Standby
diesel generator sets are the "lifeline" of emergency power supply for enterprises. Once a fault occurs, it may cause production interruption, data loss or even safety accidents. However, improper operation during maintenance may cause secondary damage or safety hazards. This article combines industry specifications and practical experience to summarize the six core principles of fault maintenance to help you solve problems efficiently and extend the life of equipment.
1. Safety first: risk prevention and control take precedence over troubleshooting
Power off and sign: The power must be cut off before maintenance, and the "No Closing" sign must be hung on the control panel to prevent accidental start-up.
Release residual pressure: Close the fuel valve, release the residual pressure in the fuel pipeline, and avoid fuel injection and injury.
Protective equipment: Wear anti-static gloves and safety shoes, and be equipped with a gas mask when working in a confined space.
2. From the outside to the inside: scientific diagnosis replaces blind disassembly
Observation method: Check the instrument panel fault code, oil level, water temperature and other parameters, and record abnormal data.
Auscultation method: Use a listening rod to identify abnormal engine noises, such as a dull "thump" sound if the connecting rod bearing is loose.
Detection method: Use infrared thermometers, endoscopes and other tools to locate high temperature points or carbon deposits in the cylinder.
3. Minimum intervention: Avoid excessive maintenance
Replacement verification: For suspected faulty parts (such as sensors and relays), replacement verification is preferred rather than direct disassembly.
Segmented testing: Divide the circuit into control modules, actuators and other units to troubleshoot the faults section by section.
Data comparison: Compare the operating parameters of the faulty unit with the normal unit to narrow the scope of investigation.
4. Original factory standards: Both accessories and processes are compliant
Accessory selection: Original or certified accessories must be used. Poor quality filters may cause premature engine wear.
Torque specification: Use a torque wrench when tightening bolts. For example, the cylinder head bolts must be tightened to the specified value three times in a cross order.
Cleanliness control: Use special tools during maintenance to avoid secondary failures caused by cotton yarn fiber residues.
5. Record traceability: closed-loop management from maintenance to prevention
File management: record fault phenomena, maintenance steps, replacement of accessories and other information to form equipment health files.
Root cause analysis: perform "5Why analysis" for repeated faults. For example, if the fuel pump still fails after three replacements, it is necessary to check the low-pressure oil circuit pressure.
Preventive maintenance: optimize the maintenance cycle based on maintenance data, such as shortening the oil change cycle from 500 hours to 400 hours.
Conclusion
The maintenance of standby diesel generator sets must take into account both efficiency and quality. Following the above principles can reduce the misjudgment rate by more than 30% and extend the life of the equipment. It is recommended that enterprises establish standardized maintenance processes and conduct safety training and technical assessments for operators on a regular basis. Remember: scientific maintenance is not only about solving problems, but also about respecting the life of equipment.
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