Alternator Fault Resolution and Generator Set Maintenance Level

3. Alternator

External physical faults (overheating, vibration, abnormal noise).

4. Start-up battery

5.Introduction to maintenance level of generator set

Level A maintenance (daily maintenance)

1. Check the daily report of generator operation.

2. Check the oil level and coolant level of the generator.

3. Daily check the generator for damage, leakage and whether the belt is loose or worn.

4. Check the air filter, clean the air filter core and replace it if necessary.

5. Drain water or sediment from fuel tank and fuel filter.

6. Check the water filter.

7. Check the starting battery and battery fluid, and add supplementary fluid if necessary.

8. Start the generator and check for abnormal noise.

9. Clean the dust of water tank, cooler and cooling net with air gun.

Level B maintenance

1. Repeat the daily inspection of level A.

2. Replace the diesel filter every 100 to 250 hours. All diesel filters cannot be cleaned, but can only be replaced. 100 to 250 hours is only a flexible time and must be replaced according to the actual cleanliness of diesel.

3. Replace the generator oil and oil filter every 200 to 250 hours. The engine oil shall comply with API CF grade or above.

4. Replace the air filter (the unit operates for 300-400 hours). Pay attention to the environment of the machine room and decide the time to replace the air filter. The filter can be cleaned with an air gun.

5. Replace the water filter and add DCA concentration.

6. Clean the filter screen of crankcase breather valve.

Level C Maintenance

When the unit operates for 2000-3000 hours, please carry out the following work:

Repeat level A and B maintenance.

1. Remove the valve cover and clean the oil stain and sludge.

2. Tighten all screws (including running part and fixing part).

3. Clean the axle box, oil sludge, iron filings and deposits with engine Jieba.

4. Check the wear degree of turbocharger, clean the carbon deposit and adjust it if necessary.

5. Check and adjust valve clearance.

6. Check the working conditions of PT pump and fuel injector, adjust the stroke of fuel injector and adjust it if necessary.

7. Check and adjust the tightness of fan belt and water pump belt, and adjust or replace it if necessary. Check the cooling net of the box and check the service performance of the thermostat.

Minor repair (i.e. level D maintenance) (3000-4000 hours)

1. Check the wear degree of valve and valve seat, and repair or replace it if necessary.

2. Check the P pump, the fuel injection quality is good, and repair and adjust it if necessary.

3. Check and adjust the torque of connecting rod and fastening screws.

4. Check and adjust valve clearance.

5. Adjust the fuel injector stroke.

6. Check and adjust the tension of fan and charger belts.

7. Clean the carbon deposit on the air inlet branch pipe.

8. Clean intercooler core.

9. Clean the whole oil lubrication system.

10. Clean the oil sludge and metal iron filings in the rocker arm chamber and oil pan.

Intermediate repair (6000-8000 hours)

1. Including minor repair items.

2. Check cylinder liner, piston, piston ring, intake and exhaust valve and other crank connecting rod mechanism, valve distribution mechanism and lubrication vulnerable parts of system and cooling system shall be replaced if necessary.

3. Check the fuel supply system and adjust the oil pump nozzle.

5. Repair and test the electric ball of the generator, clean the oil and sediment, and lubricate the electric ball bearing.

Overhaul (9000-15000 hours)

1. Including intermediate repair items.

2. Disassemble all engines.

3. Replace the cylinder block, piston, piston ring, large and small bearing shells, crankshaft thrust pad, intake and exhaust valve and complete set of engine

Engine overhaul package;

4. Adjust the oil pump and fuel injector, and replace the pump core and fuel injection head.

5. Replace the supercharger overhaul kit and water pump repair kit.

6. Correct the connecting rod, crankshaft, engine body and other components, and repair or replace them if necessary.