Diesel Generator Maintenance Guide (V1.0)

Diesel Generator Maintenance Guide (V1.0)Secret

Diesel Generator Maintenance Guide

(V1.0)Prepared byZeng Jie (66228)Date2007-09-21

Reviewed byDate

Reviewed byGuo Jianxiang (00123485)Date

Approved byDate

2007.9

Revision HistoryDateVersionDescriptionAuthor

2007-9-211.0First draftZeng Jie

2008-3-101.0RevisedZheng Shenyuan

Contents41 Objective

52 Applicability Scope

63 Competency Requirements for Maintenance Engineers

74 Operation Guide

74.1 Preparations

74.2 Monthly (or Pre-Operation) Check

134.3 Replacement of Consumables

184.4 Site Clean-Up and Maintenance Record

19Appendix: Diesel Generator Maintenance Record

1 ObjectiveThis 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.

2 Applicability ScopeThis 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.

3 Competency Requirements for Maintenance EngineersMaintenance 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.

4 Operation Guide4.1 PreparationsNo.PrepareRemarks

1GogglesChecking the electrolyte level and the voltage of a battery

2Protective glovesChecking engine oil, fuel, and antifreeze

3Maintenance toolsRoutine maintenanceAttachment:

4EarplugsProtecting your ears during trial running of a diesel generator

5Duster clothCleaning diesel generators after maintenance

4.2 Monthly (or Pre-Operation) Check1. Fuel Tank (External Fuel Tank)ObjectiveTo ensure that the fuel tank is clean, the fuel is sufficient, and the fuel pipe is in good condition without block and leak.

Check Items 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.

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.

Exception Handling Remove the sediment from the fuel tank through the drain valve at the bottom of the tank.

Fill the fuel tank (based on the fluid level gauge) and remove the overflowed diesel.

Replace any leaky or deformed fuel pipe with a new one.

Replace any rusty or blocked valve.

Precautions No smoking when filling the fuel tank.

You can replenish an external fuel tank but not a built-in one when the diesel generator is running.

0# or 10# diesel is recommended. 10# diesel should be used when the ambient temperature is below 0C.

2. Engine OilObjectiveTo ensure that the engine oil is sufficient in the total loss system, the lubrication system works normally, and all mechanical parts work well A refers to the oil filler.

It is best that the oil level reaches position D on the oil scale.

Check Items Ensure that the fuel level in the oil pan is between ADD and FULL on the oil scale.

Touch the engine oil to check its viscosity and observe its color.

Exception Handling If the oil level is lower than the ADD position, fill engine oil till the oil level is close to the FULL position.

If the engine oil becomes thicker or extremely thin, replace it with new oil.

Precautions 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 speeds up the oil drainage.

You should replace the degraded engine oil with the engine oil of the same brand and specification.

3. Cooling SystemObjectiveTo ensure that the cooling system works normally

Check Items Ensure that the cooling water is sufficient.

Ensure that the water pipes are not leaky.

Exception Handling If the cooling water is not sufficient, fill the water till the water level is 3 cm to 5 cm below the sealing cover.

If any water pipe is leaky, fasten or replace the connector.

Precautions 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.

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. BatteryObjectiveTo ensure that the battery works normally

Check Items Check the electrolyte level of the battery.

Test the density of the electrolyte of the battery by using a densimeter. The best density is 1.28.

Ensure that the wiring terminals are free of rust and the wiring is correct.

Exception Handling Fill distilled water or purified water till the level exceeds the pole plate by 5 cm to 10 cm.

Recharge the battery or check the charger in the case of low battery.

Polish the rusty wiring terminals by using a sand paper and then apply oil to the wiring terminals. Fasten the connected wires if necessary.

Precautions 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.

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 BeltObjectiveTo ensure that the belts are not loosened, aged, or brokenA loosened, aged, or broken belt is loosened degrades heat dissipation.

Check Items Check the tightness of the fan belt.

Check the tightness of the driving belt.

Ensure that no belt is aged and no crack exists on the surface of any belt.

Exception Handling Tighten the loosened fan belt by using the automatic tightener.

