As an emergency backup power source, diesel generator sets are in standby state most of the time. Once the city power supply is cut off, the diesel generator sets are required to “respond to emergencies and provide emergency power”. Otherwise, the standby units will lose their value. How can we ensure that the diesel generator sets can function normally when needed? Practice has proved that strengthening the daily maintenance of diesel generator sets: regular inspections, replacement of accessories, and inspection of lines are the most economical and effective methods. Because the diesel generator set is in a static state for a long time, the unit itself will undergo complex chemical and physical changes with the engine oil, cooling water, diesel, air, etc., which will “stop the unit”.
Main maintenance contents of diesel generator sets
1. Daily maintenance of batteries
failure of the starting battery of the unit. The battery has not been maintained for a long time, the electrolyte water volatilizes and cannot be replenished in time, there is no starting battery charger, the battery power decreases after a long time of natural discharge, or the charger used needs to be manually charged and floated regularly. Due to negligence, the battery power does not meet the requirements. In addition to configuring high-quality chargers, necessary inspection and maintenance are necessary to solve this problem.
2. The cooling water tank should be replenished in time
due to the condensation of water vapor in the air due to temperature changes, water droplets are formed and attached to the inner wall of the fuel tank, flowing into the diesel, causing the water content of the diesel to exceed the standard. Such diesel enters the engine high-pressure oil pump, which will rust the precision coupling parts—the plunger, and seriously damage the unit. Regular maintenance is effective and can be avoided.
3. Regularly change the engine oil
The engine oil is a mechanical lubrication, and the engine oil also has a certain shelf life. Long-term storage will change the physical and chemical properties of the engine oil, causing the lubrication condition of the unit to deteriorate during operation, which is easy to cause damage to the unit parts, so the lubricating oil should be replaced regularly.
4. Replacement of three filters (diesel filter, engine filter, air filter, water filter)
Three filters (diesel filter, engine filter, air filter, water filter) filter diesel, engine oil or water to prevent impurities from entering the body, and oil and impurities are inevitable in diesel, so the filter plays an important role in the operation of the unit, but at the same time these oil or impurities are deposited on the filter wall and reduce the filter’s filtering capacity. Too much deposition will make the oil circuit unobstructed, so the oil engine will be shocked due to lack of oil supply when running under load (just like a person lacking oxygen), so during the use of normal generator sets, we recommend: First, the commonly used machine The first is to replace the three filters every 500 hours for the first unit; the second is to replace the three filters every two years for the standby unit;
5. The cooling system should be cleaned regularly
The cooling system water pump, water tank and water pipe have not been cleaned for a long time, which makes the water circulation unsmooth and the cooling effect decreases. Check whether the water pipe joints are in good condition, whether the water tank and water channel are leaking, etc. If the cooling system fails, the consequences are: first, the cooling effect is not good and the water temperature in the unit is too high and shuts down; second, the water tank leaks and the water level in the water tank drops, and the unit will not work normally (to prevent the water pipe from freezing when using the generator in winter, we recommend that it is best to install a water heater in the cooling system).
6. Add lubricating oil
Due to the chemical properties of lubricating oil or ester and the iron filings generated after mechanical wear, these not only reduce its lubrication effect, but also accelerate the damage of parts. At the same time, because the lubricating oil has a certain corrosive effect on the rubber sealing ring, the oil seal itself also ages at any time, which reduces its sealing effect.
7. Clean the deposits regularly
Fuel and valve system The output of engine power is mainly fuel combustion in the cylinder and fuel is sprayed out through the fuel injector, which makes the carbon deposits after combustion deposited on the fuel injector. As the amount of deposits increases, the amount of fuel injected by the fuel injector will be affected to a certain extent, resulting in inaccurate ignition advance angle of the fuel injector, uneven fuel injection amount of each cylinder of the engine, and unstable working state. Therefore, the fuel system should be cleaned regularly, the filter components should be replaced to ensure smooth fuel supply, and the valve system should be adjusted to ensure uniform ignition.
