Diesel generator set maintenance manual

Proper maintenance is a necessary guarantee for ensuring long-term fault free operation of diesel generator sets and achieving normal power supply. Therefore, all users should follow the following steps and contents to perform normal maintenance on the unit. The maintenance content of different models of units may vary slightly. The content of this chapter is for reference only, and detailed information must refer to the random data of the engine and generator.

Unit maintenance plan

Attention: The standby unit should be started and inspected at least 2-3 times a month, with a score of 20 points or more each time; It is also recommended to operate with a load of over 30%.

☆Maintenance steps

☆1. Maintenance before each startup

I. Cleaning the surface of the unit

II. Check the cooling liquid level of the water tank; The liquid level should be as close as possible to 5cm below the welding surface of the filler cap, and it is recommended not to exceed it.

III. Check the exterior of the radiator core and intercooler in the water tank, and no foreign objects are allowed to block them.

IV. Check the blockage of the air filter; If the blockage indicator is in the red zone, the filter should be replaced immediately after the unit is shut down. The replaced air filter is not allowed to be reused.

V. Check the lubricating oil level of the diesel engine to ensure that the oil level is between the maximum and minimum values on the dipstick scale.

VI. Check if the electrical connections of the control system are loose

☆2. Maintenance after each run

I. Focus on checking and tightening the bolts of each rotating component, especially the connecting bolts of the fuel injection pump, water pump, pulley, fan, etc., and tighten the anchor bolts at the same time.

II. Check for any three leaks and clean if necessary

III. Eliminate simple faults and abnormal phenomena found during operation

IV. Clean the dust on the air filter element

V. Check the oil level and the oil level of the fuel injection pump, and if necessary, add oil of quality that meets the technical requirements.

VI. Check the cooling water level in the water tank and add soft and pure water if necessary.

VII. Check if the electrical connections of the control system are loose

VIII. Cleaning the surface of the unit

☆3.Maintenance every 50 hours

In addition to completing the above maintenance items, the following additional tasks should be added:

I. Check the battery; Measure the battery voltage and fully charge it if necessary. When handling batteries, please wear protective goggles as they contain explosive gases and corrosive sulfuric acid. Igniting near the battery may cause an explosion.

II. Check for any three fluid leaks

III. Check if the three filter system is in good condition and replace it if necessary

IV. Check and adjust the tightness of the fan belt

V. If necessary, add or replace the cooling water in the water tank and the machine body

VI. Check whether the wiring terminals of the generator and electronic control parts are secure

VII. Units with oil-water separators should be regularly drained, cleaned, or replaced with filter elements every 50 hours of use.

VIII. After the initial operation of the new unit for 50 hours, all engine oil and oil filter elements should be replaced.

☆4.Maintenance every 250 hours

I. Change the engine oil and drain the oil when heating up the engine. The normal replacement time for engine oil and oil filter is every 250 hours, and the replacement cycle for engine oil and oil filter is 100 hours when used under harsh conditions. Pay attention to safety when replacing, as hot oil can cause burns.

II. Replace the oil filter and bypass filter; Use special tools to remove the filter. Make sure to fill the new filter with engine oil to drain the air, then screw it on by hand. After touching the gasket, tighten it another 1/2 turn. Start the unit and check for any oil leakage.

III. Replace the diesel filter; Use special tools to remove the diesel filter. Lubricate the gasket and screw in a new filter filled with clean diesel by hand. After touching the gasket, tighten it by half a turn. Note that no dust should enter the fuel system. And it can only be replaced after the unit has completely cooled down to avoid ignition caused by diesel splashing onto the exhaust pipe.

IV. The replacement time of diesel filter element is every 300 hours

☆5.Maintenance every 400 hours

I. Check all water pump overflow ports.

II. The replacement time of the air filter is every 400 hours. The replacement of the air filter should be carried out according to the air filter indicator. If the air filter indicator enters the red area, the air filter needs to be replaced.

☆6. Maintenance every 800 hours

Ⅰ.If possible, please remove the accumulated sludge in the fuel oil faucet;

Ⅱ.Check if the oil pipes entering and exiting the turbocharger are leaking;

Ⅲ.Check if there is any air leakage at the air valve and its interface;

Ⅳ.Check if all air valves are damaged, replace them if necessary, and tighten all fixing screws again after replacement;

Ⅴ.Clean the fuel tank and pipelines;

Ⅵ.Clean the oil pan and oil filter;

Ⅶ.Check and tighten the connecting rod bolts, main bearing bolts, and cylinder head bolts;

Ⅷ.Check the specific gravity of the battery electrolyte and supplement it if necessary;

IX. Check and calibrate instruments;

X. Check and adjust the excitation circuit.

☆7.Maintenance every 1200 hours

Ⅰ.Complete all tasks for inspection every 800 hours;

Ⅱ.Check the valve clearance. And it is required to be carried out by qualified engineering and technical personnel who have received professional training. Stop the machine during inspection.

☆8.Maintenance every 6 months

Ⅰ.Replace the coolant filter. Turn off the cooling faucet, use a special tool to remove the filter, and reinstall a new one. Finally, turn on the faucet.

☆9.Maintenance every 12 months

Ⅰ.Complete all inspection work every 6 months

Ⅱ.If the unit is equipped with an air compressor, please replace the air filter on the air compressor; The method is to open the valve fastening device, remove the filter and destroy it, install a new filter and tighten the fastening screw.

III. Clean the cooling system/replace the coolant (only applicable to units without coolant filters);

IV. Check for leaks.

☆10.Maintenance every 24 months

I. Clean the cooling system/replace the coolant; (Only applicable to units with coolant filters)

II. Check for leaks. Low coolant level, malfunctioning thermostatic valves, malfunctioning exhaust fans, or blockages in intercoolers/radiators or other parts of the cooling system can all cause high coolant temperatures.