Diesel Generator Maintenance Guide (V1.

0) Secret

Diesel Generator Maintenance Guide

(V1.0)

Prepared by Zeng Jie (66228) Date 2007-09-21

Reviewed by Date

Reviewed by Guo Jianxiang (00123485) Date

Approved by Date

2007.9

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Revision History
Date Version Description Author

2007-9-21 1.0 First draft Zeng Jie

2008-3-10 1.0 Revised Zheng Shenyuan

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Contents

1 Objective.........................................................................................................................................4
2 Applicability Scope.......................................................................................................................5
3 Competency Requirements for Maintenance Engineers.......................................................6
4 Operation Guide............................................................................................................................7
4.1 Preparations.......................................................................................................................................................7
4.2 Monthly (or Pre-Operation) Check....................................................................................................................7
4.3 Replacement of Consumables..........................................................................................................................13
4.4 Site Clean-Up and Maintenance Record..........................................................................................................18

Appendix: Diesel Generator Maintenance Record.....................................................................19

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 Diesel Generator Maintenance Guide (V1.0) Secret

1 Objective

This document describes the contents, operation modes, and precautions for routine
maintenance of diesel generators. Field maintenance engineers should comply with this guide
to supply the maintenance service for diesel generators.

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2 Applicability Scope

This document applies to service delivery of diesel generator maintenance engineers. If a

customer does not purchase the diesel generator maintenance service from Huawei, this
document can be used as a reference for Huawei engineers to give suggestions on routine
maintenance of diesel generators to the customer.

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3 Competency Requirements for

Maintenance Engineers

Maintenance engineers should have a knowledge of components, working principles, and

basic maintenance of diesel generators. In addition, maintenance engineers should have
experience in maintaining diesel generators, such as replacing filters (including a lube oil
filter, a fuel filter, and an air filter), using common tools, and operating the related meters.

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4 Operation Guide

4.1 Preparations
No. Prepare Remarks

1 Goggles Checking the electrolyte level and the voltage of a battery

2 Protective gloves Checking engine oil, fuel, and antifreeze
3 Maintenance tools Routine maintenance

List of
Maintenance Tools for Diesel Generators.xls
Attachment:

4 Earplugs Protecting your ears during trial running of a diesel generator

5 Duster cloth Cleaning diesel generators after maintenance

4.2 Monthly (or Pre-Operation) Check

1. Fuel Tank (External Fuel Tank)

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To ensure that the fuel tank is clean, the fuel is sufficient, and the fuel pipe is in good
Objective
condition without block and leak.

 Ensure that no water, iron dust, or other

sediment exists in the fuel tank.
 Ensure that the fuel level reach at least 1/2 of
the capacity of the fuel tank.
Check Items
 Ensure that the fuel pipes are not leaky or
deformed.
 Ensure that the valve in the fuel pipe is in good
condition without rust and block.

 Remove the sediment from the fuel tank through the drain valve at the bottom of the
tank.
Exception  Fill the fuel tank (based on the fluid level gauge) and remove the overflowed diesel.
Handling
 Replace any leaky or deformed fuel pipe with a new one.
 Replace any rusty or blocked valve.
 No smoking when filling the fuel tank.
 You can replenish an external fuel tank but not a built-in one when the diesel
Precautions generator is running.
 0# or –10# diesel is recommended. –10# diesel should be used when the ambient
temperature is below 0°C.

2. Engine Oil

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To ensure that the engine oil is sufficient in

the total loss system, the lubrication system
Objective
works normally, and all mechanical parts
work well
 Ensure that the fuel level in the oil pan is
between ADD and FULL on the oil scale.
Check Items
 Touch the engine oil to check its
viscosity and observe its color.
 If the oil level is lower than the ADD
position, fill engine oil till the oil level is
Exception close to the FULL position.
Handling
 If the engine oil becomes thicker or
extremely thin, replace it with new oil.

A refers to the oil filler.

 Do not check the oil level when the
diesel generator is running.
 Drain the degraded oil after the diesel oil
has been running for 10 minutes. This
Precautions
speeds up the oil drainage.
 You should replace the degraded engine
oil with the engine oil of the same brand
and specification.
It is best that the oil level reaches position D
on the oil scale.

3. Cooling System

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Objective To ensure that the cooling system works normally

Check Items
 Ensure that the cooling water is sufficient.
 Ensure that the water pipes are not leaky.

 If the cooling water is not sufficient, fill the

water till the water level is 3 cm to 5 cm below
Exception the sealing cover.
Handling
 If any water pipe is leaky, fasten or replace the
connector.

