What needs to be done for daily maintenance of diesel generator set?
In order to prolong the service life of the diesel generator set and its efficiency, in addition to seasonal maintenance, the daily maintenance of the diesel generator set should not be ignored. Only by starting from the details, can the diesel generator set be effectively used. So what needs to be done for daily maintenance of diesel generator sets?
First: Check the diesel and lubricating oil. Because the diesel generator is static for a long time, the various materials of the unit itself will undergo complex chemical and physical changes with the oil, cooling water, diesel, air, etc., which will affect the generator set. Sexual but persistent damage. So how to manage diesel and lubricants?
Pay attention to the location of diesel storage: diesel fuel tanks should be placed in a closed room, on the one hand for the consideration of the fire safety system, on the other hand, to ensure that the diesel will not deteriorate. Because the water vapor in the air will condense due to temperature changes, the condensed water droplets will hang on the inner wall of the fuel tank. If it flows into the diesel, it will cause the water content of the diesel to exceed the standard, and the diesel with the excessive water content will enter the high-pressure oil pump of the diesel engine. , It will gradually corrode the components in the unit. This corrosion will have an important impact on the performance of the precision coupling. If the impact is serious, the entire unit will be damaged.
Pay attention to the lubricating oil storage period: generator lubricating oil has a shelf life. Long-term storage will cause its physical and chemical properties to change. The deteriorated lubricating oil will deteriorate the lubrication state of the unit during operation, resulting in damage to the generator parts risks of.
Second: Check the starting solenoid valve. When the motor unit is running, you can check the unit running by watching, listening, touching and sniffing. When starting, by listening, press the start button for three seconds to start. During the three-second startup process, two clicks can be heard under normal circumstances. If you only hear the first ring but not the second ring, you need to check whether the start solenoid valve is working properly.
Third: Check the battery pack. Diesel generator sets are not often put into use in daily use. The normal start-up of the generator and battery maintenance are key determinants. When there is a problem with the battery pack, there will be a “voltage without current” fault. In this case, you can hear the sound of the solenoid valve in the starter motor, but the coupling is not driven. A problem with the battery pack makes it impossible to stop the machine. The reason is that the battery is not charged due to the method of stopping charging the battery during the test machine. At the same time, if the mechanical oil pump is driven by a belt, the pump oil volume at the rated speed is large, but the battery pack power supply is insufficient, which will cause the spring in the shutoff valve to be unable to seal due to insufficient suction of the solenoid valve. The fuel sprayed from the hole makes it impossible to stop the machine. There is also a situation that may be overlooked is that domestic batteries have a short lifespan, about two years or so. This situation will also occur if you forget to replace them regularly.
The diesel generator set should be checked every 6-8 hours in long-term operation. After the standby unit is shut down, the new unit must be checked for 200-300 hours. Check the valve clearance and check the fuel injector. Every 50 hours of operation, drain the water in the oil-water separator; check the electrolyte level of the start-up battery. Change the lubricating oil and lubricating oil filter every 50-600 hours of operation or at least every 12 months; according to the quality of the lubricating oil, the sulfur content of the fuel and the difference in the engine’s consumption of lubricating oil, the interval for the unit to change the lubricating oil will also be The difference.
In addition, every 400 hours of operation of the diesel generator set, check and adjust the transmission belt, replace if necessary; check and clean the radiator chip; discharge the sludge in the fuel tank. Every 800 hours of operation, replace the oil-water separator; replace the fuel filter; check whether the turbocharger leaks; check the intake pipe for leaks; check and clean the fuel pipe. Adjust the valve clearance every 1200 hours of operation. Every 2000 hours of operation, replace the air filter; replace the coolant; thoroughly clean the water tank radiator chip and water channel. Every 2400 hours of operation, check the injector; thoroughly inspect and clean the turbocharger; comprehensively inspect the engine equipment; for the specific unit, the user should also refer to the engine maintenance information for correct implementation.
Maintenance and maintenance of generator sets. The inside and outside of the alternator should be cleaned regularly, and the frequency of cleaning depends on the environment where the unit is located. When cleaning is required, follow the steps below: disconnect all power supplies, wipe off all dust, dirt, oil, water or any liquid on the outside, and clean the ventilation net, because these things enter the coil, Overheat the coil or damage the insulation. It is best to use a vacuum cleaner to remove dust and dirt, and do not use air blowing or high-pressure water spray to clean it.
The diesel generator is in a static state, and the various materials of the unit itself will undergo complex chemical and physical changes with oil, cooling water, diesel, air, etc., which will “stop the unit”. Therefore, it is necessary and economical to strengthen daily maintenance. effective method.