8. Check whether the AVR module is working properly
The control part of the unit The control part of the oil engine is also an important part of the maintenance of the unit. The unit has been used for too long, the line joints are loose, and the AVR module is working properly.
Ten rules for maintenance and repair of generator sets
The generator is subject to “level three maintenance” every half month, which lasts for 4 hours, with a trial run of 15 minutes, and the relevant parameters of the generator during operation are recorded; annual maintenance is reported to the superior company for approval; inspections are carried out according to regulations, and the smoke exhaust system is unobstructed, the ventilation system, exhaust and supply fans are in good condition, the air volume is unobstructed, the machine room lighting is in good condition, and the emergency lights are in good condition; the battery level is checked at the specified time. If the level is insufficient, add electrolyte, measure the specific gravity and charge in time, and make records; at the specified time, remove the air, engine oil, diesel, and filter, clean them with gasoline, remove dust, check the turbidity of the engine oil, and replace it if it is deteriorated; replace the cooling water in the water tank at the specified time, and measure the insulation resistance of the generator; clean the floor and walls of the machine room at the specified time to ensure that the unit is free of oil stains and leakage; in the event of typhoons, fires, heavy rains, and earthquakes, implement corresponding emergency measures; all repair and maintenance records are complete and archived; equipped with professional technicians for operation, operation, and maintenance.
1.Daily and weekly maintenance of generator sets
Daily maintenance:
1) Check the work report of the previous day;
2) Check whether the engine oil, cooling water and diesel have leakage;
3) Check the liquid level of engine oil, cooling water and diesel;
4) Check the water heater;
5) Select the switch position of the automatic switching switch;
6) Measure the battery voltage value and the working condition of the battery charger;
7) Fill in the work report of the day;
2. Inspection work before starting
1)Check whether there are any debris in the machine room, especially near the engine fan;
2) Check the oil level, diesel level, and cooling water level;
3) Check whether there are any debris in the air inlet and outlet ducts, and whether the ventilation conditions are good;
4) Check the tightness of the battery connection cable connector;
5) The closing and opening direction of the circuit breaker;
6) Check the opening and closing status of the diesel fuel supply pipeline valve;
7) Check the generator set work report.
Weekly maintenance:
1) Repeat the daily A-level inspection.
2) Check the air filter, clean or replace the air filter element.
3) Drain the water or sediment in the fuel tank and fuel filter.
4) Check the water filter.
5) Check the starting battery.
6) Start the generator and check for any impact.
7) Clean the cooling fins at the front and rear ends of the cooler.
3. Check items after starting up
1. Check items when no-load:
1) Check if the sound and vibration are normal;
2) Oil pressure;
3) Only switch on the switch to supply power after the voltage and frequency are normal.
4. Check items before shutdown
1) Are all loads disconnected from the generator set and transferred to the mains?
2) The generator set can only be shut down after running at no load for 5 minutes in winter and 10 minutes in summer.
5. Others
1. Cooling water
1) The first water addition is carried out in 2-3 steps. After the first filling, wait for 10-20 minutes and then add again to confirm that the water level has not dropped after 10-20 minutes;
2) The amount of water added is 20-30mm from the top of the water tank;
3) The water is soft water, and preservatives and antiscalants are added according to the requirements of Perkins, and antifreeze is added according to environmental requirements.
4) Ensure the cleanliness of the outside of the water tank.
2. Diesel
1) 0/-10# diesel, pay attention to the sediment at the bottom of the tank, and remove it in time, and pay attention to the storage time of diesel in the tank;
2) The source of diesel.
3. Battery
1) Normal battery voltage: 12.5-12.8VDC for single battery, 25.0-25.6VDC for dual battery. The measurement must be done 30 minutes after the charger is turned off;
2) Battery charging voltage: 13.0-13.5VDC for single battery, 26.0-27.0VDC for dual battery, and must not exceed 14.0/28.0VDC;
3) The general battery life is 1-2 years;
4) It is forbidden to use a constant current charger.
4. Engine oil
Qualified products should be replaced when expired.
Doing the above can ensure the normal use of the generator set/engine in winter and extend its service life.
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