柴油發(fā)電機(jī)維修維護(hù)保養(yǎng)案例分析和故障排除

柴油發(fā)電機(jī)維修維護(hù)保養(yǎng)案例分析和故障排除柴油發(fā)電機(jī)組維護(hù)案例集一、柴油機(jī)部分案例、柴油機(jī)不能啟動(dòng)柴油機(jī)不能啟動(dòng)原因是多種多樣的，主要有以下四點(diǎn)：1、啟動(dòng)系統(tǒng)。2、燃油系統(tǒng)。3、壓縮沖程壓力不足。4、環(huán)境溫度影響1、啟動(dòng)系統(tǒng)故障分析〈1〉啟動(dòng)電池電壓低，實(shí)際容量不足〈顯示電壓為虛電壓〉；〈2〉啟動(dòng)電池電纜與馬達(dá)接線錯(cuò)誤；〈3〉啟動(dòng)馬達(dá)電磁開關(guān)故障；〈4〉康明斯、卡勒比特、威爾遜等型號(hào)柴油機(jī)啟動(dòng)接觸器故障；故障處理〈1〉用萬(wàn)用表測(cè)量單體電池電壓、充電器直流輸出是否正常，檢查鉛酸電池液面高度，適時(shí)添加蒸餾水；〈2〉拆卸馬達(dá)，檢調(diào)電磁開關(guān)內(nèi)觸點(diǎn)，如果觸點(diǎn)燒壞，更換電磁開關(guān)；〈3〉檢查電池負(fù)極電纜是否接地〈機(jī)殼〉，接線錯(cuò)誤，重新連接電纜即可；〈4〉用萬(wàn)用表測(cè)量康明斯、卡勒比特、威爾遜柴油機(jī)啟動(dòng)接觸器線圈阻值〈其阻值一般在幾十歐姆〉，不正常則更換接觸器；2、燃油系統(tǒng)故障分析燃油系統(tǒng)中漏入空氣故障處理低壓油管排空氣方法：旋松噴油泵上放氣螺塞，壓動(dòng)輸油泵的手泵，至柴油溢出不帶氣泡為止，然后旋緊螺塞，并將手泵旋緊。高壓油管排空氣方法：逐一旋松噴油泵高壓油管接頭，啟動(dòng)柴油機(jī)，至每缸出油為止，然后旋緊高壓油管接頭。康明斯柴油機(jī)油路排空氣方法與其它柴油機(jī)的不同之處，是其依靠啟動(dòng)柴油機(jī)來(lái)完成的。3、壓縮沖程壓力不足故障分析〈1〉氣門漏氣；〈2〉活塞環(huán)過(guò)度磨損。故障處理〈1〉拆卸氣缸罩、氣缸蓋，檢查氣門間隙、氣門彈簧、氣門導(dǎo)管及氣門座的密封情況，若氣門密封線不連續(xù)時(shí)，可用氣門研砂研磨成至一條連續(xù)光滑的線；〈2〉取出活塞，更換活塞環(huán)。4、環(huán)境溫度低影響故障分析〈1〉加熱器故障；〈2〉柴油過(guò)稠。故障處理〈1〉拆卸加熱器側(cè)蓋，檢查交流輸入端連線、電壓是否正常，如果正常，加熱器壞，更換加熱器；〈2〉按比例往柴油添加煤油，或選用10號(hào)、20號(hào)、35號(hào)（數(shù)字表示凝點(diǎn)溫度，10號(hào)輕柴油凝點(diǎn)為—10度）輕柴油不等。案例二、柴油機(jī)排氣煙色不正常柴油機(jī)帶負(fù)載正常運(yùn)行時(shí)，排氣煙色一般為淡灰色，負(fù)載略重時(shí)，則可能為深灰色。這里排氣煙色不正常是指：1、排氣冒黑煙；2、排氣冒白煙；3、排氣冒藍(lán)煙。1、排氣冒黑煙〈表示柴油在燃燒室燃燒不完善〉故障分析〈1〉柴油機(jī)超負(fù)載運(yùn)行；〈2〉噴油器滴油，霧化不良；〈3〉供油時(shí)間過(guò)早。故障處理〈1〉調(diào)整負(fù)載，使之在額定范圍內(nèi)；〈2〉應(yīng)在柴油機(jī)怠速運(yùn)行時(shí)，逐一松開噴油器高壓油管接頭，以停止噴油器的噴油，觀察排氣的顏色：噴油器沒(méi)有故障時(shí)，停止噴油后柴油機(jī)的轉(zhuǎn)速會(huì)顯著下降。噴油器有故障時(shí)，停止噴油后柴油機(jī)的轉(zhuǎn)速變化很小，排氣不冒黑煙，檢調(diào)該噴油器；〈3〉按說(shuō)明書要求，檢調(diào)供油提前角。維護(hù)體會(huì)對(duì)噴油器有如下要求：要有一定的噴射壓力、一定的射程、一定的噴霧錐角、噴霧良好。噴油終了能迅速停油、沒(méi)有漏油、滲油現(xiàn)象。