Generator Maintenance Knowledge:
1. Water enters the diesel engine due to condensation of moisture in the air as temperatures change, forming water droplets that adhere to the inner wall of the fuel tank and mix with the diesel. This results in diesel exceeding the water content limit, and when this diesel enters the engine's high-pressure fuel pump, it can corrode the precise coupling parts - the plungers. In severe cases, it can damage the unit. Regular inspections and maintenance are effective in preventing this.
2. The generator set's starting battery failed to start due to long-term neglect. The electrolyte fluid in the battery evaporated without timely replenishment, and there was no charger for the starting battery. After prolonged natural discharge, the battery's power decreased. Alternatively, the charger used required manual periodic switching between equalizing and float charging. Neglecting to perform this switch operation resulted in the battery's power not reaching the required level. To resolve this issue, in addition to installing a high-quality charger, necessary inspections and maintenance are essential.
3. Replacement cycle for filter elements and filters (diesel, engine, air, water filters). Filters serve to filter diesel, engine oil, or water to prevent impurities from entering the engine. Since oil and impurities are inevitably present in diesel, filters play a crucial role during operation. However, these impurities or oil residues accumulate on the filter wall, reducing the filter's efficiency. Excessive accumulation can block the oil passages, causing the oil-powered machine to shut down due to insufficient oil supply, akin to a person suffocating. Therefore, we recommend for normal generator sets: 1. Replace the three filters every 500 hours for regular operation; 2. Replace the three filters every two years for standby operation.
4. Engine Oil Shelf Life (two years): Engine oil serves as mechanical lubrication, and it also has a shelf life. Over extended storage, the physical and chemical properties of the oil can change, leading to poor lubrication during operation and potentially causing damage to the equipment's components. Therefore, it is necessary to regularly replace the lubricating oil.
5. Fuel and air supply systems: The output of engine power primarily results from the combustion of fuel inside the cylinders, which is ejected through喷油嘴 (injection nozzles). This causes carbon deposits to accumulate on the nozzles after combustion, affecting the fuel injection amount as the deposits increase. Consequently, the timing of the ignition angle of the nozzles becomes inaccurate, leading to uneven fuel injection among the engine cylinders and an unstable operating state. Therefore, regular cleaning of the fuel system and replacement of filter components ensure smooth fuel supply. Additionally, adjusting the air supply system ensures uniform ignition.
6. The cooling system, pump, water tank, and water supply pipes have not been cleaned for a long time, leading to poor water circulation and reduced cooling efficiency. Check if the pipe joints are in good condition, if there are any leaks in the water tank or water channels. If there are faults in the cooling system, the consequences may include: 1. Poor cooling performance causing the internal temperature of the unit to rise excessively and resulting in shutdown, a common issue with Weilex units; 2. Water leakage from the tank causing the water level to drop, which can prevent the unit from operating normally (To prevent pipe freezing during winter generator use, we recommend installing a water heater in the cooling system).
7. Lubrication systems and seals are compromised due to the chemical properties of lubricants or oils and iron shavings produced from mechanical wear. This not only diminishes their lubricating efficiency but also accelerates the damage to components. Additionally, the lubricant has a certain corrosive effect on rubber seals, and the oil seals themselves age over time, further reducing their sealing effectiveness.
8. The control section of the unit, including the engine control section, is a crucial part of unit maintenance. Over time, unit usage can lead to loose wiring connections, and it's important to check if the AVR module is functioning properly.
