新买的柴油发电机组该如何保养 How to maintain a newly purchased diesel generator set

柴油发电机组广泛应用于工业、商业、学校、医院等中小型企业长期(临时)用电；发电机组、工程机械、船舶用等各种固定动力。在柴油机汽缸内，经过空气滤清器过滤后的洁净空气与喷油嘴喷射出的高压雾化柴油充分混合，在活塞上行的挤压下，体积缩小，温度升高，达到了柴油的燃点。柴油被点燃，混合气体剧烈燃烧，体积迅速膨胀，推动活塞下行，称为作功。各汽缸按一定顺序依次作功，作用在活塞上的推力经过连杆变成了推动曲轴转动的力量，从而带动曲轴旋转。

一台新购买的柴油发电机组要如何保养呢？下面给您具体分析一下保养的重要性：

一、新柴油发电机的保养:

1、在轻负荷下(一般2~3马力)运转20小时。

2、运转20小时后。检查和拧紧气缸盖螺母(冷车时检查)

3、新柴油发电机运转50小时后，应做如下工作。

    （1）、用清洁柴油机和毛刷冲刷曲轴箱，并更换机油。

    （2）、用清洁柴油或煤油刷洗机油滤清器。

二、8小时保养:

1、柴油机运转8小时后，应停车检查机油量，不足时要加足。

2、检查机器外部有无漏油及螺钉松动现象，如有，应消除。

3、清除进风口和散热片间堵塞的杂物。

4、确保机器外表清洁。

5、拆下气门室盖，在进气门摇臂和排气门摇臂的油孔处加少量机油。

三、100小时保养:

1、清洗油箱滤环。

2、清洗柴油滤芯部件及空气滤芯部件、并从里向外吹气(或用气筒打气)，或用软毛刷刷除表面积污。如滤芯纸破损或滤芯端盖脱胶应予更换。在恶劣环境下工作，应增加清洗和更换次数。

3、检查和调整气门间隙。

4、清洗曲轴箱:

（1）、停车后趋热放尽机油。

（2）、用清洁柴油清洗曲轴箱。

5、拆下齿轮室盖和油底壳，用清洁柴油或煤油清洗机油集油器，若滤网破损应予更换。

6、装上油底壳齿轮室盖及观察孔盖，加入新机油。

四、500小时保养:

除完成100小时保养项目外，还需进行下列工作。

1、清洗柴油箱和油箱开关，并清洗曲轴箱内油道。

2、清除排气管积炭。

3、（A）、清洗甩油圈和曲轴连杆上的润滑油孔

  （B）、拧下曲轴油塞，清洗连杆内颈曲轴油道。

4、清洗轴承座及油道。

5、清洗没管油路，用打气筒打气或用铅丝桶油路。

6、清洗气缸盖、摇臂轴座、摇臂轴及排气摇臂的油路。

7、检查清洗喷油嘴:

（1）、检查喷油器的喷雾质量，如喷出的燃油不成细雾状或喷孔积炭油咀咬死等，应清洗喷油咀偶件。若喷油咀偶件配合过松，则应更换。

（2）、拆下喷油咀偶件，从针阀体中抽出针阀。如喷油咀偶件不能从紧帽中取出时，可先抽出针阀，垫上木块，敲出针阀体。当针阀不易抽出时，可用钢丝钳衬了布将针阀夹住轻轻拔出，防止擦毛。

（3）、如针阀体喷孔堵塞，可用针来疏通。

（4）、清除针阀上的积炭。

（5）、用清洁柴油清洗针阀和针阀体。

（6）、喷油咀有滴油现象时，应抽出针阀，在封面上涂少量机油(或牙膏)来回研磨几下。然后清洗一遍。

（7）、检查喷油咀的喷油质量。喷油应呈雾状，喷口周围无滴油现象。

8、检查气门与气门座的密封性:

（1）、拆下气缸盖。

（2）、用柴油或煤油注入进排气道，如气门与气门座之间有渗漏，应拆下气门研磨。

（3）、刮除气门和气缸盖上的积炭。

（4）、研磨气门锥面上涂些研磨膏，用气门研磨工具进行研磨。研磨时使气门在气门座上来回转动以及上下不断敲打，直到接触面上出现无光泽的整圈密封线为止。

9、检查活塞环:

（1）、拆下活塞连杆组件和活塞环。刮除活塞顶部及环槽底部积炭，并在清洁和柴油中清洗干净。

（2）、刮除活塞环上的积炭，并用清洁柴油清洗干净。

（3）、刮除气缸套前部的积炭，再在清洁的柴油中清洗干净。

（4）、将活塞环推入气缸套的尾端，用厚薄规测量其开口间隙超过最大许用值25mm应更换新环。

五、1000~1500小时的保养:

         （1）、做好500小时保养的全部内容

  （2）、按另件的配合间隙和磨损极限表检查，超过磨损极限的另件应更换。

（3）、更换柴油滤清器的纸质滤芯部件。

Diesel generator sets are widely used for long-term (temporary) electricity supply in small and medium-sized enterprises such as industry, commerce, schools, hospitals, etc; Various fixed power sources such as generator sets, construction machinery, and ships. In the cylinder of a diesel engine, the clean air filtered by the air filter is fully mixed with the high-pressure atomized diesel injected from the fuel injector. Under the upward pressure of the piston, the volume shrinks and the temperature rises, reaching the ignition point of diesel. Diesel is ignited, and the mixed gas burns violently, rapidly expanding in volume and pushing the piston downwards, which is called work. Each cylinder works in a certain order, and the thrust acting on the piston is converted into a force that drives the crankshaft to rotate through the connecting rod, thereby driving the crankshaft to rotate.

