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Generator Type

METCL diesel generator type

A diesel generator is a type of electrical generator that uses a diesel engine to produce electricity. It operates on the principle of converting mechanical energy generated by the combustion of diesel fuel into electrical energy.

Different generator type works best for different needs. From the diesel generator appearance, there is a portable generator, open frame generator, enclosed soundproof generator, trailer generator, and container generator, from the diesel generator output, there is single phase generator, 3 phases generator, high voltage generator, and DC diesel generator, from the cooling system, there is air cooled generator and water cooled generator.


1. What is diesel generator efficiency?
Our METCL diesel generators are designed to convert fuel (diesel) into electrical energy with minimal waste. Diesel generator efficiency refers to how effectively the generator converts fuel energy into usable electrical power.
2. How is diesel generator efficiency measured?
Diesel generator efficiency is usually expressed as a percentage and is calculated by comparing the actual electrical power output to the input fuel energy. It is essential to understand that generator efficiency varies with load conditions.
3. What is the ideal load for maximum diesel generator efficiency?
The ideal load for maximum diesel generator efficiency typically falls between 70-80% of its rated capacity. Operating the generator within this load range ensures optimal fuel consumption while maintaining performance and reliability.
4. Does the efficiency of a diesel generator vary with load?
Yes, the efficiency of a diesel generator varies with the load it is supplying. Efficiency tends to decrease when operating at light loads (below 30%) or heavy loads (beyond 80%). It is recommended to match the load to the generator’s capacity for best efficiency.
5. How does generator efficiency affect fuel consumption?
Generator efficiency directly affects fuel consumption. The higher the efficiency, the less fuel is required to produce a given amount of electrical power. Optimal efficiency translates into cost savings and reduced environmental impact.
6. Can a diesel generator operate below low load (less than 30%)or no load?
Diesel generators can operate below their rated load, but it may lead to poor Combustion, excessive wear and oil leaks of the turbocharger, pressure in the crankcase increases, hardening of the surfaces of the cylinder liners and lower efficiency of the exhaust gas treatment system

Factors Affecting Diesel Generator Fuel Consumption:
Several factors contribute to the fuel consumption of diesel generators. The most significant factors include the load, generator size, and efficiency. The load refers to the amount of power required by the connected devices or machinery. Higher loads demand more fuel consumption, while lower loads result in reduced consumption. Generator size also plays a crucial role, as larger generators tend to consume more fuel due to their higher power output capacity. Additionally, the efficiency of the generator affects fuel consumption, with newer models boasting improved efficiency ratings.
Calculating Diesel Generator Fuel Consumption:
To accurately calculate fuel consumption per hour, a simple formula can be used. The formula is as follows:
Fuel Consumption (in liters per hour) = (Power Output (in kW) x Specific Fuel Consumption (in liters per kWh)) / Generator Efficiency
For example, if a generator has a power output of 100 kW, a specific fuel consumption of 0.2 liters per kWh, and an efficiency rating of 90%, the fuel consumption per hour would be:
Fuel Consumption = (100 kW x 0.2 liters/kWh) / 0.9 = 22.22 liters/hour
Tips to Reduce Fuel Consumption:
Minimizing fuel consumption not only saves costs but also contributes to environmental sustainability. Here are some practical tips to achieve fuel efficiency:
1. Regular Maintenance: Proper maintenance, including regular oil and filter changes, ensures optimal generator performance and reduces fuel consumption.
2. Load Management: Avoid overloading the generator beyond its capacity. Distribute the load evenly or consider using multiple generators for larger power requirements.
3. Efficient Power Distribution: Utilize energy-efficient devices and equipment to reduce overall power demand, thereby decreasing fuel consumption.
4. Optimal Generator Sizing: Choose a generator size that matches your power requirements. Oversized generators consume more fuel even when operating at lower loads.

Importance of Continuous Operation:
Continuous operation of diesel generators is of utmost importance in critical sectors such as hospitals, data centers, telecom base station and manufacturing plants. These industries heavily rely on uninterrupted power supply to ensure the smooth functioning of life-saving equipment, data storage, and production processes. Even in residential settings, a prolonged power outage can lead to significant inconveniences and potential risks. Therefore, understanding the limitations and factors affecting the continuous operation of diesel generators is crucial for ensuring uninterrupted power supply.
Factors Affecting Continuous Operation:
Several factors influence the continuous operation of diesel generators. These factors include fuel capacity and consumption, maintenance requirements, and environmental conditions.
Fuel Capacity and Consumption:
The fuel capacity of a diesel generator determines how long it can run continuously. Generators with larger fuel tanks can operate for more extended periods without refueling. Additionally, the fuel consumption rate of the generator plays a significant role in determining its runtime. Generators with higher fuel efficiency can run for more extended periods on the same amount of fuel compared to less efficient models.
Maintenance Requirements:
Regular maintenance is essential for the smooth operation of diesel generators. Neglecting maintenance can lead to decreased performance and potential breakdowns. Regular oil changes, filter replacements, and inspections of critical components are necessary to ensure the generator’s optimal performance. Failure to adhere to maintenance schedules can result in reduced runtime and increased downtime due to unexpected failures.
Environmental Conditions:
The environmental conditions in which a diesel generator operates can significantly impact its continuous operation. Extreme temperatures, high humidity, and dusty environments can affect the generator’s performance and lifespan. Generators designed for specific environmental conditions, such as those with enhanced cooling systems for hot climates, are better suited for continuous operation in challenging environments.

