Diesel Generator Maintenance And Repair

Maintenance Work

1. Cleaning: Regularly clean the exterior of the diesel generator set, including the trailer and the outer sides of the engine room, ensuring there is no dust, oil stains, or debris. Also, inspect and clean the intake and exhaust systems to ensure smooth ventilation.

2. Fuel and Oil Inspection: Check the fuel level in the diesel tank to ensure it is sufficient for at least 8-12 hours of operation. Additionally, check for fuel leaks and replace the diesel fuel filter regularly. For the engine oil, regularly check the oil level, oil filter, and replace the engine oil and oil filter periodically to prevent oil leaks and contamination.

3. Belt and Bolt Inspection: Check the tension of the fan belt and alternator belt, adjusting if necessary. Also, inspect machine bolts for looseness to ensure all connections are secure.

4. Antifreeze and Cooling System: Check the antifreeze level for adequacy and leaks, and replace the antifreeze regularly. Additionally, clean the radiator and external cooling system to ensure efficient operation of the cooling system.

5. Air Filter and Intake/Exhaust System: Inspect and clean or replace the air filter to ensure its filtering effectiveness. Also, check the intake and exhaust pipes for blockages to prevent obstructions.

6. Inspection of Other Key Components: Regularly inspect critical components such as the turbocharger, PT pump, actuator, rocker chamber cover, valve guides, intake and exhaust valves to ensure their proper operation. Components like the charging alternator and water tank should also undergo regular inspection and maintenance.

7. Monthly and Annual Maintenance: Maintain monthly operational records to track the generator’s performance. Conduct comprehensive annual maintenance, including replacing filters and cleaning the internal parts of the water tank.

During maintenance, prioritize safety operations and adhere to the manufacturer’s provided operation and maintenance manuals. Seek professional technical assistance for unfamiliar tasks. Regular maintenance ensures the stable operation of the diesel generator set, prolonging its lifespan and reducing the likelihood of unexpected failures.

Repair Work

Firstly, before repairing a diesel generator, always disconnect the power source and use appropriate electrical tools to ensure safety. Additionally, maintaining engine cleanliness is crucial to avoid contamination from dust and dirt.

Next, regular inspections of the diesel generator are key aspects of repair work. Inspect the electrical system, including power lines, cables, switches, etc., to ensure normal operation and safety. Also, check the grounding and insulation of the electrical system to prevent electric shock accidents. Regularly check the battery status of the generator to maintain normal charging, and replace the battery promptly if insufficient capacity is detected.

Furthermore, maintenance of the fuel system is equally vital. Regularly inspect the fuel system of the diesel generator, including the fuel tank, fuel filter, fuel pump, etc., to ensure normal operation and cleanliness. Replace the fuel filter regularly to prevent fuel contamination and inadequate fuel supply. Also, check the working condition and sealing of the fuel pump to ensure stable fuel supply.

Maintenance of the cooling system is equally crucial. Regularly inspect the cooling system of the diesel generator, including the water tank, water pump, radiator, etc., to ensure normal operation and cleanliness. Clean the radiator and cooling system pipes regularly to prevent blockages and ensure effective heat dissipation.

During repairs, pay attention to the engine’s sealing to prevent leaks of oil and other substances. Additionally, ensure proper engine lubrication by timely oil changes to maintain normal engine operation. Proper engine cooling is also essential to prevent engine overheating and damage.

In addition to maintenance of key components mentioned above, attention should also be paid to addressing common issues. For instance, when the air filter is blocked, regularly replace the filters; when there is excessive or incorrect lubricating oil, check the oil level or replace the lubricating oil and filter; when the engine temperature is too high, ensure the intake temperature is not higher than 40°C; when the exhaust pipe is blocked or there is excessive back pressure, reduce the back pressure to ensure smooth engine exhaust, etc.