1. Basic Regular Maintenance Cycle (Standard Operating Environment)

① Every 250 Operating Hours (Core Maintenance)

• Replace engine oil: Use genuine diesel engine oil that meets the engine specifications (such as CF-4, CH-4 grade), and drain the old oil completely when the engine is warm (to ensure that impurities and sludge are fully discharged) before adding new oil to the standard scale.

• Replace oil filter: The oil filter filters impurities in the engine oil to protect the engine's friction parts. It must be replaced synchronously with the engine oil to avoid blockage or secondary pollution caused by the old filter.

• Supplementary inspection items: Check the oil level and oil quality again after oil replacement; inspect the tightness of oil pipelines and joints to prevent oil leakage; check the engine's operating noise and vibration, and deal with abnormalities in time.

② Every 500 Operating Hours (Key Maintenance)

• Replace fuel filter: The fuel filter is responsible for filtering impurities, water and colloids in the diesel. Long-term use will cause blockage, affecting fuel supply and engine combustion efficiency. Both the primary and secondary fuel filters (if equipped) need to be replaced synchronously.

• Replace or clean air filter: The air filter prevents dust and impurities from entering the engine cylinder, avoiding wear of pistons, cylinders and other parts. If the operating environment is relatively clean, it can be disassembled and cleaned with compressed air; if it is seriously blocked or damaged, it must be replaced with a new one.

• Supplementary inspection items: Check the coolant level and concentration (ensure the antifreeze and anti-boiling performance), and add or replace the coolant if necessary; inspect the fan belt and charging belt for tension, wear and cracks, adjust the tension or replace if damaged; check the tightness of all connecting bolts, hoses and wiring.

③ Every 1000 Operating Hours (Comprehensive Maintenance)

• Repeat all items of 250-hour and 500-hour maintenance.

• Replace the fuel tank strainer and clean the fuel tank (remove sediment and water at the bottom of the tank).

• Inspect the exhaust system: Check the exhaust pipe, muffler for air leakage, corrosion and damage, and replace the gasket if necessary.

• Check the cooling system: Clean the radiator and water jacket to remove scale and dust, ensure heat dissipation efficiency; inspect the water pump for leakage and operation status.

• Inspect the electrical system: Check the battery status (voltage, electrolyte level), clean the battery terminals; inspect the alternator, starter motor for wear and operation status; check the wiring of the control panel for looseness and insulation performance.

④ Every 2000 Operating Hours or 1 Year (Overhaul Maintenance)

• Check the engine cylinder head, piston, piston ring, connecting rod and other internal components for wear, and adjust or replace if necessary.

• Inspect the turbocharger (if equipped) for operation status, oil leakage and wear, and clean or maintain it.

• Calibrate the fuel injection pump and injector to ensure accurate fuel injection and improve combustion efficiency.

• Check the ATS automatic transfer switch (if equipped) for switching sensitivity and contact wear, and maintain or replace it.

2. Key Factors Affecting Maintenance Cycle

• Harsh environment: In dusty, high-temperature, high-humidity or high-altitude areas, the air filter and fuel filter are more likely to be blocked, and the engine oil deteriorates faster. It is recommended to shorten the maintenance cycle by 30%-50% (e.g., replace oil and oil filter every 150-200 hours).

• High-load operation: If the generator is in long-term full-load (≥80% rated power) or overload operation, the engine wear and oil consumption will increase, and the maintenance cycle should be shortened by 20%-30%.

• Fuel quality: If the diesel used has poor quality (high impurity content, high water content), the fuel filter replacement cycle should be shortened to every 300-400 hours to avoid fuel system blockage.

3. Professional Maintenance Notes

• The maintenance cycle and items must be subject to the engine manual. Different brands and models of engines may have different requirements, and the manufacturer's specifications shall prevail.

• All maintenance parts (engine oil, filter elements, belts, etc.) must use genuine or compliant accessories to avoid damaging the engine and affecting the unit's service life.

• Maintenance must be performed when the generator is shut down, cooled down and disconnected from the power supply to ensure operational safety.

• Establish a maintenance record, record the maintenance time, operating hours, maintenance items and replaced parts in detail, which is convenient for subsequent tracking and maintenance.

• If the generator is idle for a long time (more than 3 months), even if the operating hours do not reach the maintenance cycle, it is recommended to perform a basic maintenance (replace engine oil, clean filter elements) before restarting to avoid damage caused by oil deterioration and impurity accumulation.

4. Summary

• Every 250 hours: Replace engine oil + oil filter;

• Every 500 hours: Replace fuel filter, air filter (clean or replace);

• Every 1000 hours: Comprehensive maintenance of all key components;

• Every 2000 hours or 1 year: Overhaul maintenance;

• Specific operations shall be subject to the engine manual, and the cycle shall be shortened appropriately in harsh environments or high-load operation.