Remove the fastening screw before tightening the driving belt. Tighten the driving belt till you can press down the belt by about 10mm.

Replace a belt on which cracks exist.

Precautions Replace all worn belts in pairs.

Replace any belt with a new belt of the same specification.

6. ATS and ACDBObjectiveTo ensure that both the ATS and the ACDB work normally

Check Items Ensure that the power and signal cables connecting the diesel generator, ATS, and ACDB are firmly connected.

Ensure that no electrical part is burned out.

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

Exception Handling Fasten any loosened cables.

Replace any burned electrical parts.

Fasten all grounding cables.

PrecautionsEnsure that the diesel generator, ATS, and ACDB are well grounded

7. Protective Cover, Screws, and NutsObjectiveTo ensure that the protective cover and all screws and nuts are firmly fixed

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

Exception HandlingFasten the loosened protective cover and all loosened screws and nuts.

PrecautionsDo not start the engine if no protective cover is installed.

8. Running TestObjective 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 weeks) can start in the case of emergency power supply

To ensure that the diesel generator, ATS, and ACDB can work normally

Check Items 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).

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.

Exception Handling 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 case of leakage (oil, water, or air).

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

Operating Procedure Run the diesel generator without any load for 10 minutes before draining the original engine oil (to speed up the drainage).

Remove the drain plug to drain the original engine oil, and then insert the plug.

Fill new engine oil through the oil filler till the oil is close to the upper limit specified by the oil scale.

The position that the arrowhead points to is the drain plug. The drain plug varies slightly with oil pan models.

Service Standards 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 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.

Precautions Replace the oil filter when replacing engine oil.

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

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

Operating Procedure 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. Apply engine oil to the sealing ring. 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.

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

After replacement of the oil filter, the oil pressure should be in the allowed range when the diesel generator is running.

Precautions Replace engine oil when replacing the oil filter.

Use a new sealing ring when replacing an oil filter.

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

Operating Procedure 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.

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.

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

After replacement of the fuel filter, the diesel generator works normally at a satisfactory speed.

Precautions Replace the fuel filter when the engine is cooled. Do not spray any diesel to the exhaust pipe.

Use a new sealing ring when replacing the fuel filter. Do not fasten the filter too tightly.

12. Air FilterFrequencyReplace the air filter once every 500 hours or when the indicator of the air filter turns red.

Operating Procedure Check the indicator of the air filter. If the alarm system turns red, it means that the air filter needs to be replaced.

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 StandardsReplace the cartridge with a clean new one of the same specification.

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

13. Cooling Water FilterFrequencyReplace the cooling water filter once every 500-hour operation (or quarterly).

Operating Procedure 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 surface. Screw the new filter to the original position, and then further fasten it by two-third circle.

Open the water inlet.

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

Precautions Replace the fuel filter when the engine is cooled to avoid scald.

Use a new sealing ring when replacing the water filter. Do not fasten the filter too tightly.

14. Cooling WaterFrequencyReplace the cooling water once every 1000-hour operation (or annually).

Operating Procedure Remove the upper cover from the water tank. Open the drain valve at the bottom of the water tank and ensure the water outlet is unblocked. Drain the cooling water, 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.

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

Precautions Do not remove the upper cover from the water tank within 15 minutes upon shutdown of the diesel generator.

Do not fill the cooling system with any sea water, electrolyte, or other corrosive matters.

15. Running TestAfter 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 RecordAfter 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).Appendix: Diesel Generator Maintenance Record

2008-4-26Huawei ConfidentialPage 7 of 19

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List of Maintenance Tools for Diesel Generators

No.Tool NameSpecification

1Tool box

2Vigorous plier7"

3cutting pliers

4flat nose pliers

5Belt wrench

6monkey wrench8"

7Solid wrench17mm

8Solid wrench15mm

9Solid wrench14mm

10Solid wrench13mm

11Solid wrench12mm

12Solid wrench11mm

13Solid wrench10mm

14Solid wrench8mm

15hammer

16Cinquefoil screwdriver4"

17Cinquefoil screwdriver6"

18screwdriver4"

19screwdriver6"

20Hex tools334-4"

