Diesel engine maintenance technical service (A-level maintenance)

Diesel generator sets can be divided into two types according to the use situation: one is based on the mains, the generator set is a backup power supply equipment, and the other is based on the generator as the main power supply equipment. The length of use of the generators in the two cases is very different. The maintenance of diesel generators is generally determined by the accumulated hours of startup. The above-mentioned first power supply method is only tested for a few hours per month. It takes too long to carry out technical maintenance after the maintenance hours. Therefore, it should be flexibly grasped according to the specific situation, and timely technical maintenance can eliminate the bad phenomenon of the machine as soon as possible, ensure that the unit is in good condition, 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. The technical maintenance categories are divided into:
1. First-level maintenance inspection (daily or weekly)
2. Secondary maintenance inspection (every 250 hours or one month)
3. three maintenance inspection (every 1500 hours or half a year)
Note: 1. “Third-level maintenance”, “intermediate maintenance” and “overhaul maintenance” should be completed by diesel generator distributors or dealers.
2. The standby generator should regularly start the diesel unit to run for about 30 minutes to evaporate the water in the diesel engine and achieve the functions of moisture-proof and anti-corrosion.

(1), first-level maintenance inspection
<1> Check the oil level
Check the oil level with the dipstick of the diesel engine. In order to get an accurate reading, the oil level should be checked after 15 minutes of shutdown and when the oil flows back to the oil pan. Keep the oil level matched with the original oil pan and keep the oil level as close to the high “H” mark as possible.
Warning: Never operate the diesel engine when the oil mark is lower than the low mark “L” or higher than the high mark “H” (if necessary, add oil of the same quality and grade in the diesel engine).
<2> Check the cooling system
Keep the coolant topped up to the working surface, check the coolant level every day or before every start-up, analyze the cause of the coolant consumption, and check the coolant level, only after the cooling system cools down.
<3> Check the connections of the intake pipe
Check each connection of the intake pipe, whether the clamp is loose, whether the hose is cracked, perforated or worn, whether there is a broken or other damage to the hose, tighten the clamp or replace the parts as needed to ensure that the intake system is well sealed and ensure that all Air passes through the air filter.
<4> Appearance inspection
Check for outside air leaks, coolant or oil leaks. Tighten screw connections, joints, etc. or replace gaskets as needed. Check the oil dipstick’s fuel pipe caps to see if they are tight.
<5> Check for damage
Check the fuel system, etc., including the wrong investigation or bumping of the fuel pump, and check all connections for leaks or damage.
<6> Check the drive belt
Visually check whether the belts of fans, water pumps and chargers are damaged or loose, and the buckles should be replaced with new ones. And adjust the tightness, if necessary, ask a professional technician to adjust.
<7> Matters needing attention during maintenance
1. Low lubricating oil pressure.
2. Insufficient power.
3. The coolant or oil temperature is too high.
4. Excessive consumption of coolant, oil and fuel.
5. The engine sound is abnormal, the smoke color is abnormal, and the smoke exhaust pipe is red.

Two, two maintenance inspection
In each secondary maintenance inspection, all primary maintenance and inspection items must be completed, and the following items must be added:
WARNING: Adherence to regular secondary maintenance inspections is very important for the complete maintenance of the generator. A direct result of diesel engine operation (including load factor and fuel consumption) is contamination of the oil. After repairing the diesel engine, the re-added oil must be new oil, not the oil released from the oil pan.
<1>Replace diesel engine oil and oil filter
1. Start the diesel engine to make it reach the working temperature, stop and remove the oil drain plug (or open the oil drain switch) from the bottom of the oil pan to release the oil.
2. Reinstall the oil inlet plug, and the tightening torque of the plug: for CumminsLTA10, 6CT, 6BT, 4BT, and Perkins1306, 9TAG, 1006TG and below, use 35-40 ft-lbs (47-54 N.m); for Cummins NTA855, K19, Perkins2006TAG use 45-55 ft-lb (61-75 N.m); for Cummins V28, K38, K50 and Perkins3008TAG, 3012TAG, use 60-70 ft-lb (81-9 N.m) above.
3. Unscrew the combined oil filter, fill the new oil filter with the specified type of oil, tighten it by hand until the gasket touches the filter, and then tighten it by 1/2 to 3/4 turns.
NOTE: Tool tightening will deform or crack the filter head.
4. Fill the crankcase with the specified type of oil to the “H” high mark on the oil dipstick.
5. Start the diesel engine and visually check for oil leakage.
6. Stop the diesel engine, wait for 15 minutes after the standby oil flows back into the oil pan, check the oil level with the oil dipstick again, and add it if necessary.
<2>Replace diesel filter, water grid and air filter
Remove the diesel filter, water grid and air filter, and fill the new diesel filter with clean diesel oil. The water grid can be installed directly without adding water. ”, clean the air filter interface or dust tray before installing it.
<3> Cleaning the crankcase ventilator
Disassemble the crankshaft to calculate the ventilator body, use the specified cleaning solvent to clean the metal parts and rubber parts, and then check the installation, and replace the deformed and damaged parts.
Note: CUMMINS&PERKINS diesel engines usually replace the oil, oil filter, diesel filter, water grid every 250 hours or half a year (whichever comes first), add DCA anti-rust water if necessary, and replace the air filter after 450 hours of operation device.
Warning: The oil to be replaced must conform to the original oil with the label, and the filter should use the original or accessory parts with reliable quality, otherwise it will cause damage to the diesel engine or catastrophic damage such as burning the crankshaft and pulling the cylinder.
<4> Appearance inspection
Check for outside air leaks, coolant or oil leaks. Tighten screw connections, joints, etc. or replace gaskets as needed. Check the oil dipstick’s fuel pipe caps to see if they are tight.
<5> Check for damage
Check the fuel system, etc., including the wrong investigation or bumping of the fuel pump, and check all connections for leaks or damage.
<6> Check the drive belt
Visually check whether the belts of fans, water pumps and chargers are damaged or loose, and the buckles should be replaced with new ones. And adjust the tightness, if necessary, ask a professional technician to adjust.
<7> Matters needing attention during maintenance
1. Low lubricating oil pressure.
2. Insufficient power.
3. The coolant or oil temperature is too high.
4. Excessive consumption of coolant, oil and fuel.
5. The engine sound is abnormal, the smoke color is abnormal, and the smoke exhaust pipe is red.