How to maintain a newly purchased diesel generator set? Below is a detailed analysis of the importance of maintenance:

一、 Maintenance of the new diesel generator:

1. Run for 20 hours under light load (usually 2-3 horsepower).

2. After 20 hours of operation. Check and tighten the cylinder head nut (check when cold driving)

3. After 50 hours of operation, the new diesel generator should perform the following tasks.

(1) Clean the diesel engine and brush the crankcase, and replace the engine oil.

(2) Brush the oil filter with clean diesel or kerosene.

二、 8-hour maintenance:

1. After the diesel engine has been running for 8 hours, it should be stopped to check the oil level, and if it is insufficient, it should be refilled.

2. Check for oil leakage and loose screws on the outside of the machine, and if so, eliminate them.

3. Remove any debris that is blocked between the air inlet and the heat sink.

4. Ensure that the exterior of the machine is clean.

5. Remove the valve cover and add a small amount of oil to the oil holes of the intake and exhaust valve rocker arms.

三、 100 hour maintenance:

1. Clean the fuel tank filter ring.

2. Clean the diesel and air filter components, and blow air from the inside out (or inflate with an air cylinder), or use a soft bristled brush to remove surface dirt. If the filter paper is damaged or the filter end cap is detached, it should be replaced. When working in harsh environments, the frequency of cleaning and replacement should be increased.

3. Check and adjust the valve clearance.

4. Cleaning the crankcase:

(1) After parking, heat up and drain the engine oil.

(2) Clean the crankcase with clean diesel.

5. Remove the gear chamber cover and oil pan, clean the oil collector with clean diesel or kerosene, and replace the filter if it is damaged.

6. Install the oil pan gear chamber cover and observation hole cover, and add new engine oil.

四、 500 hour maintenance:

In addition to completing the 100 hour maintenance project, the following tasks need to be carried out.

1. Clean the diesel tank and fuel tank switch, and clean the oil passage inside the crankcase.

2. Remove the carbon buildup from the exhaust pipe.

3. (A) Clean the lubricating oil holes on the oil slinger and crankshaft connecting rod

(B) Unscrew the crankshaft oil plug and clean the crankshaft oil passage inside the connecting rod neck.

4. Clean the bearing seat and oil passage.

5. Clean the oil circuit, use a pump to inflate the air or use a lead wire bucket for the oil circuit.

6. Clean the oil circuits of the cylinder head, rocker arm shaft seat, rocker arm shaft, and exhaust rocker arm.

7. Check and clean the fuel injector:

(1) Check the spray quality of the fuel injector. If the fuel sprayed is not in the form of fine mist or the nozzle with carbon deposits in the nozzle is stuck, clean the nozzle couple. If the fitting of the fuel injector nozzle is too loose, it should be replaced.

(2) Remove the fuel injector assembly and extract the needle valve from the needle valve body. If the fuel injector assembly cannot be removed from the tight cap, the needle valve can be pulled out first, a wooden block can be placed on it, and the needle valve body can be knocked out. When the needle valve is difficult to pull out, a steel wire pliers lined with cloth can be used to clamp the needle valve and gently pull it out to prevent scratching.

(3) If the nozzle of the needle valve body is blocked, a needle can be used to clear it.

(4) Clean the carbon deposits on the needle valve.

(5) Clean the needle valve and needle valve body with clean diesel.

(6) When there is oil dripping from the fuel injector, the needle valve should be removed and a small amount of engine oil (or toothpaste) should be applied to the cover and ground back and forth a few times. Then clean it once.

(7) Check the fuel injection quality of the fuel injector. The fuel injection should be mist like, and there should be no dripping around the nozzle.

8. Check the sealing between the valve and valve seat:

(1) Remove the cylinder head.

(2) Inject diesel or kerosene into the intake and exhaust passages. If there is leakage between the valve and the valve seat, the valve should be removed and ground.

(3) Scrape off the carbon deposits on the valves and cylinder heads.

(4) Apply some grinding paste on the conical surface of the grinding valve and use a valve grinding tool for grinding. During grinding, rotate the valve back and forth on the valve seat and continuously tap it up and down until a dull sealing line appears on the contact surface.

9. Check the piston rings:

(1) Remove the piston connecting rod assembly and piston ring. Scrape off the carbon deposits on the top of the piston and the bottom of the ring groove, and clean them thoroughly in cleaning and diesel.

(2) Scrape off the carbon deposits on the piston rings and clean them with clean diesel.

(3) Scrape off the carbon deposits at the front of the cylinder liner, and then clean it thoroughly with clean diesel.

(4) Push the piston ring into the tail end of the cylinder liner, measure its opening clearance with a thickness gauge, and replace it with a new ring if it exceeds the maximum allowable value of 25mm.

五、 1000-1500 hour maintenance:

(1) Complete all the contents of 500 hour maintenance

(2) Check according to the fit clearance and wear limit table of the other parts, and replace the parts that exceed the wear limit.

(3) Replace the paper filter element components of the diesel filter.