Industrial Services & Equipment Repair in Abu Dhabi, UAE

During routine service of diesel generators (typically every 250–500 running hours depending on capacity), the following works are generally carried out to ensure reliable performance and prevent breakdowns:

🔧 1. Engine Maintenance

• Drain and replace engine oil

• Replace engine oil filter

• Check and clean/replace air filter

• Replace fuel filters (primary & secondary)

• Check fuel lines for leakage or blockage

• Inspect turbocharger (if applicable)

💧 2. Cooling System

• Check radiator coolant level

• Inspect coolant condition (top-up or replace if required)

• Clean radiator fins (air blowing)

• Check hoses, clamps, and water pump for leaks

• Inspect radiator cap and thermostat

🔋 3. Electrical System

• Check battery voltage and electrolyte level

• Clean battery terminals and apply grease

• Check alternator output voltage

• Inspect charging system and wiring connections

• Check starting motor operation

⚙️ 4. Fuel System

• Drain water/sediments from fuel tank (if drain point available)

• Check fuel pump operation

• Inspect injectors for proper functioning (basic inspection)

🛢️ 5. Lubrication & Mechanical Checks

• Check for oil leaks in engine and pipelines

• Inspect belts (fan belt, alternator belt) for wear/tension

• Tighten loose bolts, nuts, and mountings

• Check vibration levels and alignment

⚡ 6. Control Panel & Protection System

• Check all gauges and indicators

• Test safety shutdowns:

• Low oil pressure

• High temperature

• Over-speed (if applicable)

• Inspect control wiring and terminals

• Verify AMF/ATS panel operation (if installed)

🔊 7. Exhaust System

• Inspect exhaust piping for leaks or damage

• Check silencer condition and supports

🧹 8. General Cleaning & Inspection

• Clean generator set (engine + alternator)

• Remove dust, oil, and debris

• Ensure proper ventilation around DG set

• Check canopy condition (for weather protection)

Signs include unusual noises, excessive smoke, difficulty starting, and fluctuating power output. Addressing these issues promptly can prevent major breakdowns.

For generators up to 250 KVA, service should be carried out every 250–300 operating hours. For generators ranging from 300 KVA to 1500 KVA, service is recommended every 400–500 operating hours. Comprehensive preventive maintenance should be performed at every 5000 operating hours.

Daily checks include verifying engine oil levels, radiator coolant levels, and inspecting for any visible leaks or damages to ensure proper operation.

Routine service includes engine oil replacement, air filter cleaning/replacement, fuel filter replacement, radiator coolant inspection, and checking the battery voltage and terminals.

Effective troubleshooting is the foundation of successful equipment repair—it ensures problems are solved correctly the first time, reduces operational losses, and improves overall system performance.

An Annual Maintenance Contract (AMC) for a generator is a formal agreement between the equipment owner and a service provider to carry out regular inspection, preventive maintenance, and necessary repairs over a fixed period (usually one year).

An AMC is like a health insurance + regular check-up plan for your generator.

Instead of waiting for breakdowns, it ensures continuous care, which leads to:

✔ Better performance

✔ Lower repair cost

✔ Longer equipment life

✔ Reliable operation

• Non-Comprehensive AMC

• Covers labor/service only

• Spare parts charged separately

• Comprehensive AMC

• Covers both labor and most spare parts

• Higher cost but lower risk of unexpected ex

A typical AMC for diesel generators (like Perkins, Cummins, CAT, Kirloskar, Kubota, JCB, DAF, John Deere, Deutz etc.) includes:

• Periodic preventive maintenance

• Routine servicing (every 250–500 hours depending on capacity)

• Engine oil and filter replacement

• Fuel, air, and coolant system checks

• Inspection & testing

• Battery condition and charging system

• Alternator performance and insulation

• Control panel functionality and safety systems

• Breakdown support

• Emergency repair services

• Troubleshooting and fault diagnosis

• Consumables / spares (depending on contract type)

• Filters, belts, coolant, lubricants

• Major parts (covered in comprehensive AMC)

• Performance monitoring

• Load testing

• Fuel efficiency checks

• Record keeping and reporting

An AMC significantly improves generator lifespan in the following ways:

1. Prevents Major Failures

Regular inspections help detect issues like:

• Oil leaks

• Overheating

• Worn-out parts

👉 Early detection avoids costly breakdowns and engine damage.