2、排氣冒白煙〈表示柴油滴在燃燒室未燃燒〉故障分析〈1〉氣缸墊損壞；〈2〉供油時(shí)間過(guò)遲；〈3〉柴油中有水。故障處理〈1〉更換氣缸墊；〈2〉按說(shuō)明書要求，檢調(diào)供油提前角；〈3〉安裝燃油油水分離器。維護(hù)體會(huì)為使氣缸得到良好密封，氣缸蓋與氣缸體之間必須加氣缸墊。氣缸蓋用螺栓緊固在氣缸體上，擰緊螺栓時(shí)應(yīng)有一定次序，即按由中央對(duì)稱的向四周擴(kuò)展的順序分次進(jìn)行，最后一次扭力扳手按說(shuō)明書規(guī)定的扭矩值擰緊。拆卸螺栓反之。3、排氣冒藍(lán)煙〈表明有機(jī)油串入燃燒室燃燒〉故障分析〈1〉油底殼機(jī)油油面過(guò)高；〈2〉油環(huán)卡死在環(huán)槽內(nèi)或斷裂；〈3〉連桿軸瓦與連桿軸頸間隙過(guò)大。故障處理〈1〉保持油底殼機(jī)油位于標(biāo)尺靜滿刻度，可適時(shí)放掉一些機(jī)油；〈2〉清理活塞環(huán)槽內(nèi)積碳，更換油環(huán)；〈3〉拆卸油底殼、連桿螺栓取出軸瓦，直觀軸瓦表面是否有燒壞跡象,如果有，更換連桿軸瓦。案例三、柴油機(jī)機(jī)油壓力低故障分析〈1〉油底殼內(nèi)機(jī)油平面低；〈2〉機(jī)油壓力調(diào)節(jié)器彈簧斷裂；〈3〉機(jī)油濾清器橡皮圈墊老化滲油〈一般為國(guó)產(chǎn)柴油機(jī)〉；〈4〉機(jī)油壓力表壞；〈5〉油底殼內(nèi)機(jī)油集濾器堵塞。故障處理〈1〉保持油底殼機(jī)油位于標(biāo)尺靜滿刻度，適時(shí)添加機(jī)油；〈2〉更換機(jī)油壓力調(diào)節(jié)器彈簧；〈3〉更換橡皮圈墊；〈4〉更換壓力表；〈5〉拆卸油底殼，清洗機(jī)油集濾器。維護(hù)體會(huì)機(jī)油壓力調(diào)整方法：擰下調(diào)節(jié)閥上的油封螺帽，松開鎖緊螺母，在用平口起子轉(zhuǎn)動(dòng)調(diào)節(jié)螺栓，旋進(jìn)調(diào)節(jié)螺栓、壓力升高。反之，壓力降低，調(diào)整到規(guī)定范位為止，再緊固螺母和油封螺母。案例、柴油機(jī)運(yùn)行時(shí)，油溫升到90度以上，排氣冒藍(lán)煙故障分析連桿螺栓松動(dòng)，燒軸瓦的征兆。故障處理檢查連桿螺栓是否松動(dòng)，拆卸連桿軸瓦、直觀連桿軸瓦表面是否有燒壞跡象,如果燒壞，更換軸瓦，按說(shuō)明書要求的扭矩用扭力板手?jǐn)Q緊連桿螺栓。維護(hù)體會(huì)如遇到以上情況應(yīng)緊急停機(jī)。查明故障原因，防止重大事故發(fā)生（如飛車）。柴油機(jī)正常運(yùn)行時(shí)，機(jī)油油溫一般在70---90度之間。案例、柴油機(jī)技術(shù)保養(yǎng)后，空載試機(jī)，三相交流同步發(fā)電機(jī)輸出電壓360V故障分析〈1〉進(jìn)、排氣門間隙分別調(diào)整為0.30MM、0.35MM正常；〈2〉更換氣缸墊；〈3〉校檢噴油器、噴油泵；〈4〉清理活塞積碳，更換活塞環(huán)；〈5〉三相交流同步發(fā)電機(jī)運(yùn)行正常。案例七、威爾遜柴油機(jī)自動(dòng)〈AUTO〉運(yùn)行時(shí)，出現(xiàn)油壓低告警停機(jī)故障分析〈1〉“606”控制器面板油壓低指示燈亮；〈2〉油底殼機(jī)油位于標(biāo)尺靜滿刻度；〈3〉檢查機(jī)油濾清器正常；〈4〉檢查油底殼內(nèi)機(jī)油集濾器正常。故障處理以上分析：判斷是油壓感應(yīng)塞故障。拔掉油壓感應(yīng)塞連線，手動(dòng)啟動(dòng)柴油機(jī)，機(jī)組運(yùn)行正常。油壓感應(yīng)塞壞，更換此組件后，模擬市電停電，斷開市電取樣空氣開關(guān)〈3P〉，柴油機(jī)自動(dòng)〈AUTO〉啟動(dòng)，機(jī)組運(yùn)行正常。維護(hù)體會(huì)出現(xiàn)此故障：〈1〉檢查柴油機(jī)機(jī)油是否溢出，〈2〉檢查油壓感應(yīng)塞。