Abstract: Daily maintenance of diesel generators requires attention to removing carbon and gum deposits from the fuel injection nozzle and combustion chamber of the booster pump, in order to restore power performance; Eliminate faults such as engine chattering, unstable idling, and poor acceleration; Restore the optimal atomization state of the fuel injector, improve combustion, save fuel, and reduce harmful gas emissions; Lubrication and protection of fuel system components to extend service life. In this article, the company mainly introduces the following precautions in maintenance and upkeep.
1、 Maintenance cycle
1. The maintenance cycle for the air filter of diesel generator sets is once every 500 hours of operation.
2. The charging and discharging efficiency of the battery is tested every two years, and it should be replaced after poor storage.
3. The maintenance cycle for the belt is once every 100 hours of operation.
4. The coolant of the radiator is tested every 200 hours of operation. Cooling fluid is an essential heat dissipation medium for the normal operation of diesel generator sets. Firstly, it provides anti freezing protection for the water tank of the generator set, preventing it from freezing, expanding, and exploding in winter; The second is to cool down the engine. When the engine is running, using antifreeze as a circulating cooling liquid has a significant effect. However, long-term use of antifreeze can easily come into contact with air and cause oxidation, affecting its antifreeze performance.
5. The engine oil has a mechanical lubrication function, and the oil also has a certain retention period. If stored for a long time, the physical and chemical properties of the oil will change, causing the lubrication condition of the generator set to deteriorate during operation, which is easy to cause damage to the generator set parts. Repair and maintain the engine oil every 200 hours of operation.
6. The maintenance and upkeep of the charging generator and starter motor should be carried out every 600 hours of operation.
7. The maintenance and upkeep of the generator set control screen is carried out every six months. Clean the dust inside with compressed air, tighten each terminal, and handle and tighten any rusted or overheated terminals
8. Filters refer to diesel filters, machine filters, air filters, and water filters, which filter diesel, engine oil, or water to prevent impurities from entering the engine body. Oil and impurities are also inevitable in diesel, so filters play an important role in the operation of generator sets. However, at the same time, these oil and impurities are also deposited on the filter wall, reducing the filtering ability of the filter. If they deposit too much, the oil circuit will not be smooth, When the oil engine is running under load, it will experience shock due to the inability to supply oil (such as oxygen deficiency). Therefore, during the normal use of the generator set, we recommend that the three filters be replaced every 500 hours for commonly used generator sets; The backup generator set replaces the three filters annually.
2、 Routine inspection
1. Daily check
During daily inspections, it is necessary to check the exterior of the generator set and whether there is any leakage or liquid leakage in the battery. Check and record the voltage value of the generator set battery and the temperature of the cylinder liner water. In addition, it is necessary to check whether the heater for the cylinder liner water, the charger for the battery, and the dehumidification heater are operating normally.
(1) Generator set start-up battery
The battery has been left unattended for a long time, and the electrolyte moisture cannot be replenished in a timely manner after volatilization. There is no configuration to start the battery charger, and the battery power decreases after natural discharge for a long time. Alternatively, the charger used needs to be manually switched between balanced and floating charging. Due to negligence in not switching, the battery power cannot meet the requirements. In addition to configuring a high-quality charger, necessary inspection and maintenance are necessary to solve this problem.
(2) Waterproof and moisture proof
Due to the condensation phenomenon of water vapor in the air due to temperature changes, it forms water droplets and hangs on the inner wall of the fuel tank, flowing into diesel, causing the water content of diesel to exceed the standard. Such diesel entering the high-pressure oil pump of the engine will rust the precision coupling plunger and seriously damage the generator set. Regular maintenance can effectively avoid this.
(3) Lubrication system and seals
Due to the chemical properties of lubricating oil and the iron filings generated after mechanical wear, these not only reduce its lubrication effect, but also accelerate the damage to parts. At the same time, lubricating oil has a certain corrosive effect on rubber sealing rings, and the oil seal itself also ages at any time, resulting in a decrease in its sealing effect.
(4) Fuel and gas distribution system
The main output of engine power is the combustion of fuel in the cylinder to do work, and the fuel is sprayed out through the fuel injector, which causes the carbon deposits after combustion to deposit on the fuel injector. As the deposition amount increases, the injection amount of the fuel injector will be affected to a certain extent, resulting in inaccurate ignition timing of the fuel injector, uneven fuel injection in each cylinder of the engine, and unstable working conditions. Therefore, regular cleaning of the fuel system and replacement of filtering components will ensure smooth fuel supply, Adjust the gas distribution system to ensure even ignition.
