Requirements for Major, Intermediate, and Minor Overhauls of Generator Sets
Minor Overhaul:
1. Inspect the wear level of generator set valves and valve seats; repair or replace as needed;
2. Inspect the operational status of the generator set's PT pump and injectors; repair or calibrate as needed;
3. Inspect and adjust the torque of connecting rods and all fastening screws;
4. Inspect and adjust valve clearances;
5. Adjust injector stroke;
6. Inspect and adjust fan/alternator belt tension;
7. Clean carbon deposits from intake manifolds;
8. Clean the intercooler core;
9. Clean the entire diesel generator set's oil lubrication system;
10. Clean sludge and metal shavings from the rocker arm chamber and oil pan.
Intermediate Overhaul:
1. Includes minor overhaul items for diesel generator sets;
2. Disassemble the engine (except the crankshaft);
3. Inspect wear-prone components including cylinder liners, pistons, piston rings, intake/exhaust valves, crankshaft connecting rod mechanism, valve timing system, lubrication system, and cooling system; replace as needed;
4. Inspect the diesel generator set's fuel supply system; calibrate fuel pump and injectors;
5. Repair and inspect generator armature; clean oil deposits and lubricate armature bearings.
Overhaul:
1. Includes all items from the diesel generator set's intermediate overhaul;
2. Completely disassemble the generator set's engine;
3. Replace cylinder block, pistons, piston rings, main and connecting rod bearings, crankshaft thrust washers, intake/exhaust valves, and the complete engine overhaul kit;
4. Calibrate fuel pump and injectors; replace pump core and injector nozzles;
5. Replace turbocharger overhaul kit and water pump repair kit for diesel generator set;
6. Straighten connecting rods, crankshaft, engine block, and other components; restore or replace as necessary.