As temperatures drop and winter approaches, diesel generators often face difficulties during cold starts and overall operation. For a 200kVA diesel generator, proper maintenance is essential—not only to ensure reliable performance but also to extend the life of the machine.
This article will guide you through the complete maintenance routine for your 200kVA generator, including daily checks, periodic servicing, and winter-specific care tips.
1. Daily Maintenance Routine
🔧 Daily Checklist:
Review the previous day’s operation report;
Check for any oil, coolant, or diesel leaks;
Confirm oil, coolant, and diesel levels are within range;
Inspect engine coolant heater functionality;
Check the Automatic Transfer Switch (ATS) status;
Measure battery voltage and check charger operation;
Complete the daily maintenance log.
📒 Daily Log Should Include:
Generator parameters: 3-phase voltage, current, frequency, power, power factor;
Operating time;
Engine parameters: coolant temperature, oil pressure, battery voltage;
Engine noise, vibration, and exhaust conditions.
2. Periodic Maintenance
🗓 Weekly (Every 7–10 Days):
Repeat daily checks;
Inspect and clean air filter;
Drain fuel tank and fuel filter sediment and water;
Run generator under no load for 20–30 minutes to verify system health.
⏳ Every 6 Months (or every 250 operating hours, whichever comes first):
Repeat daily and weekly tasks;
Replace engine oil and oil filter;
Replace air and fuel filters;
Check and adjust coolant additive levels, replace coolant filter;
Inspect fan and alternator belts;
Clean radiator exterior if dirty;
Inspect hoses, fuel pump, crankcase breather;
Test ATS system by simulating a power outage.
🕛 Every Year (or every 1500 hours, whichever comes first):
All the above maintenance;
Inspect and adjust fuel injectors and valve clearance;
Tighten turbocharger bolts;
Perform a full load test (50–80% load) for 3 hours to check performance under pressure.
3. Winter-Specific Maintenance Tips
Coolant System: Use antifreeze to prevent freezing damage to radiator and hoses.
Battery Check: Ensure proper battery voltage to avoid cold-start failures.
Heater Inspection: Confirm engine heater is functioning for cold-weather starts.
Warm-Up Time: Let generator run at no load for 5+ minutes before shutoff to avoid condensation and carbon buildup.
4. Pre-Start & Post-Run Checks
✅ Before Starting:
Ensure the generator room is clear of obstructions, especially around the fan;
Check oil, fuel, and coolant levels;
Confirm ventilation system is clean and operational;
Verify battery cable tightness and breaker positions;
Check fuel valve and operation logs.
🔄 After Starting:
No-Load Checks: Listen for abnormal noise or vibration, monitor oil pressure, voltage, and frequency;
Load Checks: Observe load behavior, power factor, current balance, and fuel consumption estimation.
⛔ Before Shutdown:
Ensure all load has transferred back to utility power;
Let generator run idle for 5–10 minutes (depending on temperature) before switching off.
5. Final Checks Before Leaving
Verify battery charger (220VAC) is functioning;
Confirm engine coolant heater is operating;
Inspect ATS switch position and main breaker status;
Check generator control panel (RUN/AUTO/OFF);
Confirm fuel valve is open and fuel level is sufficient;
Complete operation report.
6. Important Maintenance Details
💧 Coolant:
Use soft water mixed with antifreeze and anti-rust agents;
Fill in stages and wait 10–20 minutes before topping off;
Maintain water level 20–30mm below radiator cap.
⛽ Diesel Fuel:
Use #0 or -10 diesel in winter;
Regularly drain water and sediment from the bottom of the tank;
Use clean, fresh diesel from reliable sources.
🔋 Battery:
Standard voltage: 12.5–12.8V (single), 25.0–25.6V (dual);
Charging voltage: 13.0–13.5V (single), 26.0–27.0V (dual);
Replace batteries every 1–2 years;
Do not use constant-current chargers.
🛢 Engine Oil:
Use approved oil and replace on schedule or as needed.
✅ Final Thoughts
A well-maintained 200kVA generator is essential for reliable power supply—whether it’s used in factories, hospitals, hotels, construction sites, or for rental. With proper daily inspections, scheduled maintenance, and special attention during the winter months, you can maximize uptime, reduce repair costs, and extend the overall lifespan of your generator.
Need expert advice or support for your 200kVA generator maintenance? Contact Hosem Power—your trusted power solution provider.
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