1, Dead Start Battery or Battery Switch Fault

2, Is the Diesel Generator System Power Switch ON or Failure?

3, Is the emergency stop button at the Initial  OFF position?

4, Start Relay (Solenoid) Fault

5, Is the Intermediate Relay inside the control panel working?

6, Start Motor Fault

7, Low Coolant Level or Coolant Temp Sensor Fault.

8, Low Lube Oil Level or Lube Oil Pressure Sensor Fault.

9, Lack of diesel fuel supply

Battery, Start relay, Lack of fuel are the most common reason why a generator not starting, Get more details from METCL

I. Brief Explanation of Diesel Generators:
A diesel generator is a power supply devices that convert diesel fuel into electrical energy, These diesel generators are known for their reliability, durability, and fuel efficiency, making them a popular choice in various industries such as construction, healthcare, and telecommunications.
2. Components of a Diesel Generator:
a) Diesel Engine: The heart of a diesel generator, the engine is responsible for the combustion process that generates power. Diesel fuel is injected into the engine’s combustion chamber, where it mixes with compressed air and ignites, producing high-pressure gases.
b) Alternator: The alternator is connected to the engine and converts the mechanical energy produced by the engine into electrical energy. It consists of a rotor and a stator, which work together to generate an alternating current (AC) output.
c) Fuel System: The fuel system stores and supplies diesel fuel to the engine. It includes components such as the fuel tank, fuel pump, and fuel injectors. The fuel is injected into the combustion chamber at the right time and in the right quantity to ensure efficient combustion.
d) Cooling System: To prevent overheating, diesel generators are equipped with a cooling system. This system typically includes a radiator, coolant, and a fan. It helps maintain the optimal operating temperature of the engine, ensuring its longevity and performance.
3. Working Mechanism:
The operation of a diesel generator can be summarized in the following steps:
1. Fuel Combustion and Energy Conversion:
– The engine draws in air and compresses it, raising its temperature.
– Diesel fuel is injected into the combustion chamber at high pressure.
– The fuel mixes with the compressed air and ignites, creating a controlled explosion.
– The explosion pushes the piston down, converting the chemical energy of the fuel into mechanical energy.
2. Role of Engine, Alternator, and Other Components:
– The mechanical energy produced by the engine is transmitted to the alternator through a shaft.
– The alternator’s rotor spins within the stator, creating a rotating magnetic field.
– This magnetic field induces an electrical current in the stator windings, generating electricity.
– The electricity produced by the alternator is then available for use.

Generator Type

From The Generator Appearance

  • Portable Generator: A portable generator is a compact and mobile power generation commonly used for outdoor activities, construction sites, camping trips, emergency backup power, and other temporary power needs.
  • Open Frame Generator: Unlike An enclosed generator, which has a fully enclosed casing around the engine and other components, open frame generators typically have a skeletal frame that supports the engine, alternator, and other essential parts.
    Open frame generators may offer a range of power outputs, from small units to larger models. They are generally less expensive than enclosed generators, but they tend to be noisier due to the lack of sound insulation provided by an enclosure.
  • Enclosed Generator: An enclosed generator, also known as a soundproof or outdoor generator, is a type of diesel generator that features a fully enclosed casing around its engine and other internal components. Unlike open-frame generators, which have an exposed frame structure, an enclosed generator provides a housing that encloses the engine, alternator, fuel tank, and other critical parts.
  • Trailer Generator: A trailer generator is a type of diesel generator that is mounted on a trailer for ease of transportation and mobility. It combines the power generation capabilities of a diesel generator with the convenience of being towed behind a vehicle. The trailer generator is commonly used in applications where temporary or mobile power is required, such as construction sites, outdoor events, emergency response situations, and remote locations.
  • Container Generator: A container generator refers to a diesel generator that is housed within a standard 20ft or 40ft shipping container. This setup combines the power generation capabilities of a diesel generator with the portability, protection, and ease of transportation provided by a shipping container.

From The Generator Output

  • Single-Phase Generator: A single-phase generator is suitable for a wide range of applications, including providing backup power for homes, small businesses, farms, construction sites, mobile food trucks, events, and recreational vehicles (RVs). It is also used in remote areas where three-phase power is not available or practical.
  • 3 Phase Generator
  • High Voltage Generator
  • DC Diesel Generator: A DC diesel generator produces direct current (DC) electricity, like DC48V. The DC diesel generator is commonly used in various applications where direct current power is required including telecommunications infrastructure, remote monitoring stations, off-grid power systems (such as solar and wind installations with battery storage), emergency backup power for critical equipment, and specialized industrial processes.

From The Cooling System

  • Air-Cooled Generator: An air-cooled generator is a type of diesel generator powered by a diesel engine and equipped with an air-cooling system to regulate the engine’s temperature during operation. Unlike a water-cooled diesel generator, which uses a liquid coolant (usually water and antifreeze) circulated through the engine to dissipate heat, an air-cooled generator relies on airflow to cool the engine.
  • Water Cooled Generator
  • Sea-water Exchanger Generator: A sea-water exchanger generator is a type of diesel generator equipped with a heat exchanger system that utilizes seawater for cooling purposes. This setup is commonly used in marine applications where access to fresh water for cooling is limited or impractical, such as onboard ships, offshore platforms, coastal facilities, and other maritime installations where reliable power generation is essential.