Months 0–3: Arrival and Break-In Period
The first three months after new equipment arrives are critical.
Week 1: Installation and positioning. The foundation must be level, vibration dampers properly compressed, and the exhaust pipe independently supported. Improper installation leads to problems down the line.
Week 2: Initial startup. Add engine oil, coolant, and fuel. Before starting, turn the flywheel by hand to ensure there is no binding. Run the generator at no load for 15 minutes, checking all instrument readings, inspecting all connections for leaks, and listening for any abnormal noises.
Month 1: Break-in operation. During the first 50 hours, keep the load below 70% of the rated power. During break-in, metal particles in the oil are normal. After 50 hours, change the engine oil and oil filter.
Bonded maintenance application: The bonded policy is largely not applicable at this stage. The equipment is new, and no imported repair parts are needed.
Months 3–12: Routine Operation Period
The equipment enters normal use. The focus of maintenance is on regular servicing and operational record-keeping.
Every 250 hours: Change oil, oil filter, and diesel fuel filter; clean the air filter. This basic maintenance cannot be skipped.
Every 500 hours: Inspect valve clearance, fuel injectors, and the turbocharger. These checks can identify early-stage issues.
Operational records: Record voltage, frequency, oil pressure, coolant temperature, and exhaust smoke color daily. Continuous data recording reveals trends in performance changes.
Bonded maintenance application: Still largely not applicable. The equipment remains under warranty, and the manufacturer handles service.
Years 2–5: Stable Operation Period
The equipment enters its golden period of stable performance, but some consumable parts begin approaching their replacement intervals.
Year 2: Replace coolant. Coolant has a shelf life; if not replaced for two years, it can degrade and corrode the cooling passages.
Year 3: Inspect the battery. Typical battery life is around three years. Replace earlier if performance declines.
Year 4: Inspect vibration dampers. Rubber components age over time, and aged dampers allow increased vibration levels.
Year 5: Conduct a comprehensive inspection. Measure cylinder compression, insulation resistance, and load capacity. Use the collected data to estimate remaining service life.
Bonded maintenance application: The policy may become relevant at this stage. If original parts are expensive, alternative components can be imported through bonded channels tariff-free.
Years 6–8: Overhaul Decision Period
After six to seven years of service, equipment performance begins to decline. At this point, a decision is required: continue using it, perform an overhaul, or replace it with a new unit?
Three signs indicating an overhaul is needed:
l Increased oil consumption (requiring top-ups every 100 hours)
l Reduced power output (engine speed drops under load)
l Cylinder compression more than 20% below specification
What an overhaul involves:
l Complete disassembly and inspection of all components
l Cylinder boring with oversized pistons
l Crankshaft grinding with undersized bearings
l Replacement of piston rings, bearings, and gaskets
l Post-assembly testing on a dynamometer
Service life after overhaul: Under normal use, the equipment can run for another five to six years.
Bonded maintenance application: Imported parts required for generator engine overhaul can be brought in through bonded channels tariff-free, with no advance customs duty deposits. This can save tens of thousands of units of currency per generator set.
Years 9–10: Extended Service Period
After overhaul, the equipment enters its extended service phase. Maintenance during this period cannot be neglected, but spending must be carefully managed.
Key focus areas:
l Oil pressure trends (if it drops more than 5% over three consecutive days, intervene proactively)
l Coolant temperature trends (if it rises more than 3°C consecutively, intervene proactively)
l Changes in sound (if new abnormal noises emerge, locate the source promptly)
Principle of repairing rather than replacing: At this stage, components that can be repaired should be repaired whenever possible, and unnecessary imported parts should be avoided.
Bonded maintenance application: Only import parts that absolutely must be replaced. Every bit of tariff savings helps.
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