案例、高壓噴油泵常見故障〈1〉柴油機(jī)運(yùn)行，噴油分泵不出油或少出油；〈2〉柴油機(jī)停機(jī)后，壓動(dòng)輸油泵的手泵，噴油分泵不斷有柴油溢出。故障分析〈1〉噴油泵柱塞偶件或彈簧故障；〈2〉噴油泵出油閥偶或彈簧故障。故障處理〈1〉更換噴油泵柱塞偶件或彈簧；〈2〉更換噴油泵出油閥偶件或彈簧。維護(hù)體會(huì)柱塞式噴油泵泵體內(nèi)有兩對(duì)精密偶件，一對(duì)是柱塞與柱塞套筒，另一對(duì)是出油閥與出油閥座。出油閥偶件安裝在柱塞偶件的上面，并被壓緊，兩者之間緊密貼合，不能漏油。噴油泵拆卸時(shí)，注意每一個(gè)分泵零件應(yīng)做好記號(hào)并放在一起。柱塞偶件及出油閥偶件不能調(diào)換，必須成對(duì)安置。拆卸后的零件放在柴油中清洗吹凈。噴油泵總成在工作1000小時(shí)或更換零件裝配完畢后，必須進(jìn)行調(diào)整。由于噴油泵的精密程度很高，因此這一工作必須由較熟練的技工在一定設(shè)備條件下進(jìn)行。案例、康明斯柴油機(jī)運(yùn)行時(shí)，出現(xiàn)“游車”現(xiàn)象故障分析〈1〉檢查柴油濾清器正常；〈2〉檢查空氣濾清器濾芯清潔；〈3〉更換頻率電路板，空載試機(jī)，故障仍然。故障處理以上分析：可能是燃油PT泵供油不暢。校檢PT泵后，空載試機(jī)，故障仍然未排除。根據(jù)維護(hù)經(jīng)驗(yàn)，判斷是執(zhí)行器內(nèi)柱塞偶件輕微磨損所造成，更換執(zhí)行器〈PAPTNO3408324〉，帶載試機(jī)60分鐘，機(jī)組運(yùn)行正常。維護(hù)體會(huì)柴油在使用之前，首先要靜置并過(guò)濾。案例、威爾遜柴油機(jī)自動(dòng)〈AUTO〉運(yùn)行時(shí)，出現(xiàn)水溫高告警停機(jī)故障分析〈1〉“606”控制器面板水溫高指示燈亮，液晶屏顯示水溫100度，交流負(fù)載140A〈負(fù)載在額定范圍內(nèi)〉；〈2〉節(jié)溫器開啟冷卻水形成大循環(huán)；〈3〉檢查水溫感應(yīng)塞正常；〈4〉水箱冷卻水滿。故障處理以上分析：判斷是水箱冷凝器過(guò)臟，引起水溫高告警停機(jī)。拆下水箱，清洗冷凝器〈水箱〉，安裝后，柴油機(jī)自動(dòng)〈AUTO〉啟動(dòng)，機(jī)組運(yùn)行正常。維護(hù)體會(huì)清洗冷凝器〈水箱〉的水適當(dāng)添加堿，也就是說(shuō)，多放些水，少放些堿，以免損傷冷凝器〈水箱〉。案例、柴油機(jī)自動(dòng)〈AUTO〉運(yùn)行時(shí)，出現(xiàn)油壓低告警停機(jī)故障分析〈1〉控制器面板油壓低指示燈亮；〈2〉油底殼機(jī)油位于標(biāo)尺靜滿刻度；〈3〉檢查機(jī)油濾清器正常。故障處理以上分析：判斷是機(jī)油壓力控制器故障。拆卸機(jī)油壓力控制器面板，用萬(wàn)用表測(cè)量交流電壓385V，輸入電壓正常。檢查是機(jī)油壓力控制器觸點(diǎn)接觸不良，擦試并調(diào)整觸點(diǎn)。柴油機(jī)自動(dòng)〈AUTO〉啟動(dòng)，機(jī)組運(yùn)行正常。案例、柴油機(jī)自動(dòng)〈AUTO〉運(yùn)行時(shí)，出現(xiàn)水溫高告警停機(jī)故障分析〈1〉控制器面板水溫高指示燈亮，水溫表讀數(shù)為68度：〈2〉水箱冷卻水滿；〈3〉檢查風(fēng)扇皮帶張力在規(guī)定范圍之內(nèi)，水泵運(yùn)行正常，柴油機(jī)沒(méi)出現(xiàn)漏水現(xiàn)象。故障處理以上分析：判斷是節(jié)溫器未開啟。拆卸節(jié)溫器并更換，柴油機(jī)自動(dòng)〈AUTO〉啟動(dòng)，機(jī)組運(yùn)行正常。維護(hù)體會(huì)柴油機(jī)閉式強(qiáng)制循環(huán)水冷卻系統(tǒng)中，利用節(jié)溫器來(lái)改變冷卻水的循環(huán)流量，以達(dá)到自動(dòng)控制冷卻強(qiáng)度的目的。