(5) The control part of the unit
The control part of the diesel generator is also an important part of the maintenance of the generator set. If the generator set is used too long, the line joints are loose, and the AVR module is working properly.
2. Monthly inspection
Monthly inspections require switching between the generator set and the mains power supply, as well as conducting in-depth inspections during the start-up and load testing of the generator set.
3. Quarterly inspection
During quarterly inspections, the generator set needs to be at a load of over 70% to operate for one hour in order to burn out the mixture of diesel and engine oil in the cylinder.
4. Annual inspection
Annual inspection is an important part of the maintenance cycle for standby diesel generator sets, which requires not only quarterly and monthly inspections, but also more maintenance projects.
3、 Main contents of maintenance inspection
1. During the operation of the generator set, an hourly inspection is conducted, and the electrician is responsible for recording data such as diesel engine temperature, voltage, water level, diesel level, lubricating oil level, ventilation and heat dissipation system, etc. to ensure they are functioning properly. If there is any abnormal situation, it is necessary to notify all electrical equipment to shut down before following the emergency procedure to stop the operation of the generator set. It is strictly prohibited to directly stop the operation of the generator set without notifying the electrical equipment to stop in non emergency situations.
2. When in standby mode, start idling for at least 1 hour per week. Electricians shall keep operation records.
3. It is prohibited to work on the outgoing line of the running generator, touch the rotor with hands, or clean it. The generator in operation shall not be covered with canvas or other materials.
4. Check the voltage of the battery, check if the electrolyte level of the battery is normal, and if there are any loose or corroded connections at the battery. Simulate the performance of various safety protection devices and operate them under normal load to check their operation. It is best to charge the battery every two weeks.
5. After the overhaul of the diesel generator set, it must be run in. The total time for running in empty and partially loaded vehicles shall not be less than 60 hours.
6. Check if the fuel level in the diesel tank is sufficient (the fuel should be sufficient for 11 hours of transportation).
7. Check for fuel leaks and regularly replace the diesel filter.
When the fuel in the fuel injection system and cylinders of a diesel engine is unclean, it can cause abnormal wear and tear on the engine, resulting in a decrease in engine power, an increase in fuel consumption, and a significant reduction in engine service life. Diesel filters can filter out impurities such as metal particles, gum, asphalt, and water in the fuel, providing clean fuel for the engine, extending its lifespan, and enhancing its fuel efficiency.
8. Check the tension of the fan belt and charger belt, whether they are loose, and adjust them if necessary.
9. Check the oil level of the diesel engine. Never operate the diesel engine when the oil level is below the low mark “L” or above the marked “H”.
10. Check for oil leakage, check if the oil and oil filter meet the requirements, and replace the oil filter regularly.
11. Start the diesel engine and visually inspect for any oil leakage. Check whether the readings, temperature, and loudness of each instrument during the operation of the diesel engine are normal, and keep monthly operation records.
12. Check if the cooling water is sufficient and if there are any leaks. If it is not enough, the cooling water should be replaced, and the pH value should be measured before and after replacement (normal value is 7.5-9), and measurement records should be kept. If necessary, rust inhibitor DCA4 should be added for treatment.
13. Check the air filter, clean and inspect it once a year, and check if the intake and exhaust ducts are unobstructed.
14. Check and lubricate the fan wheel and belt tension shaft bearings.
15. Check the lubricating oil level of the overspeed mechanical protection device and add oil if it is insufficient.
16. Check the tightness of the main external connecting bolts.
17. During operation, check whether the output voltage meets the requirements (361-399V) and whether the frequency meets the requirements (50 ± 1) Hz. Check whether the water temperature and oil pressure during operation meet the requirements, whether there is any air leakage in the exhaust pipe and muffler, and whether there is severe vibration and abnormal noise.
18. Check whether various instruments and signal lights indicate normally during operation, whether the automatic transfer switch operates correctly, and whether the power monitoring alarm is normal.
20. Clean the outer surface of the generator set and clean the machine room. Record the operating time of the diesel generator and regularly clean the impurities at the bottom of the oil tank.
Post time: Mar-11-2024