21Sleeve wrench28 sets

22Multimeter

23Float level gauge

24Oil scale

25Densimeter

26Sand paper

27Goggles

28Protective gloves

29Earplug

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OSP Maintenance Record

Site NameSite ID

AddressProduct TypeDiesel Generator

ID of Diesel Generator 1Model of Diesel Generator 1

ID of Diesel Generator 2Model of Diesel Generator 2

CheckerDate

Check ItemDescriptionCheck RecordHandling ResultRemarks

PatrolFuel tank1.Ensure that no water, iron dust, or other sediment exists in the fuel tank.YES NO

2. Ensure that the fuel level reach at least 1/2 of the capacity of the fuel tank.YES NO

3. Ensure that the fuel pipes are not leaky or deformed.YES NO

4. Ensure that the valve in the fuel pipe is in good condition without rust or block.YES NO

Engine oil1. Ensure that the fuel level in the oil pan is between ADD and FULL on the oil scaleYES NO

2. Check viscosity and color of engine oil.YES NO

Cooling system1. Ensure that the cooling water is sufficient.YES NO

2. Ensure that the water pipes are not leaky.YES NO

Battery1. Check the electrolyte level of the battery.YES NO

2. Test the density of the electrolyte of the battery by using a densimeter.YES NO

3. Ensure that the wiring terminals are free of rust and the wiring is correct.YES NO

Fan belt and driving belt1. Check the tightness of the fan belt.YES NO

2. Check the tightness of the driving belt.YES NO

3. Ensure that no belt is aged and no crack exists on the surface of any belt.YES NO

ATS and ACDB1. Ensure that the power and signal cables connecting the diesel generator, ATS, and ACDB are firmly connected.YES NO

2. Ensure that no electrical part is burned out.YES NO

3. Ensure that the diesel generator, ATS, and ACDB are well grounded.YES NO

Component fasteningEnsure that the protective cover and all screws and nuts are firmly fixed.YES NO

Running test1. Check all parameters displayed on the control panel, including the revolutions, voltage, current, frequency, oil pressure, and water temperature.YES NO

2. Ensure that the diesel generator is free of leakage (fuel, water, or air).YES NO

3. Ensure that all joints are firmly connected and the diesel generator does not vibrate greatly.YES NO

4. Ensure that the ATS can automatically start and stop the diesel generator and can switch over power supply.YES NO

Replacement of consumablesEngine oil1. Run the diesel generator without any load for 10 minutes before draining the original engine oil (to speed up the drainage). Remove the drain plug to drain the original engine oil, and then insert the plug.YES NO

2. Fill new engine oil through the oil filler till the oil is close to the upper limit specified by the oil scale.YES NO

Oil filter1. Remove the oil filter with a belt wrench.YES NO

2. 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. Apply engine oil to the sealing ring. Screw the new filter to the original position, and then further fasten it by two-third circle.YES NO

3. After replacing the oil filter, run the diesel generator for 10 minutes. Ensure that no oil leakage exists and the oil pressure is normal.YES NO

Fuel filter1. Remove the fuel filter with a belt wrench when the diesel generator is cooled.YES NO

2. 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.YES NO

3. 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.YES NO

Air filterWhen the diesel generator is not running, open the air filter, and then replace the cartridge. Press the button on the top to reset the indicator.YES NO

Cooling water filter1. Close the water inlet, and then remove the filter with a belt wrench.YES NO

2. Ensure that the new filter is equipped with a new sealing ring. Clean the contact surface. Screw the new filter to the original position, and then further fasten it by two-third circle.YES NO

3. Open the water inlet.YES NO

Cooling water1. Remove the upper cover from the water tank. Open the drain valve at the bottom of the water tank and ensure the water outlet is unblocked. Drain the cooling water, wash the cooling system with clean water, and then close the drain valve.YES NO

2. Fill the water tank with cooling water, and then cover the water tank.YES NO

Running testAfter 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.YES NO

Maintenance Suggestions(Briefly describe the check, including all disclosed problems, their causes, corrective measures, and preventive suggestions.)

SignaturesMaintenance Party (signature and date) Huawei (signature and date)

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