節(jié)溫器安裝在氣缸蓋出水處。所以在維護(hù)過(guò)程中，不允許隨便取消節(jié)溫器，這樣會(huì)影響柴油機(jī)的正常使用。節(jié)溫器初開溫度68---72度，全開溫度為80---86度，形成冷卻水的大循環(huán)。冷卻水一定要用蒸餾水，并且加防銹、防凍液。案例、柴油機(jī)怠速運(yùn)行時(shí)，三相交流同步發(fā)電機(jī)有異常響聲故障分析同步發(fā)電機(jī)后背輪橡皮圈墊磨損。故障處理考慮到柴油機(jī)與同步發(fā)電機(jī)連接方式為推拔式。所以在拆卸同步發(fā)電機(jī)緊固螺栓同時(shí)，用葫蘆將其調(diào)起，拔出同步發(fā)電機(jī)。發(fā)現(xiàn)后背輪六個(gè)螺栓分別裝有24個(gè)橡皮圈墊磨損無(wú)剩。更換其備件，柴油發(fā)電機(jī)組運(yùn)行正常。維護(hù)體會(huì)柴油發(fā)電機(jī)組運(yùn)行時(shí)，聽到有異常響聲，應(yīng)立即停機(jī)，找出故障原因并排除。案例、柴油機(jī)噴油提前角的調(diào)整為了獲得良好的燃燒，使柴油機(jī)運(yùn)行正常，并得到最經(jīng)濟(jì)的燃油耗量，噴油泵校檢后在安裝時(shí)都必須進(jìn)行噴油提前角的調(diào)整〈供油提前角28—31度、噴油提前角20--23度〉。調(diào)整時(shí)，盤動(dòng)飛輪的齒圈，使飛輪上的定時(shí)零度線對(duì)準(zhǔn)飛輪殼上檢視窗的指針，第一缸活塞位于膨脹沖程始點(diǎn)〈用手捻推桿左右活動(dòng)自如，第一缸的進(jìn)、排氣門處于關(guān)閉狀態(tài)〉。拆下噴油泵側(cè)蓋板，轉(zhuǎn)動(dòng)接合器接盤使第一缸柱塞彈簧處于剛剛壓縮狀態(tài)。然后將飛輪反方向〈順時(shí)針〉轉(zhuǎn)動(dòng)約23度即可，緊固噴油泵螺栓〈調(diào)整調(diào)速器柴油機(jī)轉(zhuǎn)速偏低，可松開接合器接盤上的螺栓進(jìn)行微調(diào)傳動(dòng)軸接頭上刻有分度線，每格3度，然后緊固螺栓〉。在實(shí)際維護(hù)工作中，一般都是檢查供油提前角，供油提前角是指噴油泵出口處剛剛冒油時(shí)，活塞距離壓縮沖程上止點(diǎn)前的曲軸轉(zhuǎn)角。因?yàn)闄z查供油提前角比噴油提前角方便而準(zhǔn)確。如果查出柴油機(jī)供油提前角，若再想知道該機(jī)的噴油提前角，只須將供油提前角的數(shù)值減去8度，就是噴油提前角。維護(hù)體會(huì)柴油機(jī)供油時(shí)間過(guò)早或過(guò)遲都是有害的。柴油機(jī)供油時(shí)間過(guò)早，即供油提前角過(guò)大。當(dāng)活塞距離上止點(diǎn)不遠(yuǎn)時(shí)，噴油泵就開始供油。這時(shí)，由于氣缸氣體的壓力和溫度都較低，使著火延遲期拖長(zhǎng)。造成柴油機(jī)不易啟動(dòng)，運(yùn)行粗暴，產(chǎn)生敲缸，功率下降，排氣管冒黑煙，并導(dǎo)致機(jī)件早期磨損。供油時(shí)間過(guò)遲，即供油提前角太小，由于燃燒是在工作沖程活塞已經(jīng)下行之后進(jìn)行，這就使柴油機(jī)功率下降，燃油耗油率增加，容易引起機(jī)體溫度過(guò)高，冷卻水沸騰，排氣管冒白煙或冒黑煙。柴油機(jī)噴油提前角是不同的，調(diào)整時(shí)應(yīng)按說(shuō)明書進(jìn)行。二、柴油機(jī)控制部分案例一、康明斯柴油機(jī)正常運(yùn)行時(shí)，三相交流同步發(fā)電機(jī)輸出電壓95V故障分析用萬(wàn)用表測(cè)量勵(lì)磁部分定子、轉(zhuǎn)子繞阻阻值均正常，判斷為自動(dòng)調(diào)壓〈AVR〉板故障。故障處理Maintenanceofdieselgeneratormaintenancecaseanalysisandtroubleshooting

