Maintenance Of 6.5 Horse Power Generators (H.P)

Project and Seminar Material for Mechanical Engineering ME

Project and Seminar Material for Mechanical Engineering ME


The most important thing in coupling a generator system is to know the parts that will come first before others and which one will house others. This project on ‘’servicing a generator’’ called generator- it born out of the desire for self-servicing and replacing of faulty parts of our own, generator than going to a public mechanic. It contains the basis parts and functions of generator, something you need to be familiar with before servicing.

The fourth chapter is a complete illustrated step by guide to service a 6.5KVAGenerator. The step by step approach makes the work easy and ideal. Any person with simple adherence to this work can use this to maintain and couple a generator set. The total essence of this project work is to teach its reader how to maintain a generator without consulting a technician, this book has been made to illustration the steps an individuals needs to carry out a servicing or maintenance work in his or her power generating system.

Table Of Content

Preliminary Page(s)

  • Title page
  • Approval page
  • Dedication
  • Acknowledgement
  • Abstract
  • Table of Content

Chapter One

1.0 Introduction

  • 1.1 Background of study
  • 1.2 Objectives of the study
  • 1.3 Scope of the study
  • 1.4 Limitation of the study
  • 1.5 Significance of the study
  • 1.6 Definition of terms

Chapter Two

2.0 Literature Review

Chapter Three

3.0 Operation, Danger and Precaution

  • 3.1 Operation
  • 3.2 Danger
  • 3.3 Precaution

Chapter Four

4.0 Maintenance of Generator

  • 4.1 Definition of maintenance
  • 4.2 Maintenance work
  • 4.3 Carburetor
  • 4.4 Significance of generator

Chapter Five

5.0 Summary Recommendation and Conclusion

  • 5.1 Summary
  • 5.2 Recommendation
  • 5.3 Conclusion
  • 5.4 References

Chapter One

1.0 Introduction

It is increasingly popular to service your own generator. In most case, it save money and it guarantees you to get what you want. It also, ensures you to avoid proprietary design many companies use to keep you coming for the new parts best of all, having couple the generator your self, you became very familiar with the system and with generator maintenance tips. We will be focusing on preventive maintenance of power generators as that is want should concern you as a generator owner.

Corrective maintenance should be left; for generator mechanics. One assurance that observing preventive maintenance guideline provided here will reduce your need for corrective maintenance. Following these tips will also ensure you qualify for manufacturer warranty if things go wrong. Here are your generator maintenance tips: study generator in detail before first use your generator comes with a user and manual, which contains most of the information you need, to properly use and maintain your generator. In the manual you will also find information on how to properly start or stop your generator.

It also important to state that the recommended guidelines given here should not be a replacement for reading your generator. When our recommendation conflict with, your generator user manual, we advice you follow your generator manual instead. Inspect Generator and connection before each start check oil and fuel level before starting your generator. If your generator uses coolant (like water), also check the coolant level. Ensure coolant, fuel, and engine oil are in the right level before starting the generator.

Check for leakages in the fuel line or spilled fuel, replace line if broken, clean up fuel spills, before starting your generator. Also inspect the electrical wiring. Use recommended engine oil, check level before. Start your power generator crankcase must be filled with the manufacturer recommended engine oil. If possible buy your engine oil in gallons and ensure that the logo showing that the oil meets the minimum standard required by your generator manufacturer is on the label.

If you must buy in pints ensure to ask the retailer for the container of the engine oil just to be sure it meets the need of your generator. Always ensure that the engine oil level of your crankcase is within limits before starting the generator. Ensure that the oil is clean. As the generator crankcase gets dirty with time it is important that you change all the oil after sometime.

This you do by draining; the crankcase of oil and then refilling with the recommended engine oil. We recommend that “for generator operating in Nigeria this ritual should take place every 2months. Change oil every 2 months; in addition ensure to change your engine oil within the first month of use. Consult your generator manufacturer manual for details. Replace parts with only genuine spares. Make sure the repair mechanic uses the right parts.

When replacing parts like spark plugs make sure they are the ones recommended by your generator manufacturer. Load generator at less than 70% rated capacity for best performance and longevity of your generator; load it at less than 50% of its rated capacity for continuous usage. This recommendation is very important for generators that are used frequently as is usually the case for generators operating in Nigeria. This means that a 6.5KVA generator should not be loaded beyond 1.75KVA.

If you must exceed this limit it should not be for long must not be on a daily basis or you may have to be visiting generator mechanics frequently. Improper loading is the most common cause of generator break down. The funny part is that when your generator breaks down, you blame it on the manufacturer, or china. But we put it to you that you are culprit. A generator usually have two power ratings, the maximum power which is the level of loading that must not be exceeded under any circumstances and the rated power, which is actually the power that should interest you as it determines the level of load your generator can handle. Note that although your generator can handle full loading, it is not recommended’ for generators used frequently.

