Operation, Maintenance and Maintenance of Diesel Generator Sets
Class A maintenance (daily maintenance)
1) Check the daily working day of the generator;
2) Check fuel and coolant level of generator;
3) Daily inspection of generator for damage and leakage, looseness or wear of belt;
4) Check the air filter, clean the air filter core and replace it if necessary;
5) Drain water or sediment from fuel tank and fuel filter;
6) Check the water filter;
7) Check starting battery and battery liquid, add supplementary liquid if necessary;
8) Start the generator and check for abnormal noise;
9) Clean the dust of water tank, cooler and radiator net with air gun.
Class B maintenance
1) Repeat daily A level inspection;
2) Change the diesel filter every 100 to 250 hours;
All diesel filters are not washable and can only be replaced. 100 to 250 hours is only an elastic time and must be replaced according to the actual cleanliness of the diesel fuel;
3) Change the generator fuel and fuel filter every 200 to 250 hours;
fuel must conform to API CF grade or higher in USA;
4) Replace the air filter (the set operates 300-400 hours);
Attention should be paid to the engine room environment and the time for replacing the air filter, which can be cleaned with an air gun.
5) Replace water filter and add DCA concentration;
6) Clean the strainer of crankcase breathing valve.
Class C maintenance set runs for 2000-3000 hours. Please do the following:
▶ Repeat Class A and B maintenance
1) Remove valve cover and clean fuel and sludge;
2) Tighten each screw (including running part and fixing part);
3) Clean crankcase, fuel sludge, scrap iron and sediment with engine cleaner.
4) Check the wear of turbocharger and clean carbon deposit, and adjust if necessary;
5) Check and adjust valve clearance;
6) Check the operation of PT pump and injector, adjust the stroke of injector and adjust it if necessary;
7) Check and adjust the looseness of fan belt and water pump belt, and adjust or replace them if necessary: clean the radiator net of water tank and check the performance of thermostat.
▶ Minor repair (i.e. Class D maintenance) (3000-4000 hours)
L) Check the wear of valves, valve seats, etc. and repair or replace them if necessary;
2) Check the working condition of PT pump and injector, repair and adjust if necessary;
3) Check and adjust the torque of connecting rod and fastening screw;
4) Check and adjust valve clearance;
5) Adjust the fuel injector stroke;
6) Check and adjust the tension of fan charger belt;
7) Clean the carbon deposits in the intake branch pipe;
8) Clean the intercooler core;
9) Clean the whole fuel lubrication system;
10) Clean the sludge and metal scraps in the rocker arm room and fuel pan.
Intermediate repair (6000-8000 hours)
(1) Including minor repair items;
(2) Disassemble engine (except crankshaft);
(3) Check the fragile parts of cylinder liner, piston, piston ring, intake and exhaust valves, crank and connecting rod mechanism, valve distribution mechanism, lubrication system and cooling system, and replace them if necessary;
(4) Check fuel supply system and adjust fuel pump nozzle;
(5) Ball repair test of generator, clean fuel deposits and lubricate ball bearings.
Overhaul (9000-15000 hours)
(1) including medium repair items;
(2) Dismantle all engines;
(3) Replace cylinder block, piston, piston ring, large and small bearing shells, crankshaft thrust pad, intake and exhaust valves, complete engine overhaul kit;
(4) Adjust fuel pump, injector, replace pump core and fuel injector;
(5) Replace the supercharger overhaul kit and the water pump repair kit;
(6) Correct connecting rod, crankshaft, body and other components, repair or replace if necessary
Post time: Jan-10-2020
