Diesel generator sets, according to the usage can be divided into two kinds: one is the main electricity supply, generator backup power equipment; other is the main generator for power supply. Generators used in both cases the length of time varied widely, the general maintenance of the internal combustion engine to power the cumulative number of hours to set, the first power supply test machine only a few hours a month, such as cumulative to the B, C group technical maintenance hours and then the technical maintenance, the time will be very long, it should be flexibility depending on the circumstances, timely technical maintenance, the machine can be promptly eliminate the adverse situation, to ensure long-term unit in good condition, and extended machine life. So make the diesel engine is working and reliable, the engine must perform technical maintenance system, technical maintenance is divided into categories:
A-level maintenance checks (daily or weekly)
B-level maintenance check (250 hours or 4 months)
C-level maintenance checks (every 1,500 hours or 1 year)
In the repair and maintenance checks (every 6000 hours or 1.5 years)
Overhaul maintenance checks (each more than 10,000 hours)
The following are the five levels of technical maintenance of the content.
First, Class A diesel generator maintenance inspection
If the operator to make use of the generator to obtain the most satisfactory results, the engine must maintain the best mechanical condition and maintenance department at the operator needs to be run daily reports, to arrange a time to make the necessary adjustments, and according to a report on the tips of require more maintenance scheduled project work, compare and correct interpretation of the engine to run reports daily, and then take practical measures to eliminate the vast majority of failures, without the need for emergency repairs.
1, before starting, check engine oil level, there are two marks on the dipstick, the high water mark "H" and low mark "L";
2, with the generator on the oil gauge check the oil surface, in order to get accurate readings, the oil should be shut down 15 minutes flat inspection, oil dipstick should maintain the original oil pan and matching flat close as possible to keep oil high "H" mark , pay attention to when the plane below the low oil labeled "L" or above the high water mark "H", Never operate the engine;
3, should increase with the engine cooling liquid surface, fill the cooling system to maintain the work surface, filling the fuel every day or every time to check the coolant surface, check the coolant consumption reasons, check the coolant in the cooling plane only after the ;
4, check the belt is loose, if the belt slipping phenomenon should be adjusted;
5, following normal boot, and check the following:
Lubricating oil;
Power is adequate;
Cooling water and oil temperature is normal;
The engine sound is normal;
Unit emission conditions;
Cooling liquid fuel or lubricating oil consumption;
Fuel, coolant or oil leaks.
Second, the Class B diesel generator maintenance inspection
In each "B" level maintenance checks, to complete all of the "A" level examination programs, plus the following replacement of engine oil, the main project and the results of the analysis of the limits listed below:
(A), "B" level examination in a oil change:
Starting the engine so as to reach operating temperature, stop the engine, remove from the oil pan at the bottom of the drain plug, release the oil;
Replace the oil drain plug on the oil pan, drain plug torque is 50 to 60 foot pounds (70 to 80 Nm);
Filling the crankcase oil to the oil dipstick on the "H" high mark;
Starting the engine, visual inspection with or without leakage;
Stop the engine, wait for 15 minutes in standby oil flow back to the sump after the re-check the oil dipstick with a plane, for giving added. Use of lubricants should meet the specifications, and should be fitted with the original filter.
(B), oil replacement cycle:
Oil replacement cycle is determined according to the unit's instructions;
Provides cycle for 250 hours or 4 months (whichever occurs first);
Determine oil change intervals based on the following variable factors:
1> per hour fuel consumption;
2> per hour oil consumption;
3> oil filter system.
Generator to run 400-500 hours per year and a half or replacement style, run 250 hours per year, replacing diesel or grid, oil grid, water grid.
