be aware of the routine

preventive maintenance of a Diesel Generator
 Course Outline:
 Overview of Generator

 History and its basic principles

 Intermediate parts of Diesel Generator

 Preventive Maintenance and Monitoring

 Content of a PMS

 Safety Procedures and PPE Equipment

 Careers in Maintenance
What is a Generator?

• is a machine or rather an equipment that

converts mechanical energy into electrical
power for use in an external circuit.
Generator was ……
• a brain child by a British scientist named Michael
Faraday in sometime between 1831 - 1832.

• Then Faraday’s Disk was born afterwards it was

evolved it into the first electromagnetic generator.
Operating Principle….
 AC Generator is a device that produces an electromotive force (emf) by changing the
no. of magnetic flux, (Φ), passing through a coil. Once coil is rotated between magnetic poles by cranking
the handle, an AC Voltage Waveform is produced.

Operating principle of Generator is based on induced electromagnetic, which is

defined by Faraday’s Law, which states

An electromotive force, Eemf, induced in a wire coil is proportional to the number of

turns, N, in the Coil and the Rate of Change, dΦ / dt, of the number of Magnetic Flux Lines, Φ, passing
through the surface (A) enclosed by the Coil.

An Induced Effect is always such as to compete against the cause that produced it.
 IMPORTANCE OF EMERGENCY POWER

 Saves Lives

 Business Continuity

 Avoidance of Losses

 Electricity is part of Human Necessity

Visual Basic parts of Gen-Set..
Control Panel…
Other parts…
Fuel Tank
The Muffler..
 Basic Visual Routine Check-up
a
Predictive Maintenance Approach
for
DIESEL GENERATOR
1st step - Check Fuel level

Water – Fuel Separator

or
Water Filter
 2nd step - Check Water level

WARNING!!!!!!!!!

DO NOT ATTEMPT TO CLIMB ON

TOP OF THE RADIATOR or Gen-set

Very DANGEROUS!!!!
 3rd step - Check Oil level

Identify for the color of oil and

its viscosity

DIP-STICK
4th step - Check the Battery voltage using multi-tester at the same
time measure level of distilled water.

 Ideal Voltage of Battery:

<<<< 12.6 volts = Fully Charge

>>>> 12.3 volts = Battery is near the weak stage

 Hydrometer tools is used to measure

the specific gravity of Lead Acid Battery
 5th Step - Check Air Filter
AIR FILTER SERVICE GAUGE

Parts of Air-Filter

Note importance….

Air-filter is used to eradicate air pollution

from entering the combustion chamber of
Diesel Generator
Air Filter Paper
Air Dust particle is one of the cause of un- burn fuel
AIR FILTER SERVICE GAUGE and excessive smoke of Gen-set.
6th Step - Record all data indicated at the control panel

Collecting all technical information

such as Volts, Ampere, Frequency,
Oil Pressure as future reference can
greatly predict status of both the
alternator and diesel engine.
Basic Personal Protective Equipment (PPE)
Preventive Maintenance Schedule
Scheduled Maintenance is a programmed upkeep actions carried out at
regular time intervals that aimed prevent of breakdowns of machines or
equipment.

Primary objective is to prevent equipment failure before it actually occurs.

The most common planned program is called the 52 week program.

52-week (PPM) Preventive Maintenance Schedule is prepared for the

entire year to plan all the PPM activities. Any activity that does not occur as
per schedule, action plans, corrective and preventive actions are defined.

The 52-week schedule helps in efficient monitoring of all the preventive

maintenance activities to prolonged the operation of such equipment.
 What is inside a PMS for GEN-SET?
Checklist Guide for Preventive Maintenance Schedule:
 Daily – visual inspection, technical data recording or monitor parameters

 Weekly – radiator’s water level,

fuel filter gauge,
water level,
distilled water level for battery,
battery voltage level and ampere reading,
visual inspection of battery physical appearance,
visual inspection of Oil Level
No Load Test

Note: Maximum of 10mins. of operating time during “NO LOAD TEST”. Upon starting the diesel
engine. Then allow another 15mins of cooling time before turning of the engine

 Monthly – visual inspection of the following:

air filter gauge,
fuel filter gauge,
water level,
physical inspect the oil filter, fuel tank and radiator prior to Load Testing
30-minutes Load Testing Run

Note: The safe operating load must have a Minimum Load of 15% to 20%. of rated capacity during
“LOAD TEST” once power was transfer to emergency power. Then allow 15mins of cooling time before
prior to turn-off the Diesel Engine.

Better consult your service provider for clear safety guidelines.

 Semi-annually – perform the following activities:
visual inspection or replacement of parts
oil filter,
air-filter,
fuel filter,
fan belt if necessary
check battery water level
battery as required
Visual inspection of mechanism Manual Transfer Switch or ATS
LOAD Testing

Note: Minimum of 30mins. of operating time during “LOAD TESTING”. Upon starting the diesel
engine. Then allow another 15mins of cooling time before turning of the engine

 Annually – total replacement of parts and In-depth Inspection procedure will be conducted:
change oil with corresponding oil laboratory sampling analysis
check.

Note: Minimum of 30mins. of operating time during “LOAD TESTING”. Upon starting the diesel
engine. Then allow another 15mins of cooling time before turning of the engine.

Annual and Semi –Annual Preventive Maintenance is usually done by Accredited

Specialist or Service Provider
SAMPLE POWER DIAGRAM OF EMERGENCY POWER
Difference Between Manual Transfer Switch & Automatic Transfer Switch
 Careers in Maintenance
• Power Plant Managers
• Power Plant Superintendents
• Maintenance Technicians
• Building Managers
• Building Engineers
• Property Managers
• Property Engineers
• Manufacturing Managers
• Product Specialists
• Energy Conservation Consultants
• Facility Managers
• Facility Engineers
• Suppliers
• Techno – Entrepreneurs / Businessman
Popular Product Names