The essence of creating this thread is to educate diesel generator user of the importance of having the basic knowledge of the machine in their possession.

Diesel generators are expensive to acquire and also expensive to maintain. Simple knowledge of the basics can save you lots of stress and money.

So, let know where and how Perkins diesel engine was founded.

Perkins Engines Company Limited, a subsidiary of Caterpillar Inc, is primarily a diesel engine manufacturer for several markets including agricultural, construction, material handling, power generation and industrial. It was established in Peterborough, England, in 1932. Over the years Perkins has expanded its engine ranges and produces thousands of different engine specifications including diesel and petrol engines.

F. Perkins Limited, established on 7 June 1932, was founded in Queen Street, Peterborough, to design and manufacture high-speed diesel engines by Frank Perkins and Charles Wallace Chapman.

Chapman was design engineer (technical director) and company secretary and had a ten percent shareholding. He was to remain with the business for more than a decade before re-joining the Royal Navy Reserve though remaining a consultant to the company.

Frank Perkins obtained further initial support from directors Alan J M Richardson and George Dodds Perks.

Before Chapman and Perkins the diesel engine was a heavy and slow revving workhorse, lacking performance. Chapman's concept was the high-speed diesel – an engine that could challenge gasoline as the primary motive power.

The company’s first high-speed diesel engine was Perkins' four-cylinder Vixen, which made its debut in 1932: in October 1935 Perkins became the first company to hold six world diesel speed records for a variety of distances set at the Brooklands race track in Surrey.

Sales were strong and by the time of World War II the company made two series of engines, P4 and P6. Soon after the war, the company went public,.and established a number of licensees for local manufacturing and sale.

What is a diesel engine?

Like a gasoline engine, a diesel engine is a type of internal combustion engine. Combustion is another word for burning, and internal means inside, so an internal combustion engine is simply one where the fuel is burned inside the main part of the engine (the cylinders) where power is produced.

That's very different from an external combustion engine such as those used by old-fashioned steam locomotives. In a steam engine, there's a big fire at one end of a boiler that heats water to make steam. The steam flows down long tubes to a cylinder at the opposite end of the boiler where it pushes a piston back and forth to move the wheels. This is external combustion because the fire is outside the cylinder (indeed, typically 6-7 meters or 20-30ft away). In a gasoline or diesel engine, the fuel burns inside the cylinders themselves.

Internal combustion wastes much less energy because the heat doesn't have to flow from where it's produced into the cylinder: everything happens in the same place. That's why internal combustion engines are more efficient than external combustion engines (they produce more energy from the same volume of fuel).

How is a diesel engine different from a gasoline engine?

Gasoline engines and diesel engines both work by internal combustion, but in slightly different ways. In a gasoline engine, fuel and air is injected into small metal cylinders. A piston compresses (squeezes) the mixture, making it explosive, and a small electric spark from a sparking plug sets fire to it. That makes the mixture explode, generating power that pushes the piston down the cylinder and (through the crankshaft and gears) turns the wheels. You can read more about this and watch a simple animation of how it works in our article on car engines.

Diesel engines are similar, but simpler. First, air is allowed into the cylinder and the piston compresses it—but much more than in a gasoline engine. In a gasoline engine, the fuel-air mixture is compressed to about a tenth of its original volume. But in a diesel engine, the air is compressed by anything from 14 to 25 times. If you've ever pumped up a bicycle tire, you'll have felt the pump getting hotter in your hands the longer you used it. That's because compressing a gas generates heat. Imagine, then, how much heat is generated by forcing air into 14–25 times less space than it normally takes up. So much heat, as it happens, that the air gets really hot—usually at least 500°C (1000°F) and sometimes very much hotter. Once the air is compressed, a mist of fuel is sprayed into the cylinder typically (in a modern engine) by an electronic fuel-injection system, which works a bit like a sophisticated aerosol can. (The amount of fuel injected varies, depending on how much power the driver wants the engine to produce.) The air is so hot that the fuel instantly ignites and explodes without any need for a spark plug. This controlled explosion makes the piston push back out of the cylinder, producing the power that drives the vehicle or machine in which the engine is mounted. When the piston goes back into the cylinder, the exhaust gases are pushed out through an exhaust valve and, the process repeats itself—hundreds or thousands of times a minute!

Four stroke engine

The four-stroke engine is the most common types of internal combustion engines and is used in various automobiles (that specifically use gasoline as fuel) like cars, trucks, and some motorbikes (many motorbikes use a two stroke engine). A four stroke engine delivers one power stroke for every two cycles of the piston (or four piston strokes). There is an animation to the right (Figure 1) of a four-stroke engine and further explanation of the process below.

Intake stroke

The piston moves downward to the bottom, this increases the volume to allow a fuel-air mixture to enter the chamber.

Compression stroke

The intake valve is closed, and the piston moves up the chamber to the top. This compresses the fuel-air mixture. At the end of this stroke, a spark plug provides the compressed fuel with the activation energy required to begin combustion.
Power Stroke: As the fuel reaches the end of it’s combustion, the heat released from combusting hydrocarbons increases the pressure which causes the gas to push down on the piston and create the power output.

