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Maintenance and maintenance of diesel generator sets

The correct maintenance of the diesel engine, especially the preventive maintenance, is the easiest and most economical maintenance, so it is the key to extending the service life and reducing the use cost. First of all, the daily report during the use of the diesel engine must be done, and necessary adjustments and repairs must be made in a timely manner according to the reflected conditions. Based on this and referring to the contents of this chapter, different maintenance schedules can be formulated according to the special working conditions and user experience of different users.
The contents of daily statements generally have the following aspects:
The date and start and stop time of each shift; routinely record the readings of all instruments; the use of power; whether there is leakage or excessive consumption of fuel, oil, coolant; exhaust smoke and abnormal sounds; before and after the failure And handling opinions.
First, the main content of maintenance Users should perform regular maintenance according to the technical maintenance items listed in this section. The maintenance classification is as follows:
Routine maintenance (work per shift);
One-dimensional technical maintenance (cumulative work 100h or every other month);
Two-dimensional technical maintenance (cumulative work 500 h or every six months);
Three-level technical maintenance (cumulative work 1000-1500h or every other year);
No matter what kind of maintenance is carried out, the inspection and installation should be carried out in a planned and step-by-step manner, and the tools should be used reasonably. The force should be appropriate. The surface of each component after disassembly should be kept clean and coated with anti-rust oil or grease to Prevent rust; pay attention to the relative position of the removable parts, the structural characteristics of the non-removable parts, as well as the assembly gap and adjustment methods. At the same time, the diesel engine and accessories should be kept clean and complete.
1. Routine maintenance Routine maintenance items and maintenance procedures can be performed as shown in the following table:


Serial number

Maintenance item

Proceed

1

Check the fuel quantity of the fuel tank

Observe the amount of fuel in the fuel tank and fill it up as needed

2

Check the oil level in the oil pan

The oil level should reach the engraved mark on the oil scale. If it is insufficient, it should be added to the specified amount.

3

Check oil level of fuel injection pump governor

The oil level should reach the engraved line mark on the oil gauge, and when it is insufficient, add enough

4

Check three leaks (water, oil, gas)

Eliminate oil leakage and water leakage on sealing surfaces such as oil and water pipe joints; eliminate air leakage in intake and exhaust pipes, cylinder head gaskets, and turbochargers

5

Check the installation of various diesel engine accessories

Including the stability of the attachment installation, the anchor screw and the reliability of the connection to the work machine

6

Check each meter

Observe whether the reading is normal, otherwise it should be repaired or replaced in time

7

Check the fuel pump drive connection plate

Whether the connecting screw is loose, otherwise, re-adjust the fuel injection advance angle and tighten the connecting screw

8

Clean the appearance of diesel engines and auxiliary equipment

Use a dry cloth or a diesel-soaked rag to remove grease, water, and dust on the surface of the fuselage, turbocharger, cylinder head cover, air filter, etc .; clean or blow the charged generator with compressed air or dissipate heat Dust on surfaces such as fans, fans, etc.

In addition to the routine maintenance items of the first-level technical maintenance, the work that needs to be added is shown in the following table:


Serial number

Maintenance item

Proceed

1

Check battery voltage and electrolyte specific gravity

Use a hydrometer to measure the specific gravity of the electrolyte. This value should be 1.28-1.30 (when the ambient temperature is 20J), and generally should not be lower than 1.27. At the same time, the liquid level should be 10-15mm higher than the electrode plate.

2

Check the tension of the triangle rubber band

Check and adjust the belt tightness according to the introduced belt tension adjustment method

3

Cleaning the oil suction filter of the oil pump

Remove the cover of the large window of the boot, pull off the coarse filter spring lock, remove the filter and clean it in diesel, then blow it off

4

Cleaning the air filter

Inertia oil bath air filter should clean steel wool core and change engine oil; basin (cyclonic) air filter should remove dust from dust collecting tray and maintain paper filter

5

Cleaning the filter element in the air pipe

Take out the oil core in the fuel door of the body door cover, clean it in diesel or gasoline, and blow it up.

