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Diesel Generator Maintenance Plan

Sep. 16, 2019

Proper maintenance is necessary to ensure the long-term trouble-free operation of the diesel generator set and to achieve normal power supply. Therefore, all users should perform normal maintenance on the genset according to the following steps and contents. The maintenance of different models may be slightly different. For details, please refer to the maintenance manual of the engine and generator.

Diesel generator maintenance plan

Note: Standby diesel generator should start inspection at least 2-3 times a month, each time more than 20 minutes; at the same time, it is recommended to run with load more than 30%.

Maintenance before start

I. Cleaning the surface of the generator set.

II. Check the coolant level of the water tank; the liquid level should be as close as possible to the 5cm below the welding surface of the filling cover. It is recommended not to exceed it.

III. Check the outside of the radiator core and the intercooler of the water tank. No foreign objects are allowed to block.

IV. Check the air filter blockage; if the blockage indicator is in the red zone, the filter should be replaced immediately after the unit is shut down. The air filter under replacement is not allowed to be reused.

V. Check the oil level of the diesel engine to ensure that the oil level is between the maximum and minimum values of the dipstick scale.

VI, check if the electrical connection of the control system is loose.

Maintenance after operation

I. Check and tighten the bolts of various rotating parts, especially the connecting bolts such as fuel injection pump, water pump, belt pulley and fan, etc., and tighten the anchor bolts at the same time.

II. Check if there are three leaks and clean up if necessary.

III. Eliminate the simple faults and abnormalities found during operation.

IV. Clean the dust on the air filter element

V. Check the oil level of the machine and the oil level of the fuel injection pump. If necessary, add oil that can meet the technical requirements.

VI. Check the cooling water level of the water tank and add soft pure water if necessary.

VII. Check if the electrical connection of the control system is loose.

VIII. Comprehensive cleaning of the unit surface.


diesel generator set


Every 50 hours of maintenance

In addition to completing the above maintenance items, the following tasks should be added:

I. Check the battery; measure the battery voltage and fill it if necessary. When handling the battery, please wear goggles. The battery contains explosive gas and corrosive sulfuric acid. Ignition near the battery can cause an explosion.

II. Check for three liquid leakage.

III. Check if the three filter system is good and replace it if necessary.

IV. Check and adjust fan belt tightness.

V. Add or replace the water tank and cooling water in the body if necessary.

VI. Check whether the wiring wires of the generator and the electronic control part are secure.

VII. Gen set with oil-water separator should be drained regularly and cleaned or replaced every 50 hours.

VIII. After the initial operation of the new unit reaches 50 hours, all oil and oil filter elements should be replaced.

Every 250 hours of maintenance

I. Change the oil and drain the oil when the machine is hot. The normal replacement time of the oil and oil filter is every 250 hours, and the replacement period of the oil and oil filter is 100 hours when used under bad condition. Pay attention to safety when replacing, hot oil can cause scald.

II. Replace the oil filter and bypass filter; remove the filter with a special tool. Be sure to fill the new filter with oil to drain the air, then screw it by hands, touch the gasket, and twist it 1/2 turn. Start the unit to check for oil leaks.

III. Replace the diesel filter; remove the diesel filter with a special tool. Lubricate the gasket and hand-tighten the new filter filled with clean diesel oil. Tighten half a turn after touching the pad. Note that no dust can enter the fuel system. It can only be replaced after the unit has been completely cooled to avoid fire caused by splashing of diesel fuel on the exhaust pipe.

IV. Diesel filter replacement time is every 300 hours.

Every 400 hours of maintenance

I. Check all pump overflow ports.

II. The air filter replacement time is every 400 hours. The air filter replacement should be carried out according to the air filter indicator. If the air filter indicator enters the red area, the air filter needs to be replaced.

Every 800 hours of maintenance

I. If possible, thoroughly remove the accumulated sludge from the fuel oil faucet;

II. Check if the oil pipe entering and leaving the turbocharger leaks;

III. Check the air valve and its interface for leaks;

IV. Check all air valves for damage, replace when necessary, and retighten all fixing screws after replacement;

V. Cleaning the fuel tank and pipeline;

VI. Cleaning oil sump and oil filter;

VII. Check and tighten the connecting rod bolts, main bearing bolts, cylinder head bolts;

VIII. Check the specific gravity of the battery electrolyte and replenish the electrolyte if necessary;

IX. Check the instrument;

X. Check and adjust the excitation circuit.

Every 1200 hours of maintenance

I. Complete all work for every 800 hours of inspection;

II. Check valve clearance. It is required to be carried out by professionally trained and qualified engineering and technical personnel. Stop for inspection.

Every 2400 hours of maintenance

I. Complete all inspections every 1200 hours;

II. Check the status of the turbocharger by professional technicians and comprehensively check the diesel engine parts and the accessories.

Every 6 months of maintenance

I. Replace the coolant filter. Close the cooling faucet, remove the filter with a special tool, and reinstall a new one. Finally turn on the faucet.

Every 12 months of maintenance

I. Complete all inspections every 6 months;

II. If the unit is equipped with an air compressor, please replace the air filter on the air compressor; the method is to open the valve fastening device, remove the filter, install a new filter and tighten the fastening screw;

III. Clean cooling system / replace coolant (only for units without coolant filter);

IV. Check for leaks.

Every 24 months of maintenance

I. Clean the cooling system / replace the coolant; (only for units with coolant filter);

II. Check for leaks. Low coolant level, throttle valve failure, exhaust fan failure, or blockage in the intercooler/radiator or other parts of the cooling system can cause high coolant temperature.

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