Operation, Maintenance and Repair of Diesel Generator Sets
Class A Maintenance (Daily Maintenance)
Check the daily operation log of the generator set.
Check the oil level and coolant level of the generator set.
Daily inspection for damage and fluid leakage; check whether belts are loose or worn.
Inspect the air filter element, clean it, and replace it if necessary.
Drain water and sediment from the fuel tank and fuel filter.
Inspect the water filter.
Check the starting battery and electrolyte; top up supplementary fluid as required.
Start the unit and check for abnormal noises.
Blow dust off the water tank, cooler and radiator grille with an air gun.
Class B Maintenance
Complete all daily inspection items of Class A Maintenance.
Replace the diesel fuel filter every 100 to 250 operating hours.
Diesel fuel filters cannot be cleaned and must be replaced only. The 100–250 hour interval is flexible; replacement shall be carried out according to the actual cleanliness of diesel fuel.
Replace engine oil and oil filter every 200 to 250 operating hours.
The engine oil shall meet US API CF grade or higher.
Replace the air filter after 300–400 operating hours of the unit.
The replacement cycle of the air filter shall be determined based on the environment of the generator room. This filter element can be cleaned with an air gun.
Replace the water filter and replenish DCA additive to the specified concentration.
Clean the breather filter screen of the crankcase.
Class C Maintenance (Carry out after 2000–3000 operating hours of the unit)
Complete all items of Class A and Class B Maintenance
Remove the valve chamber cover and clean grease and sludge.
Tighten all bolts (including moving parts and fixed components).
Clean the crankcase, sludge, metal filings and deposits with engine cleaner.
Inspect the wear condition of the turbocharger, clean carbon deposits, and calibrate it if needed.
Inspect and adjust valve clearances.
Check the operating status of the PT pump and fuel injectors, adjust injector stroke, and calibrate as required.
Inspect and adjust the tension of fan belt and water pump belt; adjust or replace them when necessary. Clean the radiator grille and test the performance of the thermostat.
Minor Overhaul (Class D Maintenance) (3000–4000 operating hours)
Check the wear of valves, valve seats and other components; repair or replace them as needed.
Inspect the working condition of PT pump and fuel injectors; repair and calibrate if required.
Inspect and retighten connecting rods and all fastening bolts to specified torque values.
Inspect and adjust valve clearances.
Adjust fuel injector stroke.
Check and adjust the tension of fan and alternator belts.
Clean carbon deposits inside the intake manifold.
Clean the intercooler core.
Flush the entire engine oil lubrication system.
Remove sludge and metal filings from the rocker chamber and oil sump.
Medium Overhaul (6000–8000 operating hours)
Cover all items of Minor Overhaul.
Disassemble the engine (except the crankshaft).
Inspect wearing parts including cylinder liners, pistons, piston rings, intake and exhaust valves, crank-linkage mechanism, valve train, lubrication system and cooling system; replace worn parts if necessary.
Inspect the fuel supply system and calibrate fuel pumps and injectors.
Disassemble, inspect and repair the alternator stator and rotor; remove grease and deposits, and lubricate alternator bearings.
Major Overhaul (9000–15000 operating hours)
Cover all items of Medium Overhaul.
Fully disassemble the entire engine.
Replace cylinder block, pistons, piston rings, main and connecting rod bearings, crankshaft thrust washers, intake and exhaust valves, and a full engine overhaul kit.
Calibrate fuel pumps and injectors; replace pump cores and injector nozzles.
Install turbocharger overhaul kit and water pump repair kit.
Straighten connecting rods, crankshaft, engine block and other components; repair or replace defective parts as required.
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Post time: Jul-08-2026