6

Cleaning the fuel filter

Every 200 hours, remove the filter element and the shell, and clean or change the core in diesel or kerosene, while removing water and sediment

7

Cleaning the oil filter

Generally every 200h:
①Clean the wound primary filter element② For wiper-type filters, turn the handle to remove the oil on the surface of the filter element, or brush it in diesel oil

8

Clean the turbocharger's oil filter and oil inlet pipe

Clean the filter element and tube in diesel or kerosene, and then blow dry to prevent contamination by dust and debris.

9

Change the oil in the oil pan

Replace every 200h-300h according to the use of the oil (the degree of viscosity reduction of the dirty oil)

10

Fill with lubricating oil or grease

Fill all grease nipples and mechanical tachometer connectors with grease or oil that meets the requirements

11

Cleaning the cooling water radiator

Pass clean water into the radiator and remove the sediment from it until it is clean

In addition to the first-level maintenance items, the second-level technical maintenance items must be added as follows:


Serial number

Maintenance item

Proceed

1

Checking the injector

Check the injection pressure, observe the spray condition, and perform necessary cleaning and adjustment

2

Checking the fuel injection pump

Readjust if necessary

3

Check valve clearance and injection advance angle

Adjust if necessary

4

Check the inlet and exhaust valves and seals

Remove the cylinder head, observe the seal of the mating cone, wear, and repair if necessary

5

Check for water leaks from the pump

If the overflow is dripping, the seal ring should be replaced

6

Check the seal of the water seal of the cylinder liner

Remove the cover of the large window of the body, and check whether there is water leakage from the lower end of the cylinder liner; otherwise, remove the cylinder liner and replace the new rubber water seal

7

Check the fuel injection plug on the transmission cover

Remove the front cover and check whether the injection hole of the injection plug is unblocked. If it is blocked, it should be cleaned.

8

Check cooling water radiator and oil radiator, oil cooler

If there is water leakage or oil leakage, necessary repairs should be made

9

Check the tightening of main parts

Check the connecting rod, crankshaft nut, cylinder head nut, etc., if necessary, remove it and tighten it to the specified torque

10

Inspection of electrical equipment

Whether all electrical connectors are firmly connected and should be replaced if they are damaged

11

Cleaning oil and fuel system lines

Including cleaning the oil pan, the oil pipeline, the oil cooler, the fuel tank and its pipeline, removing the dirt and blowing it clean

12

Cleaning cooling system water pipes

The cooling system of the diesel engine can be filled with a solution of 150g of caustic soda (NaOH) per liter of water and left for 8-12h. Then start the diesel engine, let the temperature of the water reach 75 ° C or higher, release the cleaning solution, and then clean the cooling system with clean water

13

Cleaning the gas and oil channels of the turbocharger

Includes cleaning of oil contamination and carbon deposits on air guide wheels, compressor impellers, internal surfaces of compressor casings, turbines and turbine casings

In addition to the second-level technical maintenance items, the third-level technical maintenance items must be added as follows:


Serial number

Maintenance item

Proceed

1

Checking the cylinder head assembly

Check the valve, valve seat, valve guide, valve spring, push rod and rocker mating surface for wear and tear, and repair or replace if necessary

2

Checking the piston rod assembly

Inspect piston rings, cylinder liners, connecting rod small-head bushings, and connecting rod bushes for wear and replace if necessary

3

Inspection of crankshaft assembly

Check the thrust bearings, thrust plates for wear and tear, and check whether the inner and outer rings of the rolling main bearings have circumferential movement. Replace them if necessary.

4

Check transmission mechanism and valve phase

Check the gas distribution phase, observe the wear of the gear gear meshing surface, and measure the meshing clearance, repair or replace if necessary

5

Checking the injector

Check the spray condition of the injector, and grind or replace the fuel injector if necessary

6

Checking the fuel injection pump

Check the tightness of the plunger and the wear of the flying iron pin, and replace if necessary

7

Checking the turbocharger

Inspect impellers and housings and clearances, floating bearings, turbine rotor shafts, and air seals, oil seals and other parts for wear and tear, and repair or replace if necessary

8

Check oil pump, fresh water pump

Disassembling and measuring vulnerable parts and making adjustments

9

Check the cylinder head and inlet and exhaust pipe gaskets

Damaged or lost seal should be replaced

10

Check charging generator and starter motor

Clean all parts, bearings, and add new grease after blow-drying, check the wear of the starter gear and whether the transmission is flexible

Source: Zhongsheng Generator Time: 2017/3/22