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Technical maintenance and inspection of diesel generator

The diesel generating set can be divided into two kinds according to the use situation: one is based on the electricity supply of the city and the spare power equipment of the generator set; the other is to supply the power supply by the generator set. The length of the time of the two kinds of generator sets is very different. The maintenance of the internal combustion engine is usually fixed by the accumulative hours. The first type of power supply is only a few hours per month. For example, the number of technical maintenance hours in the B and C group will be too long, so it should be based on the specific circumstances. Live control and timely technical maintenance can eliminate the bad situation of the machine in time, ensure that the unit is in good condition for a long time and extend the service life of the machine. Therefore, in order to make the diesel engine work normally and reliably, the technical maintenance system of the diesel engine must be implemented.
A grade a maintenance check (daily or weekly)
B level maintenance check (250 hours or 4 months)
Grade C maintenance check (every 1500 hours or 1 years)
Maintenance check (every 6000 hours or 1 and a half)
Overhaul inspection (over 10000 hours per hour)
The following five levels of technical maintenance are for reference.
One, a grade a maintenance check of diesel generator set
If the operator is to make the most satisfactory use of the generator, the engine must maintain the best mechanical state. The maintenance department needs to get the daily operation report from the operator, arrange the time to make the necessary adjustment, and arrange more maintenance work in advance according to the needs of the report, and compare and correct the maintenance work. Explain the engine's daily operation report, and then take practical measures to eliminate most of the failures without emergency repairs.
1. Check the engine oil level before turning on the engine. There are two marks on some oil rulers, high marks "H" and low mark "L".
2, use the oil scale on the generator to check the oil plane. In order to get the accurate reading, the oil plane should be checked at 15 minutes. The oil scale should be matched with the original oil plate. Keep the oil plane close to the high "H" mark as far as possible, and notice that the oil plane is lower than the low mark "L" or higher than the high mark. "H", never operate the engine;
3, it should be added to the plane of the engine coolant, keep the cooling system full to the working plane, check the coolant plane every day or each time, check the reason for the cooling fluid consumption, check the coolant plane only after cooling.
4, check whether the belt is loose, if there is a slip phenomenon, the belt should be adjusted.
5. The following situations are normal and turn on the machine.
Oil pressure of lubricating oil;
Whether or not the power is sufficient;
Whether the cooling water and the oil temperature are normal;
The sound of the engine is normal.
Exhaust gas of the unit row;
The fuel or lubricating oil of the coolant is consumed.
Leakage of fuel, coolant or lubricating oil.
Two, B maintenance check of diesel generator set
In each "B" maintenance inspection, complete the "A" level inspection project, and the following items should be added to the engine oil replacement. The main items and the limits of the analysis results are listed below.
(1) one item of oil replacement in the "B" grade inspection:
Start the engine to reach the working temperature, stop the engine, remove the oil drain plug from the bottom of the oil pan, and release the oil.
Return the oil drain plug to the oil pan, and the torque of the plug is 50~60 pounds (70~80 Newton meter).
Fill the crankcase with the "H" high mark on the oil gauge.
Start the engine and check the oil leakage.
Stop the engine, wait 15 minutes, wait for the oil flow back to the oil pan, check the oil level again with the oil gauge, if necessary, add it. The lubricating oil used should conform to the specifications and the original filter should be installed.
(two) the cycle of the replacement of the lubricating oil:
The cycle of oil change is determined according to the instructions of the unit.
The prescribed period is 250 hours or 4 months (whichever comes first).
The oil change cycle is determined according to the following variables:
1> fuel consumption per hour;
2> oil consumption per hour;
3> oil filter system.
Each generator runs 400-500 hours or a year and a half to replace the style, each running for 250 hours or a year to replace diesel oil, oil grid and water grid.
Three, diesel generating set C level maintenance inspection;
Implementation of B level technical maintenance content;
Thorough cleaning of fuel includes fuel tank, filter, oil pipe, diesel pump and fuel injection nozzle.
Thoroughly check the cleaning and lubricating system, including crankcase, oil pipe, oil filter, oil pump, oil cooler and so on, and change the oil, especially if the oil cooler and oil pipe are rusty or damaged.
Check generator, motor commutator misalignment, and use sandpaper to polish the dirt and check the spring of the brush.
Check valve timing system and STC valve and adjust it if necessary.
Cleaning cooling system, the cleaning solution consists of 150 grams of caustic, plus six liters of water, before cleaning the cooling system water before the whole, and then poured into the same amount of cleaning solution, so as not to precipitate the suspension of the solution, and then clean the cooling system with water purification;
After every 1500 hours, the generator and motor are dismantled, the old bearings on the machine parts are cleaned, the butter is new, and the gear drive device of the starter is checked.
Generally inspect generator parts and make necessary amendments and adjustments.
Four, repair and maintenance of diesel generator set
1, the implementation of C level technical maintenance content;
2, check cylinder cover component: remove cylinder head, check cylinder cover, valve, valve seat, valve guide, valve spring, rocker and rocker arm wear, repair or replace when necessary;
3, remove the wear of piston, connecting rod, cleaning, piston and cylinder liner, and replace it if necessary.
4, check the connecting rod, connecting rod bearing, valve train, adjuster and other parts, if loose or damaged, should be overhauled;
5. Dismantle the cover plate and check the cylinder liner sealing water from the lower end of the cylinder liner.
6, open the front cover, check whether the fuel injector on the transmission cover is blocked or not. If it is blocked, it should be unblocked.