Dieselgeneratorsetmaintenancecaseset

A,dieselenginepartofthecase,thedieselenginecannotstart

Thedieselenginecannotstartavarietyofreasons,mainlythefollowingfourpoints:1,startthesystem.2,thefuelsystem.3,thepressureofthecompressionstroke.4,theambienttemperature

1,startthesystem

FailureAnalysis

<1>tostartthebatteryvoltageislow,theactualcapacityoflessthan<displaythevoltageofthevirtualvoltage>;

<2>startbatterycableandmotorwiringerror;

<3>tostartthemotorelectromagneticswitchfailure;

<4>Cummins,Kalebite,Wilson,modelenginestartcontactorfailure;

Troubleshooting

<1>withamultimetertomeasurethecellvoltage,thechargerDCoutputisnormal,checkthefluidleveloflead-acidbatteries,timelyadddistilledwater;

<2>andthenremovethemotor,prosecutorselectromagneticswitchcontactsifthecontactsburnout,replacethesolenoidswitch;

<3>Checkthenegativebatterycableisgroundedtothe"chassis"wiringerror,reconnectthecablescanbe;

<4>measuredwithamultimeterCummins,Kalebite,Wilsondieselstartcontactorcoilresistance<itsresistanceisusuallyinthetensofohms>notnormal,replacethecontactor;

2,thefuelsystem

FailureAnalysis

Leakageintotheairinthefuelsystem

Troubleshooting

Thelow-pressuretubingtoexhaustair:Loosentheinjectionpumptoputgasplug,pressuretomovethefuelpumpthehandpumptodieseloverflowwithoutbubblessofar,andthentightentheplug,andhandpumptightened.Thehigh-pressuretubingtoexhaustair:onebyoneLoosentheinjectionpumphigh-pressuretubingconnector,starttheengineuntiltheoilpercylinder,andthentightenthehighpressuretubingconnector.Cumminsdieselengineoilrowairmethodandotherdieselengines,iscompletedtostarttheengine.

3,thepressureofthecompressionstroke

FailureAnalysis

<1>valveleakage;

<2>excessivepistonringwear.

