HOHANK INTERNATIONAL GEN LATAM

Generator Maintenance Guide / 04

How to send information when a generator is reported for repair so that engineers can make a quicker decision

Many faults are not due to inability to determine, but due to incomplete on-site information. Controller photos, alarm codes, operating hours, load, oil circuit, voltage frequency and fault video can significantly shorten the remote judgment time.

Applicable scene

Suitable for remote mining areas, high after-sales door-to-door costs, recurring alarms, or sites that require remote engineers to make first judgments.

Reporting for repairs in remote mining areas is most afraid of scattered information: today a photo of the controller will be sent, tomorrow a video will be posted, and the day after tomorrow it will be said that the filter element was recently replaced. This makes it difficult for engineers to determine the scope of the problem, and the site will continue to shut down while waiting.

The goal of repair report materials is not to write beautifully, but to publish all the key facts at once. Who is the device, what is the alarm, under what load does it occur, how long has it been running, what maintenance has been done recently, and whether it can be handled on site first. This information determines whether to provide remote guidance, prepare spare parts, or arrange to be on site.

Device and controller information

  • Equipment nameplate, engine nameplate, generator nameplate and controller model photos.
  • Current alarm code, historical alarm list, controller home page data and shutdown page photos.
  • Appearance photos of control cabinets, terminal blocks, circuit breakers, ATS or parallel cabinets.

Operation and maintenance information

  • Current operating hours, daily operating hours, load rate and main electrical equipment when the fault occurs.
  • Last maintenance time, maintenance items, which filters, oil, belts, batteries or sensors were replaced.
  • Whether new equipment was added, the startup sequence was changed, the load was adjusted, or power outage switching occurred before the fault.

On-site phenomenon data

  • Take videos before and after the fault, including controller data, unit sound, smoke exhaust, oil circuit, radiator and load status.
  • Record oil pressure, water temperature, voltage, frequency, battery voltage, fuel level and ambient temperature.
  • Indicate whether the failure affects drainage, crushing, ventilation, communications, camps, or other critical loads.

Execution steps

On-site personnel follow fixed steps so that engineers can make judgments based on the same set of facts.

Maintenance actions must be performed repeatedly and evidence must be left. The following steps are suitable as the basic process before team handover and repair report.

01

First determine the degree of urgency

The first sentence of the repair report should indicate whether it affects critical loads. If drainage, ventilation, communication or production main lines have been stopped, engineers will judge with higher priority.

02

Send information in a fixed order

It is recommended to send the information in five parts: "nameplate and controller, alarm and video, operating hours and maintenance, load and site environment, and what support is needed" to reduce repeated supplementary information.

03

Don’t just send an alarm code

The same alarm may be caused by oil, heat, load, wiring, sensors or control parameters. Alarm codes must be viewed together with field data.

Exception signal

In these cases, do not just reset and continue running.

  • The scene only said "the generator is broken" and there was no alarm, operating hours and load information.
  • The alarm has occurred repeatedly, but it is only reset each time without recording the conditions for its occurrence.
  • Spare parts have been replaced or wiring adjustments have been made recently, but they were not stated when reporting for repair.
  • The fault affects critical loads, but the current downtime risk is not clearly stated in the data.

Record list

It is recommended to keep these data for each inspection and repair report

  • Fault occurrence date, time, operating hours and load at that time.
  • Alarm code, controller page photo and fault video.
  • Records of recent maintenance and spare parts replacement.
  • Site voltage frequency, oil pressure, water temperature, fuel, battery and environmental conditions.

How engineers can assist

The more complete the information, the faster the remote judgment, and the more efficient the door-to-door judgment.

If alarms, trips, starting difficulties, abnormal voltage, abnormal fuel consumption, or unstable loads have occurred on site, please give priority to retaining controller photos, fault videos, operating hours, recent maintenance records, oil status, load lists, and ATS/power distribution photos.

  • If the information is complete, engineers can usually first determine whether it is an on-site operation, maintenance, load change, wiring problem, or whether spare parts or on-site inspection are needed.
  • If there is any suspicion of a spare part problem, photos, model number, installation location, and symptoms before and after replacement should be provided.
  • If you need to go to the scene, you should prepare fault information, on-site contacts, road conditions, tool conditions and possible spare parts in advance.
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