7. Check the wear of crankshaft assembly, thrust bearing and thrust plate, whether the inner and outer rings of the rolling bearing are swimming or not, and replace them if necessary.
8, check the transmission mechanism, remove the front cover plate, observe the gear gear meshing surface wear and tear, and carry on the meshing clearance measurement, when necessary repair or replace.
9, check the injector, check the injector fuel injection on the special test bench, and polish or replace the fuel injector and other components if necessary.
10. Check the sealing condition of the fuel injection pump, check the plunger and the wear of the anti rust pin, and replace it if necessary.
11. Check the oil pump, cooling water pump and supercharger, disassemble and measure vulnerable parts, and make adjustments.
12, check the charger and start the motor, clean the components, add the new lubricating oil after the bearing blow dry, check the gear wear and the flexibility of the drive gear.
13, cleaning the sediment and dirt in the waterway;
14, when installing, the piston ring, connecting rod bush, upper repair kit and lower repair kit must be replaced.
Note: the intermediate maintenance and maintenance should be carried out by the professional maintenance personnel for about 6000 hours or a year and a half, depending on the actual situation of the generator.
Five. Overhaul and maintenance inspection of diesel generator set
The overhaul should be determined on the basis of about 10000 hours of work and actual use. Some units may not continue to work because of improper use or long-term heavy load, and they may not be able to continue to work.
1. the internal combustion engine is unable to work. After loading, the axle speed obviously decreases, the sound changes abrupt and the exhaust smoky.
2. the internal combustion engine is difficult to start at normal temperature, and the crankshaft bearing, connecting rod bearing and piston pin are knocking in the running process.
3. when the internal combustion engine works normally, the cylinder pressure can not reach 70% of the required pressure.
4. the oil pressure is lower than 30Psi.
5. the oil consumption of engine oil increases significantly.
6. the degree of ellipticity of the cylinder, the clearance between the piston and the cylinder, the ellipticity of the crankshaft journal and the connecting rod journal exceeding the prescribed limit.
7. the crankshaft of the generator is bent, the commutator of the exciter is lost seriously, the commutator spark brush has cracks, the commutator is ablated, and the insulation degree of the generator cabinet and the magnetic coil is too low, and the insulation resistance of the coil can not reach the normal number after the tide is dried.
After 8. repair and maintenance with the professional maintenance personnel to carry out the maintenance of the maintenance content, the crankshaft body, connecting rod, piston, camshaft and other components to check, depending on the technical parameters for maintenance or renewal, crankshafts, linkages, cylinder sleeves, piston rings, overhauls must be replaced.
A detailed maintenance method
Daily maintenance:
1, check the work daily of diesel generator.
2, check diesel generator: Oil plane, coolant plane.
Is there any damage or leakage of diesel generator in 3 and daily inspection? Is the belt loose or worn?
Two, weekly maintenance:
1, repeat the daily A-level diesel generator inspection.
2, check the air cleaner, clean or replace the air cleaner core.
3, release the fuel tank and the water or sediment in the fuel filter.
4, check water filter.
5, check the starting battery.
6, start the diesel generator and check whether there is any effect.
7, use the air gun and the radiator at the front and rear end of the water cooler. Such
B level detailed maintenance method
1. Repeat the weekly check of the A-stage diesel generator daily and diesel generator.
2, replace diesel engine oil. (the oil replacement period is 250 hours or one month)
3, change the oil filter. (oil filter cartridge replacement period is 250 hours or one month).
4, replace the filter cartridge of the fuel filter. (the replacement period is 250 hours or a month)
Replace 5, replace the coolant or check the coolant. (the replacement period of the water filter element is 250-300 hours, and the coolant DCA is added to the cooling system).
6, clean or replace the air filter. (air filter replacement cycle is 500-600 hours)
C level detailed maintenance method
1, replace diesel filters, oil filters, water filters, and replace water and oil in tanks.
2, adjust the tightness of the fan belt.
3, check the turbocharger.
4, dismantling, checking and cleaning PT pumps and actuators.
5, disassemble the cover of the rocker chamber and check the T-shaped pressure plate, valve guide and intake and exhaust valves.
6, adjust the nozzle lift and adjust the valve clearance.
7, check the charging generator.
8, check radiator radiator and wash radiator external radiator.
9, add the water tank treasure in the water tank, clean the inside of the water tank.
(10) check the sensor and connecting wire of diesel engine.
11) check the diesel engine instrument box. It
D level detailed maintenance method
1, replace oil, diesel, bypass, water filter, replace engine oil and engine water.
2, clean or replace the air filter.
3, disassemble the cover of the rocker chamber, inspect the valve guide and the T-shaped pressboard.
4, check and adjust the gap between the valve.
5, change the upper and lower pad of the rocker arm.
6, check the fan and bracket, and adjust the belt.
7, check the turbocharger. Such
8, check the electrical circuit of the diesel generator.
9, check the motor excitation part of the line.
10, the connection line in the measuring instrument box.
11, check water tank and external cleaning.
12, repair or replace the pump.
13, remove the wear of one cylinder main bearing and connecting rod tile.
14, check or adjust the working condition of electronic speed regulation.
15, aim at the lubrication point of the diesel generator to lubricate grease.
16, aim at the diesel generator excitation part for dust removal.
17, check the axial and radial clearance of turbocharger, such as overcorrection should be repaired in time.
18, cleaning and correcting the nozzle and fuel pump