 Do not open the filler on the water tank when the motor is hot or the pressure in the
water tank is high.
 Do not check the water level till 15 minutes after the generator stops.
Precautions  When you are filling water, air in the pipe cannot be removed at a time. Therefore,
you should fill water by stages. That is to say, wait for a moment after you fill some
water, and then fill water again. Repeat this process till you see the water level in the
inlet pipe.

4. Battery

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Objective To ensure that the battery works normally

 Check the electrolyte level of the battery.

 Test the density of the electrolyte of the battery by using
Check Items a densimeter. The best density is 1.28.
 Ensure that the wiring terminals are free of rust and the
wiring is correct.

 Fill distilled water or purified water till the level exceeds the pole plate by 5 cm to 10
cm.
Exception  Recharge the battery or check the charger in the case of low battery.
Handling
 Polish the rusty wiring terminals by using a sand paper and then apply oil to the
wiring terminals. Fasten the connected wires if necessary.
 Keep the battery away from any sparkle or flame, because the volatile gas of the
electrolyte is flammable.
 Mis-connected polarities of a battery will damage the electrical system and the
battery.
Precautions
 For an automatic start generator set, ensure that the start switch is off; otherwise, the
generator set might suddenly starts.
 When removing a battery, disconnect the cathode and then the anode. When installing
a battery, connect the anode and then the cathode.

5. Fan Belt and Driving Belt

To ensure that the belts are not loosened, aged, or broken
Objective
A loosened, aged, or broken belt is loosened degrades heat dissipation.
 Check the tightness of the fan belt.
Check Items  Check the tightness of the driving belt.
 Ensure that no belt is aged and no crack exists on the surface of any belt.
 Tighten the loosened fan belt by using the automatic tightener.
Exception  Remove the fastening screw before tightening the driving belt. Tighten the driving
Handling belt till you can press down the belt by about 10mm.
 Replace a belt on which cracks exist.
 Replace all worn belts in pairs.
Precautions
 Replace any belt with a new belt of the same specification.

6. ATS and ACDB

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Objective To ensure that both the ATS and the ACDB work normally

 Ensure that the power and signal cables connecting the diesel generator, ATS, and
ACDB are firmly connected.
Check Items  Ensure that no electrical part is burned out.
 Ensure that the diesel generator, ATS, and ACDB are well grounded.
 Fasten any loosened cables.
Exception  Replace any burned electrical parts.
Handling
 Fasten all grounding cables.

Precautions Ensure that the diesel generator, ATS, and ACDB are well grounded

7. Protective Cover, Screws, and Nuts

Objective To ensure that the protective cover and all screws and nuts are firmly fixed

Check Items Ensure that the protective cover and all screws and nuts are firmly fixed.

Exception
Fasten the loosened protective cover and all loosened screws and nuts.
Handling

Precautions Do not start the engine if no protective cover is installed.

8. Running Test

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 To ensure that the diesel generator can work normally after a basic check
 To ensure that a diesel generator that has not worked for a long time (within two
Objective
weeks) can start in the case of emergency power supply
 To ensure that the diesel generator, ATS, and ACDB can work normally
 Check all parameters displayed on the control panel, including the revolutions,
voltage, current, frequency, oil pressure, and water temperature.
 Ensure that the diesel generator is free of leakage (fuel, water, or air).
Check Items  Ensure that all joints are firmly connected and the diesel generator does not vibrate
greatly.
 Ensure that the ATS can automatically start and stop the diesel generator and that the
ATS can switch over power supply.
 Shut down the diesel generator in the case of any exception.
 Search for the reason immediately or turn to the technical support engineers in the
case of any exceptional parameter.
 Check all pipes and connectors and replace or fasten any loosened connectors in the
Exception
case of leakage (oil, water, or air).
Handling
 In the case of exceptional vibration of the diesel generator, find out and fasten the
loosened joints.
 Locate the reason immediately or turn to the Technical Support if the ATS is in an
exceptional state.

4.3 Replacement of Consumables

The replacement frequency of consumables described in this document refers to a practice in
the industry and is for reference only. Maintenance engineers can adjust the replacement
frequency based on the environment and the operation of the diesel generator.
Do not replace any consumables when the diesel generator is running.
9. Engine Oil

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Replace the engine oil after the first 50-hour operation, and then replace it once every
Frequency
250-hour operation (or quarterly).

 Run the diesel generator

without any load for 10
minutes before draining the
original engine oil (to speed
up the drainage).
Operating  Remove the drain plug to
Procedure drain the original engine oil,
and then insert the plug.
 Fill new engine oil through
the oil filler till the oil is The position that the arrowhead points to is the drain
close to the upper limit plug. The drain plug varies slightly with oil pan
specified by the oil scale. models.
 Replace engine oil with new engine oil of the same or a higher SAE/API grade.
 After filling engine oil, measure the engine oil with an oil scale and ensure that the oil
Service Standards level is close to the upper limit position on the oil scale.
 After replacement of the engine oil, the oil pressure should be in the allowed range
when the diesel generator is running.