Troubleshooting

<1>Removethecylindercover,cylinderhead,checkthevalveclearance,valvesprings,valveguidesandvalveseatseal,valveseallineisnotcontinuous,availablevalveresearchsandgroundintoacontinuoussmoothline;

<2>Removethepiston,replacethepistonrings.

4,ambienttemperature,low-impact

FailureAnalysis

<1>heaterfailure;

<2>dieseltoothick.

Troubleshooting

<1>Removetheheatersideofthecover,checktheACinputconnection,thevoltageisnormal,ifnormal,badheater,replacetheheater;

<2>proratatoaddkerosenetothediesel,orselectiononthe10th,the20th,No.35(thenumbersindicatethepourpointtemperature,onthe10th,lightdieseloilsolidifyingpointof-10degrees)lightdieselranges.

Case2,dieselexhaustsmokecolorisnotnormal

Thedieselengineloadduringnormaloperation,theexhaustsmokecolorisgenerallylightgray,slightlyheavierload,itmaybedarkgray.Exhaustsmokecolorisnotnormal:

1,theexhaustblacksmoke;

2,exhaust,whitesmoke;

3,theexhausttakethebluesmoke.

1,theexhaustblacksmoke<saidthedieselcombustionchamberimperfect>

FailureAnalysis

<1>dieselenginesuper-loadoperation;

<2>injectordropofoil,pooratomization;

<3>oiltooearly.

Troubleshooting

<1>toadjusttheload,sothatwithintheratedrange;

<2>dieselengineidlerunningonehigh-pressuretubingconnector,loosentheinjectorandinjectortostopfuelinjectiontoobservetheexhaustColor:injectorwithoutafault,stopfuelinjectiondieselenginespeeddecreasedsignificantly.Injectorfailuretostopthefuelinjectiondieselenginespeedchangeisverysmall,notblacksmokeexhaust,theprosecutorsoftheinjector;

<3>theinstructions,prosecutorsfuelsupplyadvanceangle.

Maintenanceexperience

Injectorhasthefollowingrequirements:tohaveacertaininjectionpressure,acertainrangeofthesprayconeangle,spraywell.Theendoftheinjectorcanquicklystoptheoil,nooilleakage,oilleakagephenomenon.

2,theexhaustwhitesmoke<saiddieselfueldropletsinthecombustionchamberunburned>FailureAnalysis

<1>cylinderheadgasketisdamaged;

<2>oiltoolate;

<3>dieselwater.Troubleshooting

<1>replacethecylinderheadgasket;

<2>theinstructions,prosecutorsfuelsupplyadvanceangle;

<3>Installthefueloilandwaterseparator.

Maintenanceexperience

Thecylindertogetagoodsealbetweenthecylinderheadandcylinderblock,cylinderheadgasketmustbeadded.Thecylinderheadboltedonthecylinderblockandtightentheboltsshouldhaveacertainorder,thatis,accordingtotheorderofexpansionbythecentralsymmetryaroundthetimethelasttorquewrenchaccordingtotheinstructionsprescribedtorquevaluetighten.Demolitionofboltsandviceversa.

3,exhausttakeLanyan<thattheoilstringintothecombustionchamber>

FailureAnalysis

<1>thesumpoillevelistoohigh;

<2>oilringstuckintheringslotorfracture;

<3>rodbearingandrodjournalgapistoolarge.

Troubleshooting

<1>tokeepthesumpoilislocatedinthescalestaticfull-scale,maybetimelytoletgoofsomeoftheoil;

<2>tocleanupthecarbondepositionofpistonringslot,replacetheoilring;

<3>Removetheoilpan,connectingrodboltstoremovethebearing,intuitivebearingsurfaceburnsigns,ifany,replacetheconnectingrodbearing.

Threecases,lowengineoilpressure

FailureAnalysis

<1>sumpoilflat;

<2>oilpressureregulatorspringbreak;

<3>oilfilterrubberringpadagingoilleakage<generaldomesticdiesel>;

<4>badoilpressuregauge;

<5>theoilsumpsetoffilterclogging.

Troubleshooting

<1>keepthesumpoilinthescalestaticfull-scale,timelyaddoil;

<2>toreplacetheoilpressureregulatorspring;

<3>toreplacetherubberringpad;

<4>replacethepressuregauge;

<5>andthenremovetheoilpan,oilcleaningsetfilters.

Maintenanceexperience

Oilpressureadjustmentmethod:Removethecontrolvalveontheoilsealnut,loosenthelocknut,turntheadjustingscrewwiththeflatscrewdriver,precessionoftheadjustingbolt,thepressureincreased.Onthecontrary,thepressureisreduced,theadjustmenttotherequiredrangeofbitfar,thentightenthenutandsealnut.

