Diesel generator sets can be divided into two types according to their use conditions: one is the standby power supply equipment of the generator set, and the other is that the generator set is mainly used for the power supply equipment. The duration of use of these two types of generator sets varies widely. The maintenance of internal combustion engines is generally determined by the cumulative number of hours of start-up. The above-mentioned first power supply method is only used for a few hours per month, for example, to the technical maintenance of B and C groups. The number of hours of technical maintenance, the time will appear too long, so should be flexible according to the specific circumstances, timely technical maintenance, can eliminate the current bad machine status, ensure that the unit is in good condition for a long time, and can extend the life of the machine.
Hansa Xiaobian reminds you that in order to make the diesel engine work normally and reliably, the technical maintenance system of the diesel engine must be implemented. The technical maintenance categories are: Class A maintenance inspection (daily or weekly); Class B maintenance inspection (250 hours or 4 Month); Class C maintenance inspection (every 1500 hours or 1 year); Mid-care maintenance inspection (every 6,000 hours or 1 year and a half); Overhaul maintenance inspection (every 10,000 hours)
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First, diesel generator set A-level maintenance inspection
If the operator wants to get the most satisfactory use effect of the generator, the engine must maintain the mechanical state. The maintenance department needs to obtain the daily operation report from the operator, arrange the time to make necessary adjustments, and pre-require the report according to the needs Arranging the project for more maintenance work, comparing and correctly interpreting the engine's daily operation report, and then taking practical measures will eliminate most of the failures without the need for emergency repairs.
1. Before starting the machine, check the engine oil level. There are two marks on some oil dipsticks, the high mark “H†and the low mark “Lâ€; 2. Check the oil level with the oil gauge on the generator, in order to obtain an accurate reading, the oil The plane should be inspected for 15 minutes at standstill. The oil dipstick should be kept in pair with the original oil pan. Keep the oil level as close to the high “H†mark as possible. Note that when the oil level is lower than the low mark “L†or higher than the high mark†H", never operate the engine;
3. The engine coolant level should be increased to keep the cooling system full to the working plane. Check the coolant level every day or every time for fuel injection. Check the cause of the coolant consumption. Check that the coolant level can only be performed after cooling;
4, check the belt is loose, if there is a belt slipping phenomenon should be adjusted;
5, the following conditions are normal after the boot, and the following checks:
Lubricating oil pressure; power is enough; cooling water and oil temperature are normal; engine sound is normal; exhaust emissions of the unit; coolant fuel or lubricant consumption; fuel, coolant or lubricant leaks.
Second, the diesel generator set B level maintenance inspection
During each "B" level maintenance inspection, all "A" level inspection items are to be completed, and the following items are to be added to replace the engine oil. The major items and analysis results are listed below:
(1) Oil change in "B" inspection
1. Start the engine to reach the operating temperature, stop the engine, remove the oil drain plug from the bottom of the oil pan, and discharge the oil;
2. Put the oil drain plug on the oil pan. The torque of the screw plug is 50~60 pounds (70~80 Newton meters);
3. Fill the crankcase with oil to the "H" mark on the dipstick;
4. Start the engine and visually inspect whether there is any oil leakage.
5. Stop the engine and wait 15 minutes for the standby oil to flow back into the sump. Check the oil level again with the oil dipstick and add it if necessary. Lubricants used should meet specifications and should be fitted with original filters.
(2) Cycle of oil change
1. The oil change cycle is determined according to the unit's instructions for use;
2. The specified period is 250 hours or 4 months (whichever comes first);
3. Determine the oil change cycle according to the following variables: 1> hourly fuel consumption; 2> hourly oil consumption; 3> oil filter system.
4. The generator is changed every 400-500 hours or one-and-a-half years. The diesel grid, oil grid, and water grid are replaced every 250 hours or one year.
