Diesel Generator Set Maintenance Guide
Diesel Genset Maintenance Guide：
A. Daily Maintenance
Check Daily Report of Diesel Genset .
Check fuel level and coolant level.
Check alternator for cracks or other damage, and the condition of the belts must be checked, flab or other damage.
Check the Air filter. The air filter should be replaced when necessary .
Release fuel tank and fuel filter's water and sediment.
Check the water cooling filter.
Check starting battery and electrolyte, add electrolyte when necessary.
Check the starter, check noisy defect.
Use air syringe cleaner to clean the water tank, coolant system and cooled fin net.
B. Less than 400 hours
Repeatedly check A Level Daily Maintenance steps.
After operating 100 to 250 hours, replace the fuel filter. All the fuel filters should not be cleaned, it should be replaced. 100 to 250 hours is just flexible time, actually it must be according to the practice and real fact.
After operating 200 to 250 hours, replace the oil & oil filter. All the lube oil must fit up to the CF Grade of American Petroleum Institute.
After operating 300 to 400 hours, replace the air filter. The air filter can be cleaned with air syringe, or it can be replaced. The replacement must be according to the environment and real fact.
Replace the cooling system and add coolant concentration.
Clean the crankshaft and inlet, outlet air- filter net.
C. Maintenance Interval (2000-3000 hours)
Repeatedly check A and B Level Daily Maintenance steps.
Remove the tap of valve, clean and wash oil dirt and sludge.
Fasten snails from each part (including running parts and fixed parts)
Clean and wash the crankcase, oil sludge, steel scraps and sediment with engine.
Check wearing of the engine turbo, clean and wash accumulation of carbon, adjust it when necessary.
Check and adjust valve clearance.
Check PT pump, quality of injection, adjust injection process, adjust it when necessary.
Check and adjust the tension of fan belt and water pump belt, adjust and replace it when necessary;clean and wash water tank radiator fins, then check the using capability of thermostat.
D. Maintenance Interval (3000-4000 hours)
Check valve, valve seat and other wearing, repair or change it when necessary.
Check P pump, quality of injection, repair and adjust it when necessary.
Check and adjust connecting rod and fastening twisting torque.
Check and adjust valve clearance.
Check the trip of injector.
Check and adjust tension of fan and generating belt.
Clean and wash accumulation of carbon in inlet pipes.
Clean and wash the core of air cooler.
Clean and wash the whole oil lubrication system.
Clean and wash room of rocker arm, oil sludge in the sump and Metal scrap-iron.
E. Maintenance Interval (6000-8000 hours)
Including the items of minor repair.
Disassemble generator(except crankshaft)
Check the easy worn spare parts in pitman shaft system, gas distribution system, lubrication system,cooling system of cylinder, Piston, Intake and exhaust valve, replace them when necessary.
Check fuel supplying system, adjust oil pump and injector.
Repair and test the alternator, clean oil-sediment and lubricate the bearing of alternator.
F. Maintenance Interval (9000-15000 hours)
Including the items of intermediate repair.
Disassemble all the parts in the generator.
Replace cylinder, piston, piston loop, big and small bearing bushes, trusting pad of crankshaft, intake and exhaust valve, a whole set of tools for generator repair
Adjust oil pump, injector and replace pump core, injector.
Replace a whole set of repair tools for turbo charger and a repair set for water pump.
Adjust the parts of connecting rod, crankshaft and generator body,repair or replace them when necessary.
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