Generator Maintenance Cheat Sheet
1. Fuel Consumption Formula
Fuel Consumption (L) = kW Load × Hours × SFC (Specific Fuel Consumption)
Typical SFC for large diesel gensets: 0.23–0.25 L/kWh at 75–100% load.
Example: 600 kW × 0.75 × 24 h × 0.23 = 2,484 L/day per unit.
2. Preventive Maintenance Checklist
Daily Fuel, oil, coolant levels; battery voltage; leaks; panel alarms
Weekly Test run, drain fuel separator, inspect belts/hoses
Monthly Clean air filters, test auto-start, check battery charger
Quarterly Change oil & filters, replace fuel filters, clean radiator, test protections
Annual Valve clearance, injector testing, AVR calibration, load bank test, insulation test
3. Common Faults & Causes
Symptom Possible Causes
No start Dead battery, empty fuel, air in fuel, faulty starter
Low voltage AVR fault, winding damage, breaker open
Overheating Low coolant, clogged radiator, bad thermostat
Black smoke Excess fuel, clogged air filter, injector fault
White smoke Unburned fuel, low compression, cold start
Blue smoke Oil burning, worn rings, valve seals
4. Key Definitions
AVR: Automatic Voltage Regulator — keeps voltage stable.
Governor: Controls engine speed and load sharing.
Wet Stacking: Carbon/fuel buildup from low-load running.
Prime Power: Continuous running as main source.
Standby Power: Backup use during outages.
5. Safety Rules
- Lockout/Tagout before work
- PPE: Gloves, ear/eye protection
- Ensure ventilation (CO hazard)
- Avoid live electrical contact
6. Alternator Health Check
Use megger to test insulation resistance between windings and earth. Compare to OEM specs
(commonly ≥ 2 MΩ for large sets).
7. Quick Troubleshooting Logic
1. Confirm symptom → Isolate electrical or mechanical.
2. Check simple things first: fuel, battery, breakers.
3. Test suspect components: injectors, sensors, AVR.
4. Replace/repair faulty part.
5. Run & monitor to confirm fix.
6. Record in log to track patterns.
