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Secret
Date
Reviewed by
Reviewed by
2007-09-21
Date
Date
Approved by
Date
2007.9
2015-7-11
Huawei Confidential
Page 1 of 19
Secret
Revision History
Date
Version
Description
Author
2007-9-21
1.0
First draft
Zeng Jie
2008-3-10
1.0
Revised
Zheng Shenyuan
2015-7-11
Huawei Confidential
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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
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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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Applicability Scope
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Operation Guide
4.1 Preparations
No.
Prepare
Remarks
Goggles
Protective gloves
Maintenance tools
Routine maintenance
Attachment:
List of
Maintenance Tools for Diesel Generators.xls
Earplugs
Duster cloth
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Objective
To 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
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.
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.
Exception
Handling
Precautions
2.
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Engine Oil
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Objective
Check
Items
Exception
Handling
Precaution
s
Secret
3.
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Cooling System
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Objective
Check Items
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.
Exception
Handling
Precautions
4.
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Battery
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Objective
Check Items
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.
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.
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.
Exception
Handling
Precautions
5.
Objective
Check Items
Ensure that no belt is aged and no crack exists on the surface of any belt.
Remove the fastening screw before tightening the driving belt. Tighten the driving
belt till you can press down the belt by about 10mm.
Exception
Handling
Precautions
6.
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Objective
To 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 the diesel generator, ATS, and ACDB are well grounded.
Exception
Handling
Precautions
Ensure that the diesel generator, ATS, and ACDB are well grounded
7.
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
Handling
Fasten the loosened protective cover and all loosened screws and nuts.
Precautions
8.
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Running Test
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Objective
Check Items
Exception
Handling
Secret
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 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.
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.
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Engine Oil
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Frequency
Replace the engine oil after the first 50-hour operation, and then replace it once every
250-hour operation (or quarterly).
Operating
Procedure
Service
Standards
Precautions
2.
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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.
The oil level should not exceed the upper limit position on the oil scale.
Oil Filter
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Frequency
Replace the oil filter after the first 50-hour operation, and then replace it once every
250-hour operation (or quarterly).
Operating
Procedure
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.
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.
Service
Standards
Precautions
3.
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Fuel Filter
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Frequency
Replace the fuel filter once every 250-hour operation (or quarterly).
Operating
Procedure
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.
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.
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.
Service
Standards
Precautions
4.
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Air Filter
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Frequency
Replace the air filter once every 500 hours or when the indicator of the air filter turns
red.
Operating
Procedure
Replace the cartridge with a clean new one of the same specification.
Precautions
5.
Frequency
Replace 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 twothird circle.
Service
Standards
Replace 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.
6.
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Cooling Water
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Frequency
Replace 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
Standards
The 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.
7.
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.
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Diesel Generator
Maintenance Record.xls
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