500kVA Cummins C500D5

Diesel generators operate at much lower temperatures than petrol-fuel generators and decrease overall wear and tear associated with running a generator often for a longer period of time at much less rotation per minute.

A diesel engine needs to operate under substantial load, to reach its optimum operating temperature. If it fails to reach this temperature, then a percentage of the fuel will be unburnt and a build-up of soot can occur.

Within the engine soot can cause internal glazing of the cylinder bores, sticking of the piston rings, reducing compression and the injectors are likely to have a build-up of carbon causing more unburnt fuel to pass through the combustion chamber into the exhaust.

The first sign of this problem is heavy smoke from the exhaust, eventually, the unburnt fuel will condense in the exhaust and mix with the soot, to create a thick dark liquid that looks like engine oil. This liquid will seep from the exhaust and will appear to be an oil leak. This liquid can build up in the exhaust silencer and there is the risk of it igniting from the increased heat of the exhaust fumes, if the generator is subsequently put under full load.

If a generator continues to be operated with no load or very light load there is a possibility that permanent engine damage can occur.

When specifying a new generator, ensure that the unit is adequate for the requirement, without being too large. If the machine is future proofed with additional capacity, or the existing installation is over capacity, a load bank testing programme must be implemented. The load bank should be used to create an artificial demand for between 75% and 100% of prime load and this, in most circumstances, will burn off carbon deposits, prolonging the life of the generator. Typically, the generator should be run at 75% of prime power for 2 hours in every 100 hours use.

Never use a generator in an attached garage, even with the door open. Place generators so exhaust fumes can’t enter the home through windows, doors or other openings; the exhaust must be directed away from the building.

Four reasons why your generator fails to start:

1. Battery Failure. One of the most common reasons a generator will not start is due to a battery failure.
2. Low Coolant Levels. Without radiator coolant, an engine would soon overheat, leading to mechanical breakdown and engine failure.
3. Bad fuel mix.
4. Controls not in auto.

It is acceptable for all but the most modern diesels to experience white smoke at start-up. But this should disappear after the engine warms up.

Preventive maintenance should include a regular general inspection that includes checking the coolant level, oil level, fuel system, and starting system. The charge-air cooler piping and hoses should be inspected regularly for leaks, holes, cracks, dirt and debris that may be blocking the fins or loose connections.

Generators should not be left to run until they are out of fuel. Running out of fuel may cause your generator’s coils to lose their magnetism. This happens because the appliances being powered drain the residual magnetism of the generator when the load is abruptly stopped.

The main parts of a diesel generator:

• Diesel Engine.
• Fuel System.
• Voltage Regulator.
• Cooling System & Exhaust System.
• Lubrication System.
• Battery Charger.
• Control Panel.
• Main Assembly Frame or Skid.

Because 1500rpm diesel generators have slower running engines, which are less-stressed than the smaller models, they’re suitable for static installation for daily prime power, as well as for standby use. The lifespan of one of these generators can last for 10,000+ hours