Exhaust stroke

As the piston reaches the bottom, the exhaust valve opens. The remaining exhaust gas is pushed out by the piston as it moves back upwards.


The thermal efficiency of these gasoline engines will vary depending on the model and design of the vehicle. However in general, gasoline engines convert 20% of the fuel (chemical energy) to mechanical energy—in which only 15% will be used to move the wheels (the rest is lost to friction and other mechanical elements).

One way thermodynamic efficiency can improve in engines is through a higher compression ratio. This ratio is the difference between the minimum and maximum volume in the engine chamber .

A higher ratio will allow a larger fuel-air mixture to enter, causing a higher pressure, leading to a hotter chamber, which increases thermal efficiency.

We will be discussing about safety and precautionary measures to ensure your generator is safe and fault free.

The cost of maintenance and parts are so huge. So, one need to keep these safety tips to minimize it or if possible avoid it.

Generator safety checklist: Precautionary measures genset users should be aware of

Here are seven basic safety, and precautionary measures genset users should take to avoid unnecessary accidents.

A generator is a handy appliance to have in the house or industry. The genset generator is your best friend during power outages, as you rely on this appliance to keep your machines running. At the same time, you have to be careful when handling your genset for home or factory. Failure to do so can cause the same generator to become your worst enemy, as it can cause dangerous accidents.
Let us now look at the basic safety, and precaution measures genset users should take to avoid accidents and injuries.


1. Ensure to avoid enclosed spaces while using your genset.

Generators emit large amounts of carbon monoxide and other harmful gases. Running a generator in a confined space is like inviting danger. You inhale the carbon monoxide emitted by the machine. Now, that can be hazardous because carbon monoxide is a deadly gas capable of causing death and severe injuries.

When we say 'enclosed space,' we refer to the garages, basements, spaces below staircases, and so on. The generator should be approximately 20 to 25 feet from the house. Also, ensure to point the exhaust away from residential areas. There should be about three to four feet of open space on all sides of the generator while using it. When using a generator in a clean-up operation, you should ensure to have a carbon monoxide detector as an additional safety measure.

2. Take care of your portable gensets

Most of the gensets for home are portable gensets. The very name suggests that you can shift the generator from one place to the other comfortably. Now, you have to be careful to secure the genset when you do not use it. Keep it on a level surface so that it does not accidentally slip or start rolling down the slope. Have locking arrangements on the wheels. Do not place the genset in the pathways where people can accidentally bump into it and suffer injuries.

3. Place the power cords carefully.

Many accidents occur because people trip over the generator’s power cords. Tripping over the cords can also jerk the plugs out of the socket and thereby damage the generator outlet. It is advisable to cover the wires using cable covers or install warning flags to prevent anyone from walking straight into the path of the generator.


4. Cover your generator

Moisture is the greatest enemy of your generator. Cover your generator when you do not wish to use it. Similarly, have a genset container in place to cover the generator when using it as well. You can reduce noise pollution.

Never place the generator near areas containing stagnant water. You run the risk of an electrical shock. Water seepage into the generator parts can also damage the appliance significantly. The machine can rust, and there can be short circuits as well.

5. Do not overload your generator.

Overloading your genset can lead to overheated power outlets, short circuits, blown fuses and damaged diodes. Overloading a generator can also lead to a fire. When you have an LPG or diesel generator, such accidental fires can have far-reaching ramifications.

6. Protect from shocks and electrocution.

Never attach your generator system directly to your electrical mains connection. Always use a transfer switch in between. Seek the help of a qualified electrician for installing your generator. Inspect the electrical cords for damages, cuts and abrasions. It could end up electrocuting someone accidentally. Use appropriate cables manufactured by the OEM. Never use cheap replacements available in hardware shops. Using Ground Fault Circuit Interrupters in wet conditions is necessary to prevent people from getting shocks. Ensure that your generator has proper grounding.

7. Refuelling hazards.

Never refuel your generator when the appliance is hot. It could cause fires if you accidentally spill some of the fuel on the hot engine parts. Shut down the generator and allow the machine to cool down. Use proper fuel for refuelling your generators. Transport the fuel in safe and closed containers to prevent accidents. Do not place flammable materials near the generator. Finally, ensure not to smoke cigarettes or light matchsticks near the generator. Diesel or LPG vapours might just be hanging around to cause a disaster.
We have discussed seven basic safety, and precautionary measures genset users should take to avoid unnecessary accidents. It is always better to play safe rather than be sorry. Remember, the generator is your best friend, but it does not take time to turn into your worst enemy. It depends on how you treat it.

Before Starting Engine

Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the
engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine.
Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic
shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine.
Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the
area is free of personnel. If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work correctly, if equipped.

All protective guards and all protective covers must be installed if the engine must be started in order
to perform service procedures. To help prevent an accident that is caused by parts in rotation, work
around the parts carefully.

Do not bypass the automatic shutoff circuits.
Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent
engine damage.

Interesting