How to maintain diesel generators?

Diesel generator is a backup equipment to provide electric energy after power failure. Daily maintenance can improve the service life of generator. Diesel generator maintenance is divided into weekly maintenance work, monthly maintenance work and annual maintenance work.

Here we learn to understand the specific procedures for diesel generators maintenance and maintenance.

I. Weekly maintenance

1. Check the oil level. Keep the oil level between the upper and lower scales of the dipstick. Add the same type of oil if necessary.

2. Check diesel oil quantity, oil tank slag discharge, water discharge, leak detection. The diesel oil added needs to be precipitated for 24 hours.

3. Check the coolant level, the level should be maintained at about 5 cm below the tank cover neck, must add distilled water.

4. Check coolant heater for operation (check in winter).

5. Check the air filter indicator. If the red mark appears, replace the filter element or filter.

6. Check the battery charging voltage (only for automatic units), the normal charging voltage of 12 V battery is about 14 V, and the normal charging voltage of 24 V battery is about 27 V.

7. Clean the unit.

II. Monthly maintenance

The generator set shall operate with load for at least 30 minutes per month. The startup steps and inspection items are as follows:

Before generator set startup

1. Check weekly work items and add the following items.

2. Check the surrounding environment of the unit, keep sufficient light, air circulation and cleanliness in the oil room, do not stack sundries, and adopt noise reduction measures according to environmental protection requirements to avoid affecting the normal operation of the unit.

3. Check whether the intake and exhaust passages and exhaust pipes of the unit are blocked.

4. Ring machine inspection: check whether there is waste stuck in the radiator or engine, or whether there are loose or loose bolts, shields, tightening repair if necessary.

5. Check fan belts for looseness and wear, adjust or replace if necessary.

6. Check all instruments. The instruments shall be complete and in good condition with accurate indication. If any damage is found, please replace or repair them.

7. Check whether the wiring of generator and control panel is loose.

8. Whether cooling water, lubricating oil and diesel oil reach the specified level.

9. Check whether the generator set has leakage, oil leakage, air leakage, leakage phenomenon.

After generator set startup

1. The unit shall operate stably and normally.

2. Check the oil pressure gauge: normal working pressure is generally between 3~6.5Bar, small unit oil pressure value is generally slightly lower, large unit oil pressure value is generally slightly higher. According to the seasonal conditions of different regions, select lubricants with different viscosities.

3. Check the water temperature gauge: the water temperature depends on the ambient temperature and load size, generally should be maintained between 70~90 degrees.

4. Check charging voltmeter: charging voltage is generally 2 - 3v higher than battery voltage.

5. Check AC frequency.

6. Check AC voltage.

7. Check AC current.

8. Check the noise and leakage of the unit around the machine, and stop the machine for maintenance if necessary.

9. Check cylinder operation, cooling water circulation and exhaust color are normal, if necessary, stop inspection.

diesel generator set shutdown

Unit shutdown includes normal shutdown and emergency shutdown:

1. Normal shutdown: first cut off the load, no-load operation for 5 minutes, and then shut down.

2. Emergency shutdown: shut down immediately in case of danger and fault in unit operation.

Emergency shutdown shall be performed when:

(1) Failure of vehicle.

(2) Oil circuit blockage or high water temperature (100 degrees Celsius)

(3) abnormal noise, loose flywheel or transmission mechanism failure.

(4) The oil pressure gauge pointer drops suddenly.

After generator shutdown

1. Check that the automatic switch (for automatic units only) is in the desired position.

2. Check the fuel tank and fill it up if necessary.

3. Check fault display and repair if necessary.

4. Lubricate the parts outside the self-circulation system.

5. Keep records of operation and clean the engine room and equipment.

6. Be prepared for the next boot.

3. Annual work (to be handled by experienced technicians)

1. Check weekly work items and add the following items.

2. Replace fuel filter, drain fuel tank.

3. Crankcase breather cleaning.

4. Check valve lash and adjust if necessary.

5. Check and test engine protection system.

6. Check whether the electric ball is damp, clean the dust and sundries inside, check and record the insulation degree of each winding with a shake meter, and fill grease into the bearing.

7. Load test shall be carried out, at least 30% load shall be operated for 2 hours, and each data shall be recorded.

Change oil and oil filter after load test.