(C), C-class diesel generator maintenance check;
Executive Class B technical maintenance content;
Thorough cleaning of fuel, including fuel tank, filter, pipeline, diesel pumps, injectors;
Thorough examination of cleaning the lubrication system, including crankcase, oil pipe, oil filter, oil pump, oil cooler, etc., and replace the oil, paying particular attention to the oil cooler, pipes are corroded or damaged;
Check the generator, motor commutator is imbalance, and fouling with sandpaper to polish, check the brush spring;
Check valve timing system and the STC valve, if necessary, be adjusted;
Cleaning the cooling system, harsh cleaning solution is satisfied by the 150 grams, plus six liters of water composition, water cooling system before the first cleaning all exhausted, and then poured the same amount of cleaning solution, so as not to precipitate suspended solution, and then clean the cooling water system;
Total of 1500 hours each, the generator and the motor apart, clean all parts on the old bearings, new ones such as butter, and check the starter gear drive;
General view of the mechanical generator, and make the necessary amendments and adjustments.
Fourth, the diesel generator in the repair and maintenance checks
1, the implementation of C-level technical maintenance content;
2, check the cylinder head assembly: Remove the cylinder cover and check the cylinder head, valves, valve seats, valve guides, valve springs, rocker arm with the wear and, when necessary, grinding or replacement;
3, the dissolution of the piston, connecting rod, the washing, piston, cylinder liner wear, replace if necessary;
4, check the connecting rod, connecting rod bearings, valve bodies, regulators and other parts and, if loose or damaged, should be maintenance;
5, open the cover, check the cylinder from the cylinder seal the bottom of the water like the apron;
6, open the front cover, check the transmission cover on the fuel injector is blocked, such as congestion, it should be smooth;
7, check the crankshaft assembly, thrust bearing, thrust plate wear, rolling bearing inner and outer rings have the main swimming phenomenon, if necessary, replaced;
8, check the transmission, remove the front cover, observe the gears meshing surface wear and the backlash of the measurement, if necessary, repair or replacement;
9, check the fuel injector, check the dedicated injector fuel injection test stand, if necessary, the injector and other components for grinding or replacement;
10, check the fuel pump, check the plunger seals and other components of the rust off of wear, replace if necessary;
11, check the oil pump, cooling water pump, turbocharger, on the vulnerable parts were opened and measurement, and adjustment;
12, check the charger and start the motor, clean the components, bearings dry lubricant filling the new post, check the starter gear wear and gear is flexible;
13, clean waterways of sediment, dirt scale;
14, the installation must be replaced piston rings, connecting rod, the upper part of repair kit, lower part of the repair kits.
Note: Intermediate maintenance, the unit should run about 6000 hours a year and a half or your professional maintenance staff, depending on the generator's actual circumstances.
Fifth, diesel generator overhaul maintenance checks
Overhaul to be about 10,000 hours of work and according to actual usage to determine, and some units due to improper use or long-term heavy work, may not reach the required hours of work can not continue to work, and the need for major repairs, the general should be based on the following aspects determine:
1 engine working, weakness, decreased speed rear axle load, sound mutations, exhaust black smoke;
(2) internal combustion engine difficult to start at room temperature, the process of running crank bearings, connecting rod bearing and piston pin with percussion;
3 internal combustion engine when the cylinder pressure during normal working pressure less than the required 70%;
4 oil pressure is lower than 30Psi;
5 internal combustion engine fuel oil consumption increased significantly;
6 cylinder ovality, the gap between the piston and the cylinder; crankshaft and connecting rod journal of the ellipse, exceeding the prescribed limits;
7 generator crankshaft bending, loss of round commutator exciter serious cracks commutator sparks brush, commutator ablation, in addition to, such as generator panels and low level of magnetic field coil insulation, the moisture insulation resistance of the coil after drying less than normal, etc.;
8. Overhaul and maintenance with a professional service personnel in repair and maintenance content, the body of the crankshaft, connecting rod, piston, camshaft and other components to check, depending on the technical parameters of the maintenance or updating of the crankshaft W, connecting rod, cylinder liner , piston rings, overhaul package must be replaced.
Related Reading
http://nmnegdlg.blogspot.com/2011/06/ac-fixed-mobile-diesel-generator-set.html
