Medium Repair of Diesel Generator: Maintenance and Inspection

Regular maintenance is crucial to ensure the optimal performance and longevity of a diesel generator. After approximately six months of operation or reaching a cumulative working time of 1000 hours, it is recommended to perform a medium repair on the diesel generator. In addition to minor repairs, the following key aspects should be addressed:

1. Slip Ring and Brush Device Inspection:

• Cleaning: Ensure that the contact conductive surfaces of the slip ring (or commutator) and brush device are clean, free from oil, dirt, carbon dust, and in good contact. Use a soft, dry, clean cloth or a cloth slightly dampened with gasoline (or alcohol) to wipe them. Pay special attention to cleaning the brush holder, the root of the slip ring or commutator (under the shoulder of the wire head), and the mica groove.
• Polishing: If burn marks, blackening, or slight mechanical scratches are observed on the outer surface of the slip ring or commutator, polish them. Use No.00 fine glass abrasive paper (or emery cloth) and a piece of hardwood to smooth the outer circular surface of the slip ring or commutator. Afterward, thoroughly clean the surface.
• Mica Plate Adjustment: Ensure that the height of the mica plate between the commutator plates is 0.5 to 1.2mm lower than that of the commutator plate. If adjustment is necessary, use a small knife with a hook-shaped front end to gradually cut down along the mica chip groove until the desired height is achieved. Polish and clean the surface after adjustment.
• Brush Device: Verify that the adjusting brush is made of graphite and moves up and down freely in the brush holder without shaking. The contact area between the lower end face of the brush and the slip ring or commutator should be smooth, flat, and cover at least 3/4 of the surface. If wear exceeds 2/3 of the original brush height, adjust, grind, or replace the brush.
• Electric Brush Grinding: Prior to use, new electric brushes or brushes with ablated contact surfaces should be ground to ensure proper fit with the slip ring or commutator. Use No.00 abrasive paper, place the sanded side against the brush, and let the brush spring tightly press the brush against the slip ring or commutator. Turn the rotor counterclockwise, imitating the motor's normal operation, until over 80% of the lower end face of the brush is in close contact with the outer circle of the slip ring. After grinding, maintain the brush's original installation direction or brush holder position. Before formal use, run the motor without load for 2 to 3 minutes, gradually increasing the electrical load.

2. Bearing Inspection and Cleaning:

• Rolling bearings: Small and medium-sized motors typically use rolling bearings lubricated with grease. Ordinary motors use ZGN-3 calcium-based grease, while damp and hot motors require ZL-3 lithium-based bearing grease. Approximately every 1500 hours of continuous operation, replace the lubricating grease to ensure smooth motor operation.
• Overall Inspection: Thoroughly inspect the bearings to ensure their working quality, as it directly affects the motor's operational reliability. Pay careful attention to maintenance in this area.

3. Motor Insulation and Winding Check:

• Insulation Check: Conduct a comprehensive inspection of the motor's insulation and each winding. Verify the integrity and effectiveness of the insulation, ensuring there are no signs of damage or degradation. Also, check the electrical and mechanical connections for any loose or faulty connections.

Regular maintenance and adherence to these guidelines will contribute to the reliable operation and longevity of your diesel generator. Remember to consult the manufacturer's recommendations and seek

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