MAHARASHTRA STATE BOARD OF

TECHNICAL EDUCATION
SHIVAJIRAO S. JONDHALE POLYTECHNIC

MICRO PROJECT
Academic Year: 2022-23

TITLE OF PROJECT

MAINTENACE PROCEDURE OF
DIESEL GENEARATOR SET

Program: MECHANICAL ENGINEERING

Program code: ME5I
Course: Power Plant Engineering (PPE)
Course code: 22566
 MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate
This is to certify that

SHASHANK SAI NALLA

Roll No. 1127 of 5th Semester of Diploma in Mechanical engineering of Institute,

Shivajirao S. Jondhale POLYTECHNIC (Code: 0147) has completed the Micro
Project satisfactorily in Subject –EMD (22564) for the academic year 2022 -
2023 as prescribed in the curriculum.

Place: AMBERNATH Enrollment No: 2001470091

Date: ……………………… Exam Seat No: …………………………………….

Subject Teacher Head of the Department Principal

 INDEX

Sr No. CONTENTS
1 Introduction to Diesel Generator set
2 Steps required for maintenance of D.G. set
3 Step 1: Lubrication service
4 Step 2: Cooling system
5 Step 3: Fuel system
Step 4: Testing batteries
6 Step 5: Routine engine exercise
Step 6: Keep your diesel generator clean
7 Step 7: Exhaust system inspection
Step 8: Operating Inspections
 INTRODUCTION TO DIESEL GENERATOR

A Diesel generator is processing the electric generator to generate

electrical energy. This is the specific case of the engine generator. A
diesel compression-ignition engine often is designed to run fuel oil also
some types are adapted to run with liquid fuels or natural gas.

Generator Users require less maintenance due to their durability (it means

measures the length of product life), reliability (it means the product will
not fail within a specific period of time), and the sturdiness
characteristic (It means the durability of the product), and also they are
considered cheaper to operate due to the low fuels costs as compared to
the other types of fuels such as gasoline and propane. When you reach
the best generator dealers they’ll guide you.
Diesel Generator

Every Business needs a Standby Diesel generator For Backup Power and

the Generator Gives More power to the whole Unit. Also considered to
withstand heavy loads for long hours and start off the power supply on
the full load within minutes and must be regularly maintained to ensure
they provide quality power throughout their service life.
The best diesel generator maintenance practice is following the
maintenance schedule provided by the generator manufacturer to ensure
maximum service time for the generator and proper operation when it is
called upon to provide power.

The engine is the core component of the generator. If you want to run
your generator well without any mechanical issues or electrical issues
must maintain the generators carefully.

Once you start running the diesel generator, the exhaust system, fuel
system, DC electrical system, and engine require close monitoring for any
leaks that can cause hazardous occurrences. The very essential one is to
maintain the internal combustion engine. A backup generator is
mandatory in the industry and also proper maintenance of diesel
generators is important so take a look at these steps.

STEPS REQUIRED FOR MAINTENANCE OF D.G. SET

Step 1: Lubrication Service

The Engine oil must be checked while powering off the generator at
regular intervals using a dipstick.

Allow the oil in the upper portion of the engine to drain back into the
crankcase and follow the engine manufacturer’s recommendations for
API oil classification and oil viscosity.

Keep watching the oil level as near as possible to the full mark on the
dipstick by adding the same quality and brand of oil. The oil and filter
must also be changed at particular time intervals. Check regularly with
the engine manufacturer for procedures for draining the oil and replacing
the oil filter and their disposal is to be done appropriately to avoid
environmental damage or liability.
Step 2: Cooling System

Check the coolant oil level during shutdown periods at the specified
interval.

Must be noted these points “remove the radiator cap after allowing the
engine to cool, and, if necessary, add coolant until the level is about 3/4
in” And a More critical role in balancing diesel engines require a
balanced coolant mixture of water, antifreeze, and coolant additives.

Examine the exterior of the radiator for obstructions, and remove all dirt,
grimy or foreign material with a soft brush or cloth with caution to avoid
damaging the fins.

If available means, use the low-pressure compressed air or a stream of

water in the opposite direction of normal airflow to clean the radiator.
WARNING

Please don’t remove the pressure cap from a hot engine. Wait until the
coolant temperature is below 120°F (50°C) before removing the
pressure cap. Because heated coolant spray or steam can cause injury.

Step 3: Fuel System

This is the important point when it comes to the maintenance of diesel

generators. Diesel is subject to contamination and corrosion within a
period of time is one year, and therefore regular generator set exercise is
highly recommended to use up stored fuel before it degrades.

The fuel filters should be drained at the designated intervals due to the
water vapor that accumulates and condenses in the fuel tank.
Better check regularly testing and fuel polishing may be required if the
fuel is not used and replaced in three to six months.

Step 4: Testing Batteries

If the battery’s charges reach the dead-end level is a common cause of

standby power system failures.

The battery must be kept fully charged and well-maintained at an all-time

40% to 100% to avoid regular testing and inspection to know the current
status of the battery and avoid low battery levels.
Step 5: Routine Engine Exercise

Regular exercising keeps the engine parts lubricated and thwarts

oxidation of electrical contacts, uses up the fuel before it deteriorates, and
helps to provide diesel generator maintenance to reliable engine starting.

Engine exercise is recommended to be executed 15 days once or 25 days

once for a minimum of 30 min
Step 6: Keep your Diesel Generator Clean

Maintain your engine all-time nice and clean because it will be taken care
of Oil drips and other issues. Check day-by-day hoses and belts that are in
good condition or not.

Frequent checks can keep better conditions and other nuisances from
nesting in your equipment. However, the generator users thought is a
generator set that is rarely used and might not need a lot of care. So,
please avoid this kind of thought and keeps regular maintenance of diesel
generators based on manufacturer guidelines.
Step 7: Exhaust system inspection

In case of any leaks along the exhaust line which usually occur at the
connection points, the welds, and the gaskets. Find the place of leakages
and repair them immediately by a technician.

Step 8: Operating Inspections

When the Diesel Generator is Running these Guidelines Should Be

inspected in operation inspection.