 Replace the oil filter when replacing engine oil.

Precautions
 The oil level should not exceed the upper limit position on the oil scale.

10. Oil Filter

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Replace the oil filter after the first 50-hour operation, and then replace it once every
Frequency
250-hour operation (or quarterly).

 Remove the oil filter with a belt wrench.

 Ensure that the new filter is equipped
with a new sealing ring. Clean the
contact surface and fill the new filter
with engine oil of the specified grade.
Operating Apply engine oil to the sealing ring.
Procedure Screw the new filter to the original
position, and then further fasten it by
two-third circle.
 After replacing the oil filter, run the
diesel generator for 10 minutes and
ensure that no oil leakage exists.

 Replace the original oil filter with a new one and ensure that no oil leakage exists
when the diesel generator is running.
Service Standards
 After replacement of the oil filter, the oil pressure should be in the allowed range
when the diesel generator is running.
 Replace engine oil when replacing the oil filter.
 Use a new sealing ring when replacing an oil filter.
Precautions
 Do not fasten the oil filter too tightly. If the oil filter is fastened too tightly, oil
leakage might exist because the sealing ring is deformed and damaged.

11. Fuel Filter

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Frequency Replace the fuel filter once every 250-hour operation (or quarterly).

 Remove the fuel filter with a belt wrench.

 Ensure that the new filter is equipped with a new sealing ring. Clean the contact
surface and fill the new filter with diesel of the specified grade. Install the new filter
to the original position.
 Remove air from the fuel pipes (the low pressure pipe and then the high pressure one)
by using a hand pump. See the following figure.

Operating
Procedure

 After replacing the oil filter, run the diesel generator for 10 minutes. If air exists in
the fuel system, remove the air by using the fuel pump before starting the diesel
generator.
 Replace the original fuel filter with a new one and ensure that no leakage exists when
the diesel generator is running.
Service Standards
 After replacement of the fuel filter, the diesel generator works normally at a
satisfactory speed.
 Replace the fuel filter when the engine is cooled. Do not spray any diesel to the
exhaust pipe.
Precautions
 Use a new sealing ring when replacing the fuel filter. Do not fasten the filter too
tightly.

12. Air Filter

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Replace the air filter once every 500 hours or when the indicator of the air filter turns
Frequency
red.

 Check the indicator of the air filter. If

the alarm system turns red, it means that
Operating the air filter needs to be replaced.
Procedure  Open the air filter, and then replace the
cartridge. Press the button on the top to
reset the indicator.

Indicator of an air filter

Service Standards Replace the cartridge with a clean new one of the same specification.

Precautions Do not start a turbocharged engine if no air filter is installed.

13. Cooling Water Filter

Frequency Replace the cooling water filter once every 500-hour operation (or quarterly).

 Close the water inlet, and then remove the filter with a belt wrench.
 Ensure that the new filter is equipped with a new sealing ring. Clean the contact
Operating
surface. Screw the new filter to the original position, and then further fasten it by two-
Procedure
third circle.
 Open the water inlet.

Replace the original water filter with a new one and ensure that no leakage exists when
Service Standards
the diesel generator is running.

 Replace the fuel filter when the engine is cooled to avoid scald.
Precautions  Use a new sealing ring when replacing the water filter. Do not fasten the filter too
tightly.

14. Cooling Water

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Frequency Replace the cooling water once every 1000-hour operation (or annually).

 Remove the upper cover from the water tank. Open the drain valve at the bottom of
Operating the water tank and ensure the water outlet is unblocked. Drain the cooling water,
Procedure wash the cooling system with clean water, and then close the drain valve.
 Fill the water tank with cooling water, and then cover the water tank.

The cooling water level should be 5cm lower than the sealing surface of the sealing
Service Standards
cover.

 Do not remove the upper cover from the water tank within 15 minutes upon shutdown
of the diesel generator.
Precautions
 Do not fill the cooling system with any sea water, electrolyte, or other corrosive
matters.

15. Running Test

After replacing consumables, run the diesel generator to check its working status. Ensure that
the diesel generator is free of leakage (oil, water, or air) and all working parameters are
normal. The running test verifies that the diesel generator can work normally after
maintenance.

4.4 Site Clean-Up and Maintenance Record

After maintenance of a diesel generator, clean the site, diesel generator, and tools. In addition,
make a maintenance record signed by both the maintenance party and the supervisor (or the
customer).

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Appendix: Diesel Generator Maintenance

Record

Diesel Generator
Maintenance Record.xls

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