Why is regular maintenance required for diesel generators?
Regular maintenance is a fundamental and crucial method, as the unit remains stationary for extended periods, causing various materials within the unit to undergo complex chemical and physical changes with engine oil, coolant, diesel, and air, which can ultimately lead to the unit "breaking down."
1. Engine start battery failure: The battery has been neglected for an extended period without proper maintenance. After the electrolyte moisture has evaporated, it was not replenished in time. No charger for the start battery was provided, leading to a decrease in battery power due to prolonged natural discharge. Additionally, the charger in use may require manual periodic switching between equalizing and floating charge modes. Omission of this switching operation due to oversight resulted in the battery power not meeting the required standards. To resolve this issue, in addition to using a high-quality charger, necessary testing and maintenance are essential.
2. Water enters the diesel engine due to condensation of water vapor in the air as temperatures change, forming water droplets that adhere to the inner wall of the fuel tank and flow into the diesel. This causes the diesel to exceed the allowable water content, and when this contaminated diesel enters the engine's high-pressure fuel pump, it can corrode the precise coupling parts—pistons, leading to severe damage to the unit. Regular maintenance can effectively prevent this.
3. Oil Change Interval (Two Years) – Engine oil serves as mechanical lubrication and has a certain shelf life. Over time, stored oil can undergo physical and chemical changes, leading to deterioration in lubrication during operation and an increased risk of component damage. Therefore, it is necessary to regularly replace the lubricating oil.
4. Replacement Cycle of the Three Filters (Diesel Filter, Engine Oil Filter, Air Filter, Water Filter): Filters serve to filter diesel, engine oil, or water to prevent impurities from entering the engine. Since oil contamination and impurities are inevitable in diesel, filters play a crucial role during the operation of the unit. However, these impurities or contaminants also accumulate on the filter screen walls, reducing the filtering capacity of the filters. Excessive accumulation can lead to a blocked oil path, causing the oil machine to shut down due to insufficient oil supply, akin to human oxygen deprivation. Therefore, during the operation of normal generators, we recommend: 1. Replace the three filters for the regular units every 500 hours; 2. Replace the three filters for the standby units every two years.
5. Long-term lack of cleaning for the cooling system pump, water tank, and water supply pipes results in poor water circulation and reduced cooling efficiency. Check for proper connections at the pipe joints, leaks in the water tank and channels. If there are issues with the cooling system, the consequences may include: 1. Poor cooling performance leading to excessive internal temperatures in the equipment and subsequent shutdown, a common issue with Weilex units; 2. Water leakage from the tank causing a drop in water level, which can also lead to the equipment failing to operate normally (To prevent pipe freezing during winter generator use, we recommend installing a water heater in the cooling system).
6. The lubrication system and seals degrade due to the chemical properties of lubricants or oils and the iron shavings produced from mechanical wear. This not only reduces their lubricating efficiency but also accelerates the damage to the components. Additionally, the lubricant has a certain corrosive effect on rubber seals, and the seals themselves age over time, further diminishing their sealing performance.
7. The output of engine power in fuel and gas systems primarily results from the combustion of fuel within the cylinders, which is ejected through injectors. This leads to carbon deposits accumulating on the injectors after combustion. As the deposits increase, the fuel injection rate is affected, causing the injector ignition timing to be inaccurate and resulting in uneven fuel injection among the engine cylinders. This leads to an unstable operating condition. Therefore, regular cleaning of the fuel system and replacement of filter components ensure smooth fuel supply. Adjusting the gas distribution system ensures uniform ignition.
8. The control section of the unit; the engine's control section is also a crucial part of the unit's maintenance. With extended use, wire connections may loosen, and the AVR module's operation must be verified for proper functionality.