Case,thedieselenginerunning,theoiltemperatureroseto90degreesabove,takethebluesmokeexhaust

FailureAnalysis

Theconnectingrodboltisloose,andburningbushsignsof.

Troubleshooting

Checktheconnectingrodboltisloose,thedemolitionofconnectingrodbearings,intuitiveconnectingrodbearingsurfaceburnsigns,ifburned,replacethebearing,accordingtotheinstructionsoftorquewithatorquewrench,tightentheconnectingrodbolt.

Maintenanceexperience

Caseoftheaboveshouldbeanemergencystop.Toidentifythecauseofthefailuretopreventmajoraccidents(eg,Speed).Normaloperationofthedieselengine,engineoiloiltemperaturebetween70---90degrees.

Case,themaintenanceofdieseltechnology,no-loadtestmachine,three-phaseACsynchronousgeneratoroutputvoltageof360V

FailureAnalysis

<1>intotheexhaustvalveclearanceadjustment0.30MM,0.35MMnormal;

<2>toreplacethecylinderheadgasket;

<3>checksuminjector,fuelpump;

<4>tocleanupthepistoncarbondeposition,replacethepistonrings;

<5>three-phaseACsynchronousgeneratorisoperatingnormally.

Caseseven,Wilsondieseltheautomatic<AUTO>run-time,lowoilpressurealarmshutdown

FailureAnalysis

<1>"606"controllerpanel,lowoilpressureindicatorlight;

<2>sumpoilinscalestaticfullscale;

<3>Checktheoilfilterisnormal;

<4>Checksumpoilsetanormalfilter.

Troubleshooting

Theaboveanalysis:todeterminetheoilpressuresensorplugfailure.Unplugtheoilpressuresensorplugconnection,manuallystarttheengine,theunitisoperatingnormally.Badoilpressuresensorplug,replacethiscomponent,simulateamainspowerfailure,disconnectthemainssamplingairswitch<3P>,dieselautomatic<AUTO>thestart,theunitisoperatingnormally.

Maintenanceexperience

Thisfailureoccurs:<1>Checkengineoiloverflow,<2>checktheoilpressuresensorplug.

Case,highpressurecommoninjectionpumpfailure

<1>dieselenginerunning,theinjectorFenbengnooilorlessoil;

<2>dieselengineshutdown,thepressureactionpump,handpump,injectorwheelcylinderdieselconstantlyoverflow.

FailureAnalysis

<1>injectionpumpplungerorspringfailure;

<2>injectionpumpoutletvalveorspringfailure.

Troubleshooting

<1>replacetheinjectionpumpplungerorspring;

<2>replacethefuelinjectionvalvesofthespring.

Maintenanceexperience

Plungerinjectionpumpinthepumpbodyprecisioncouplingtwopairs,apairofplungersleeve,theotheristheseatoftheoilvalveandtheoil.Oildeliveryvalvesinstalledontopoftheplunger,andpressedclosefitbetweenthetwo,cannotspill.Injectionpumpdisassembly,payattentiontoeachwheelcylinderpartsshouldbewellmarkedandputtogether.Evenpartsoftheplungeranddeliveryvalvereplacement,mustbepairedwithplacement.Afterthedemolitionofpartsondieselcleaningblowing.Thefuelpumpassemblymustbeadjustedtowork1000hoursorreplacementpartsassembled.Duetothehighprecisionoftheinjectionpump,sothisworkmustbeperformedbytheskilledcraftsmeninacertaindeviceconditions.

Case,theCumminsdieselenginerunning,the"freeride"phenomenon

FailureAnalysis

<1>Checkdieselfuelfilterisnormal;

<2>Checktheairfilterisclean;

<3>thefrequencyofreplacementcircuitboards,no-loadtestmachine,thefaultpersists.

Troubleshooting

Theaboveanalysis:ItmaybepoorfuelPTpumpoil.SchoolinspectionPTpump,no-loadtestmachine,thefaultisstillnotexcluded.Maintenanceexperience,judgmentiscausedbytheactuatorplungerslightlywornreplacementactuator<PAPTNO3408324>,withaloadtestingmachine60minutes,theunitisoperatingnormally.

Maintenanceexperience

Dieseloilpriortouse,wemustfirstputitasideandfilter.

