Avoiding Common Air Filter Mistakes for Diesel Generators

 
Diesel generator sets serve as crucial electrical power supply equipment, and their operational efficiency and stability are directly influenced by the maintenance of air filters. Air filters are responsible for filtering the air entering the diesel engine, preventing dust and impurities from causing wear to the machinery. Therefore, maintaining the good condition of the air filter is essential for the long-term reliable operation of the diesel engine. However, some common incorrect operations in actual use and maintenance may lead to a decline in filter performance, thereby affecting the work efficiency of the entire generator set. This article will introduce the most common incorrect usage methods of air filters for diesel generator sets and their correct maintenance measures to help users avoid these common problems and ensure the best performance of the equipment.

Failure to Empty the Dust Collection Cup in Time

 
Some users fail to empty the dust collection cup of the air filter in time. If the dust in the cup is not regularly removed, it will form clumps. When the throttle is increased, the accumulated dust will be sucked into the intake passage, causing the engine oil to become dirty and thicken prematurely, the filter screen to become excessively dirty, thereby increasing intake resistance and accelerating the wear of parts. Regular inspection and emptying of the dust collection cup should be carried out to maintain good air filtering effects.

Replacing the Dust Collection Cup

 
Some users replace the damaged dust collection cup with a metal cup, making it impossible to observe the dust level from the outside. When the dust is full, it will be sucked into the intake passage, contaminating the engine oil and increasing intake resistance. Timely replacement of original factory parts should be made to avoid the use of unsuitable substitutes.

Rapid Consumption of Engine Oil

 
Sometimes, if the resistance of the air filter is too high (generally exceeding 500 mm of water column), it will cause engine oil to be sucked into the intake passage and burned. At this time, it is necessary to check whether the filter element is blocked or deformed, and clean or replace the filter element in time to prevent rapid consumption of engine oil.

Loose Connection of the Air Filter

 
If the air filter is not tightly connected to the intake pipe, and is not firmly fixed, it may shake during the operation of the diesel engine, causing the air filter to be unsealed and affecting the filtering effect. The connection between the air filter and the intake pipe should be ensured to be stable and maintain good sealing.

Damaged Filter Screen

 
Some air filter screens may fall off or be missing pieces, and the gap between the screen and the casing is too large, greatly reducing the filtering effect. This is usually caused by poor quality of the mesh plate, long-term use and fatigue, or machine vibration. Regular inspection of the filter screen and timely replacement of damaged parts should be carried out.

Excessive Engine Oil

 
When adding engine oil to the oil dish, some users mistakenly add the oil level too high, thinking that it is better this way. In fact, an excessively high oil level will block the oil holes, resulting in poor oil discharge and dust absorption effects. Engine oil should be added according to the specified oil level to ensure normal operation.

Improper Cleaning of the Filter Screen

 
After cleaning the metal filter screen of the air filter, some users directly install the wet filter screen back into the filter housing. The correct method is: after cleaning and drying the filter screen, immerse it in engine oil, take it out in time and let the excess engine oil drip off before installing it back. For high-temperature environments, it is recommended to use a mixture of 85% to 90% engine oil and 10% to 25% calcium-based grease to improve filtering effects.

Not Cleaning the Oil Dish of the Central Intake Pipe

 
If the oil dish of the central intake pipe is not cleaned regularly, dust and oil scale will accumulate, causing the engine oil to thicken and lose its filtering function. The oil dish should be cleaned regularly, and new engine oil should be replaced to maintain filtering performance.

Adding Engine Oil to the Dust Collection Dish

 
Some diesel engines are equipped with a dust collection dish at the bottom of the air filter, and some users mistakenly believe that adding engine oil can improve the filtering effect. In fact, this will cause the engine oil to splash onto the inner wall of the cyclone dust removal pipe and the central small pipe, which in turn affects the filtering effect. Adding engine oil to the dust collection dish should be avoided.

Incorrectly Blocking Gaps

 
When checking the sealing of the air filter, some users incorrectly block the gap between the filter housing and the cyclone dust removal pipe with cotton or cloth strips. This gap is actually used for blowing air to discharge dust, and blocking it will increase the dust removal amount of the cyclone pipe, causing excessive scaling of dust in the dust collection dish and accelerating the dirtiness of the filter screen. This gap should not be blocked.

Drilling Holes in the Filter

 
To facilitate the starting of the diesel engine, some users drill holes in the filter housing to ignite the start. This will directly destroy the vacuum degree of the filter, reduce the air filtering effect, cause a large amount of dust to enter the cylinder without filtration, accelerate the wear of parts, and affect the performance and life of the diesel engine. Drilling holes in the filter should be avoided to ensure its normal use.
 
The correct use and maintenance of the air filter are crucial for the operation of diesel generator sets. By understanding and avoiding the above ten incorrect usage methods and following the correct maintenance measures, the performance of the air filter can be significantly improved, and its service life can be extended. Regular inspection and maintenance of the filter not only maintain the efficient operation of the diesel engine but also reduce the frequency of faults and lower maintenance costs. Users should pay attention to the air filter, take appropriate measures, and ensure the long-term stability and efficient operation of the diesel generator set.