It is better you limit loading to less than 70% (or even 50%) of generator full load. Your electric generator should not be overloaded. It must be operated within the rated power. If you notice the sound of your generator changing due to excessive, loading switch-off some appliances. If the generator automatically switch off due to over-loading. Turn-off all appliances before turning on generator again.

For an optimum generator operation you should operate the generator at about half the rated power, load and unload generator gradually improper loading of generators is one of the most common causes of generator break down. Do not start your generator with everything connected. Start your generator at no load, then apply load gradually. Turn off all appliances, turn off control switch, then start your generator, turn on control switch, then turn on your appliances gradually one after another starting those with higher voltage, like your TV

1.1 Background Of Study

1.1.1 Definition

A power plant is defined as a machine or assembly of equipment that generates and delivers a flow of mechanical or electric energy. Focusing on electric power generator, the main equipment needed for the generation of electric power is the generator. During coupling, it is connected to a prime mover which runs; it and the electricity are generated. the type of prime move determines the type of power plant.

The major types of plant are:

  1. Steam power plant
  2. Internal combustion engine power plant
  3. Hydro electric power plant
  4. Gas tubing power plant
  5. Nuclear power plant

1.1.2 Our Concern Internal Combustion Engine Power Plant (Mobile) Known As Generating Set Or Generator

An electrical generator is a device that converts L mechanical energy to electric energy. The reserve conversion of electrical energy into mechanical energy is done by a motor. Motor and generators have many similarities, a generator forces electric ‘charger to move through an external electric circuit but it does not create electricity or charge which is already present in the wire of winding. It is some what analogous to a water pumo which creates a flow of water but does not create the water suite.

The two main parts of a generator can be described in either mechanical term.


The rotating part of an electric machine (generator)


The stationary part of an electrical machine (generator)


the power producing component of an electrical machine in a generator, alternator or dynamo. The armature windings generate the electrical current. The armature can be on either the rotor or the stator.


The magnetic field component of an electrical machine. The magnetic Field of the dynamo or can be provides by either electromagnetic or permanent mounted on either the rotor or stator. The magnetic field will magnet the rotor as will be rotation inside the magnets because power transferred into the feud circuit’s much less than in the armature circuit, the A.C. generators nearly always have the field winding, only a small amount of feild current must be moving rotor using scrip rings. The rotation of the armature coil generates the required current and the automatic voltage regulator (AVR passes the generated current through the A.C. cables

1.1 Objectives Of The Study

The aim of, the study is to impact the readers the skills of coupling generator as possible takes.

1.2 Scope Of The Study

The scope of this study will be strictly restricted portable or mobile generators ranging from 6.5KVA-7KVA

1.3 Limitation Of The Study

Many constraints limited the extent this work would have gone. They are such things as:


This is the time taken to run the entire project. We do not have all the time in our hands especially when we combine it with our regular academic work and other things.


We do not have the fund to execute this research work.

Lack of information:

There is no information base like book on this topic but we being the first to write on this topic “ coupling of generator’’ did well with the few related ones we found.

1.4 Significance Of The Study

Assembling of generator, operation and maintenance servicing are regular works for a mechanical engineering performs any person, student, or researcher reading this. Work will benefit from knowing how to these work

1.5 Definition Of Terms

Electric Generator:

A device that converts mechanical energy to electric energy. Setups: is to take the necessary steps to make equipment ready for use.


The power, producing component of an electrical machine.


The power producing component of an electrical machine.


The magnetic field component of an electrical machine.

Chapter Five

5.0 Summary, Recommendation And Conclusion

5.1 Summary

The total essence of this project work is to teach its reader how to maintain a generator without consulting a technician, this book has been made to illustrate the steps an individual needs to carry out a servicing or maintenance work in his or her power generating system.

5.2 Recommendation

  1. Based on the strength of finding this work, it is highly fundamental to make these recommendations
  2. Every body that has a generator set should at least learn how to do one or two. Servicing work on this generator set.
  3. We should also have some major tools and equipment that are used in servicing a generator in our various homes, some tools like spanner, pliers, and screwdrivers this win enable us do some unexpected corrections when the mechanic is not there presently.
  4. Some people who are not related to the study of mechanical engineering fill that it is of no need to have any knowledge on the study of servicing a generator set. But I here by recommend then to at least attend some lecture class on this study, classes like, workshop, conference, seminars, to enable them learn more on for emergency purposes.

5.3 Conclusion

For every project work to be executed one has to reason out what the project will be all about and how to make it work. Out, that is applying effort to see that the reasoned idea will be implemented in other to achieve the aim and the objective of the project.

The most important aim of this project “ the servicing of a generator set’’ is to ensure that who ever reads through this work should be able to carry out a servicing operation in a generator set.

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