Case,Wilsondieselautomatic<AUTO>run-time,highwatertemperaturealarmstop

FailureAnalysis

<1>"606"controllerpanelwatertemperatureindicatorlight,LCDdisplaytemperatureof100degrees,theACload140A<loadwithintheratedrange>;

<2>thethermostattoopenthecoolingwatertoformalargecircle;

<3>Checkthewatertemperaturesensorplugisnormal;

<4>fulltankofcoolingwater.

Troubleshooting

Theaboveanalysis:todeterminethewatertankcondenseristoodirty,causedbyhighwatertemperaturealarmshutdown.Removethetank,cleaningthecondenser<tank>Afterinstallation,thedieselengineautomatically<AUTO>start,theunitisoperatingnormally.

Maintenanceexperience

Cleaningcondenserwatertank>waterisappropriatetoaddthealkali,thatis,putsomemorewaterandlesstoputsomealkali,soasnottodamagethecondenser<tank>.

Case,thedieselengineautomatically<AUTO>run,alowoilpressureshutdownalarm

FailureAnalysis

<1>controllerpanel,lowoilpressureindicatorlight;

<2>sumpoilinscalestaticfullscale;

<3>checktheoilfilterproperly.

Troubleshooting

Theaboveanalysis:thejudgmentisthattheoilpressurecontrollerfailure.

RemovetheoilpressurecontrollerpanelwithamultimetertomeasureACvoltage385V,theinputvoltageisnormal.Checktheoilpressurecontrollercontactspoorcontact,wipe,andadjustthecontact.DieselEngineAutomatic<AUTO>start,theunitisoperatingnormally.

Case,thedieselengineautomatically<AUTO>run,highwatertemperaturealarmshutdown

FailureAnalysis

<1>controllerpanelwatertemperatureindicatorlight,watertemperaturereadingsof68degrees:

<2>coolingwatertankisfull;

<3>Checkfanbelttensionwithinthespecifiedrange,normalpumpoperation,thedieselengineisnowaterleakage.

Troubleshooting

Theaboveanalysis:thejudgmentisthatthethermostatisnotturnedon.

Removethethermostatandreplace,dieselautomatic<AUTO>thestart,theunitisoperatingnormally.

Maintenanceexperience

Dieselengineclosedforcedcirculationwatercoolingsystem,theuseofthethermostattochangetheflowofcoolingwatercirculationinordertoachievethepurposeoftheautomaticcontrolofcoolingintensity.Theoutletthermostatinstalledinthecylinderhead.Inthemaintenanceprocess,notallowedtoarbitrarilycancelthethermostat,itwillaffectthenormaluseofdieselengines.Thermostat,theinitialtemperatureof68---72degrees,thefulltemperatureof80---86degrees,theformationofthecoolingwatercycle.Thecoolingwatermustusedistilledwater,andaddedanti-rust,anti-freeze.

Abnormalsoundinthecase,thedieselengineidlerunning,three-phaseACsynchronousgenerator

FailureAnalysis

Synchronousgeneratorbackroundrubberringpadwear.

Troubleshooting

Takingintoaccountthedieselengineandsynchronousgeneratorconnectionforthepushpulltype.Tightentheboltsatthesametimeinthedemolitionofsynchronousgenerator,withagourditstuneon,pulloutthesynchronousgenerator.Foundthatthebackroundofthesixboltswerefittedwith24rubberringpadwearwithoutleft.Replacementofthespareparts,dieselgeneratorsetisoperatingnormally.

Maintenanceexperience

Dieselgeneratorsetisrunning,hearabnormalnoise,shouldbeimmediatelyshutdown,findoutthecauseofthemalfunctionandtheexclusion.

Case,dieselfuelinjectionadvanceangleadjustment

Inordertogetgoodcombustion,theengineisoperatingnormally,andthemosteconomicalfuelconsumption,schoolinjectionpumpseizedintheinstallationmustbecarriedouttheadjustmentoffuelinjectiontiming<fuelsupplyadvanceangleof28-31degrees,fuelinjectioninadvance20-23degreeangle>.

Adjustment,platemovingtheflywheelringgearontheflywheeltimingzerolinetoalignthepointeroftheinspectionwindowontheflywheelhousing,thefirstcylinderpistonintheexpansionstrokestartingpoint<handtwisteasilyputtaroundthefirstcylinderintothe,theexhaustvalveisturnedoff>.Removetheinjectionpumpsidecover,turntheadapterthensetthefirstcylinderoftheplungersp