Unit starting battery failure:
The battery is unmaintained for a long time, and the electrolyte cannot be replenished in time after the water evaporates. The battery charger is not equipped to start the battery. After the battery is discharged for a long time, the power will decrease, or the charger used needs to be manually equalized and floated. Due to negligence and failure to perform the switching operation, the battery power cannot meet the requirements. In addition to the configuration of high-quality chargers, necessary inspection and maintenance are necessary to solve this problem.
Water enters the diesel engine:
As water vapor in the air condenses due to changes in temperature, it forms water droplets that hang on the inner wall of the fuel tank and flow into the diesel fuel, causing the water content of the diesel fuel to exceed the standard. Such diesel fuel enters the engine high-pressure oil pump and will rust the precision coupling parts —– Plunger, serious damage to the unit, regular maintenance is effective and can be avoided.
Oil retention period (two years):
Engine oil is mechanical lubrication, and the oil also has a certain retention period, long-term storage, the physical and chemical properties of the oil will change, causing the deterioration of the lubrication condition of the unit when it is working, and it is easy to cause damage to the unit parts, so the lubricant should be replaced regularly.
Replacement cycle of three filters (diesel filter, machine filter, air filter, water filter):
The filter plays a role in filtering diesel, engine oil or water to prevent impurities from entering the body. In the diesel oil, dirt and impurities are also inevitable. Therefore, the filter plays an important role in the operation of the unit. At the same time, these oil or impurities are deposited on the wall of the filter screen, which reduces the filtering capacity of the filter. If the deposit is too much, the oil circuit will not be unblocked, so that the oil machine will be shocked due to the lack of oil supply when the engine is running (like a human shortage Oxygen), so during the use of normal generator sets, we recommend: first, replace the three filters every 500 hours for the commonly used generator sets; second, replace the three filters every two years for the standby generator sets.
If the water pump, water tank and water pipeline are not cleaned for a long time, the water circulation is not smooth, the cooling effect is reduced, whether the water pipe joints are good, the water tank, and the water channel are leaking, etc. If the cooling system fails, the consequences are: first, cooling If the effect is not good, the water temperature in the unit is too high and the unit stops; 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 pipes from freezing when the generator is used in winter, we recommend using the cooling system Install water heater).
Lubrication system, seals:
Due to the chemical properties of lubricating oil or oil ester and the iron filings produced after mechanical wear, these not only reduce its lubricating effect, but also accelerate the damage of parts. At the same time, the lubricating oil has a certain corrosive effect on the rubber sealing ring. In addition, the oil seal It also ages at any time to reduce its sealing effect.
Fuel and gas distribution system:
The output of engine power is mainly the fuel burned in the cylinder to do work and the fuel is sprayed out through the fuel injector, which makes the burnt carbon deposit deposited on the fuel injector. As the deposit volume increases, the fuel injection volume of the fuel injector will be affected by a certain amount. As a result, the ignition advance angle of the fuel injector is not accurate, the fuel injection volume of each cylinder of the engine is also uneven, and the working state is not stable. Therefore, the fuel system is cleaned regularly, and the fuel supply is smooth when the filter components are replaced. The gas system is adjusted to make the ignition even.
The bai replacement cycle of the three filters (diesel filter, machine filter, air filter, water filter) The filter is to filter diesel, oil or water to prevent impurities from entering the body, and the oil and impurities in the diesel are also The existence of unavoidable, so in the operation process of the unit, the filter has played an important role, but at the same time these oil or impurities are also accumulated on the filter screen wall, the filter’s filtering capacity is reduced, too much accumulation, oil circuit It will not be able to dredge, so that the diesel engine will be shocked due to the lack of oil supply when it is running on load (like human lack of oxygen). Therefore, during the normal operation of the generator set, we recommend that the common generator set replace the three filters every 500 hours; Replace three filters in two years.
Fuel and gas distribution system The output of engine power is mainly the work done by fuel burning in the cylinder. The fuel is sprayed through the fuel injection nozzle, which causes the incineration carbon deposits to accumulate in the fuel injection nozzle, and the fuel injection volume of the fuel injection nozzle will be affected with the increase of the accumulation amount, resulting in the early ignition of the fuel injection nozzle. , The fuel injection rate of each cylinder of the engine is uneven, and the working state is not stable. Therefore, the fuel system is cleaned regularly, the replacement of filter components makes the fuel supply dredge, and the gas distribution system is adjusted to make the ignition even.
The generator control part is also an important part of the unit protection and maintenance. If the unit is used for too long, it is necessary to check whether the line connector is loose and whether the AVR module is operating normally.