As the core equipment of the enterprise's emergency power supply, the stability of
diesel generator sets is directly related to production safety and economic benefits. Among the many maintenance links, the regular replacement of "three filters and two oils" is the key to extending the life of the unit and ensuring operating efficiency. This article will combine industry data and maintenance specifications to analyze the replacement cycle and operation points of "three filters and two oils" for you.
1. What is "three filters and two oils"? Why is it so important?
"Three filters" refer to air filters, oil filters, and fuel filters, and "two oils" include engine oil and diesel. Their functions and the hazards of not replacing them are as follows:
1. Air filter
Core function: filter dust and particulate matter in the air to prevent engine cylinder wear.
Hazards of not replacing: Blockage leads to insufficient air intake, incomplete combustion, reduced power, and 15%-20% increase in fuel consumption.
2. Oil filter
Core function: filter metal debris and sludge in the oil to ensure engine lubrication.
Hazards of not replacing: After the filter element is clogged, the oil pressure is abnormal, which aggravates the wear of crankshaft, camshaft and other parts.
3. Fuel filter
Core function: filter impurities and water in diesel, protect fuel injectors and high-pressure oil pumps.
Hazards of not replacing: impurities clog the fuel injectors, causing engine shaking, difficulty in starting, and even damage to the high-pressure oil pump.
4. Engine oil
Core function: lubricate, cool, clean the inside of the engine, form an oil film to reduce friction.
Hazards of not replacing: after the engine oil oxidizes and deteriorates, the lubrication performance decreases, the engine temperature rises, and the life is shortened by more than 30%.
5. Diesel
Core function: as a fuel to burn and do work, it needs to maintain cleanliness.
Hazards of not replacing: excessive water content will cause rust in the fuel system, and colloid deposition will cause filter clogging.
2. "Three filters and two oils" replacement cycle and operation points
According to the differences in equipment conditions and environment, the replacement cycle needs to be flexibly adjusted. The following are general reference standards:
1. Air filter
First replacement time: 50 hours of operation of the new machine.
Regular replacement cycle: 200-500 hours (paper filter element according to the indicator).
Special working condition adjustment: shortened to 100-200 hours in dusty environment.
2. Oil filter
First replacement time: 50 hours of operation of the new machine.
Regular replacement cycle: 200-500 hours (replaced synchronously with the engine oil).
Special working condition adjustment: shortened to 150 hours in high-load operation.
3. Fuel filter
First replacement time: 50 hours of operation of the new machine.
Regular replacement cycle: 400 hours.
Special working condition adjustment: shortened to 200 hours when the fuel quality is poor.
4. Engine oil
First replacement time: 50 hours of operation of the new machine.
Regular replacement cycle: 500 hours or annually (whichever comes first).
Special working condition adjustment: Check the acid value every 300 hours in high temperature environment, and replace it immediately if it exceeds the standard.
5. Diesel
Replacement cycle: According to the oil sample test results (usually 1000-2000 hours).
Special working condition adjustment: When the water content exceeds 0.05% or the microorganisms exceed the standard, precipitation and filtration are required.
III. Hidden costs of not replacing on time
1. Power attenuation and fuel consumption surge
Air filter blockage will reduce the engine intake by 20%-30%, resulting in incomplete combustion, increased fuel consumption, and power output will drop by more than 15%.
2. Increased engine wear
After the oil filter fails, metal debris circulates with the oil, and the wear rate of components such as the crankshaft and cylinder liner increases by 3-5 times, shortening the overhaul cycle by 50%.
3. Fuel system failure
Clogged fuel filters will cause injector pressure fluctuations and poor atomization. In severe cases, it can cause the high-pressure oil pump plunger to get stuck, and the maintenance cost is as high as 10,000 yuan.
Conclusion
The scheduled replacement of "three filters and two oils" is the link with the highest return on investment in diesel generator set maintenance. Through scientific management, not only can the operation and maintenance costs be reduced by 20%-30%, but the equipment life can also be extended to more than 1.5 times the design value. It is recommended that enterprises combine the equipment manual with the actual working conditions to formulate a dedicated maintenance plan to keep the emergency power supply in a "combat readiness state" at all times.
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