Third, the diesel generator set C-level maintenance inspection;
1. Perform Class B technical maintenance content;
2. Thoroughly clean fuel including fuel tank, filter, oil pipe, diesel pump, fuel injector;
3. Thoroughly inspect the cleaning lubrication system, including the crankcase, oil pipe, oil filter, oil pump, oil cooler, etc., and change the oil, with particular attention to whether the oil cooler and the oil pipe are rusted or damaged;
4. Check the generator, motor commutator is out of balance, and use sandpaper to collect dirt, check the brush spring;
5. Check valve timing system and STC valve and adjust if necessary;
6. Clean the cooling system. The cleaning solution consists of 150 grams of water and six liters of water. Before the cleaning, the water in the cooling system is completely drained, and then the same amount of cleaning solution is poured to prevent the suspended solution from being precipitated. Then the purified water is used again. Cleaning cooling system;
7. After each 1500 hours cumulative time, the generator and the motor are disassembled, the old bearings on the parts are cleaned, the butter is replaced, and the gear transmission of the starter is checked;
8. A general inspection of the generator components and make necessary corrections and adjustments.
Fourth, diesel generator repair repair inspection
1. Perform C-level technical maintenance content;
2. Inspect the cylinder head assembly: Remove the cylinder head and check the wear of the cylinder head, valve, valve seat, valve guide, valve spring, rocker and rocker arm, and if necessary, repair or replace.
3. Remove the wear of the piston, connecting rod, inspection and cleaning, piston and cylinder liner, and replace if necessary;
4. Check the condition of connecting rods, connecting rod bearings, valve trains, regulators, etc. If any looseness or damage occurs, repair should be done;
5. Open the cover plate and inspect the cylinder liner sealing apron from the lower end of the liner.
6. Open the front cover and check if the fuel injector on the cover of the transmission mechanism is blocked. If it is blocked, it should be unobstructed.
7. Check the wear of the crankshaft assembly, thrust bearing, and thrust plate, and check if there is any movement in the inner and outer rings of the rolling bearing. Replace if necessary.
8. Check the transmission mechanism, remove the front cover, observe the gear meshing surface wear, and measure the meshing clearance, repair or replace if necessary;
9. Inspect the fuel injector, check the fuel injection of the fuel injector on a special test bench, and if necessary, grind or replace the fuel injector and other components; check the sealing of the fuel injection pump, check the plunger and other components and the anti-rust pin. Wear condition, replace if necessary;
10. Inspect the oil pump, cooling water pump and supercharger, dismantle and measure the vulnerable parts, and adjust them;
11. Check the charger and starter motor, clean the components, add new lubricating oil after the bearings are blown dry, check the starter gear wear and whether the transmission is flexible;
12. Clean the silt and dirt scale in the waterway;
13. During installation, piston rings, connecting rods, upper repair kits, and lower repair kits must be replaced.
Note: For medium-level maintenance, professional maintenance personnel should be required to operate the unit for about 6,000 hours or one and a half years, depending on the actual conditions of the generator.
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V. Overhaul Repair Inspection of Diesel Generators
The overhaul needs to be determined based on the work of about 10,000 hours and the actual use. Some units may not continue to work due to improper use or long-term heavy load work, but may not continue to work after reaching the specified working hours, but need to carry out major repairs, generally should be based on the following aspects determine:
1. The internal combustion engine is weak, and the axial velocity decreases significantly after loading, the sound changes suddenly, and the exhaust gas emits black smoke;
2. The internal combustion engine is difficult to start at room temperature, and crankshaft bearings, connecting rod bearings, and piston pins have a knocking sound during operation;
3. The internal combustion engine cylinder pressure does not reach 70% of the specified pressure during normal operation; The oil pressure is less than 30Psi;
4. The internal combustion engine's oil fuel consumption has increased significantly;
5. Cylinder ellipticity, clearance between piston and cylinder; ellipticity of crankshaft journal and connecting rod journal exceeds the specified limit; crankshaft is bent; commutator commutator is out of round; commutator spark brush is cracked , commutator ablation, etc. In addition, if the insulation level of the generator cabinet and the magnetic field coil is too low, the insulation resistance of the coil is not up to the normal number after being subjected to the tidal drying; after the overhaul and maintenance are performed by the professional maintenance personnel, the contents of the repair and maintenance are performed. The crankshaft body, connecting rods, pistons, camshafts and other components are inspected and maintained or updated depending on the technical parameters. The crankshaft, connecting rods, cylinder liners, piston rings and overhaul kits must be replaced.
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