Proper diesel generator maintenance is important to ensure that it can work more efficiently , Here are 5 tips you need to know if you meet problems in daily use.
1.Insufficient Engine Power
Fault cause and description: engine underpower and diagnosis
Insufficient Air Intake:
(1) The air filter is too dirty, so that the intake channel is reduced.
The pressure drop of the supercharger, air leakage, blockage, etc.
(3) serious carbon deposition in the exhaust pipe, so that the exhaust resistance increased.
(4) the valve distribution is not timely, valve clearance is too large or too small.
(5) the valve spring breaks, so that the valve is not tightly closed.
(6) Engine temperature is too high.
Insufficient oil Supply:
The fuel injection pump is insufficient for diesel fuel.
The plunger and plunger sleeve of the fuel injection pump wear and leak oil.
The oil outlet valve and the seat are not sealed.
The amount of fuel injection is insufficient, spray oil atomization is not complete
Diesel filter is blocked.
There is gas in the fuel system.
Improper assembly of oil supply rod and plunger.
The spray oil timing is wrong
Insufficient cylinder pressure:
Air leakage between piston and cylinder wall.
The valve and valve seat are not sealed.
(3) Insufficient cylinder head bolt tightening force, cylinder head deformation, cylinder cushion damage leakage.
Oil injector installation hole seal gasket damage leakage.
Engine underpowered
Fault cause and description: engine underpower and diagnosis
Insufficient air intake:
(1) The air filter is too dirty, so that the intake channel is reduced.
The pressure drop of the supercharger, air leakage, blockage, etc.
(3) serious carbon deposition in the exhaust pipe, so that the exhaust resistance increased.
(4) the valve distribution is not timely, valve clearance is too large or too small.
(5) the valve spring breaks, so that the valve is not tightly closed.
Engine temperature is too high.
Insufficient oil supply:
The fuel injection pump is insufficient for diesel fuel.
The plunger and plunger sleeve of the fuel injection pump wear and leak oil.
The oil outlet valve and the seat are not sealed.
The amount of fuel injection is insufficient, spray oil atomization is not complete
Diesel filter is blocked.
There is gas in the fuel system.
Improper assembly of oil supply rod and plunger.
The spray oil timing is wrong
Insufficient cylinder pressure:
Air leakage between piston and cylinder wall.
The valve and valve seat are not sealed.
(3) Insufficient cylinder head bolt tightening force, cylinder head deformation, cylinder cushion damage leakage.
Diagnostic Methods
1, increase the throttle, the engine speed is not high, you can determine the oil fault.
2. Start the engine and run at medium speed. Remove the fuel injector on one cylinder to observe the fuel injection.If the fuel injection is weak and atomization is poor, then remove the fuel injection pump and the oil inlet pipe to see the oil situation.If the oil output is sufficient, the fault is in the high pressure oil circuit.Less oil, then the fault in the low – pressure oil line.
3. The intake pipe smoke, the failure is the intake valve is not sealed.
4. Exhaust temperature is higher, the smoke is black, generally for the intake of insufficient air.
How to Solve ?
1. Elimination of insufficient intake: check the intake system, overhaul the air filter element, and adjust the valve foot clearance.
2. Elimination of insufficient oil supply in the oil transmission pump: Check the valve and replace the piston and spring;Inspect the leaking oil inlet joint;Grind unsealed valves;
3. Elimination of insufficient oil supply in the injection pump: the oil outlet valve is not sealed, and should be matched with grinding or replacement of the oil outlet valve pair;Piston wear oil leakage, replace the plunger pair;Adjust the connecting position of the regulating arm and the pulling rod;Exhaust oil supply system air.
4. Elimination of insufficient oil injection or poor atomization of the injector: Disassemble the injector and clean it with diesel oil, then grind or replace the needle valve with the valve body or the needle valve with the seat in pairs;Adjust the pressure regulating spring;Replace the fixed screw sleeve;When the needle valve is loaded into the valve body, it shall be carried out in clean diesel oil and the sliding distribution of the needle valve in the valve body shall be checked before assembly;
The injector should be tested in the injector after assembly
Test on the test bench to adjust the injection pressure, spray quality, stop spray level and spray cone Angle.
5. Elimination of insufficient cylinder pressure: check the cylinder pad;Check the piston;Check the piston ring;Pond grinding cylinder;Grinding valve;Adjusting valve clearance;Check and adjust valve phase etc.
2.The Diesel Generator Set Does Not Run
After pressing the start button, the diesel generator unit does not turn, which is mainly due to the lack of power or failure of the battery. Please check whether the connection wire of the battery is loose. If the starter solenoid valve is not energized and cannot generate a magnetic field, it does not have enough magnetic strength.
First check whether the battery is short of power, whether the connection wire is loose.
If the battery capacity is sufficient and the wiring is good, the fault is in the starter or the starting switch.
Make a short circuit between the two terminals of the starting switch with a thick conductor. If the starter operates normally at this time, the fault can be judged on the switch.
The main circuit can’t be connected because of the ablation of switch contact, spring damage, improper adjustment of push rod, etc., repair or replace according to the specific circumstances.
If there is a strong spark after the switch short circuit, but the starter does not turn, then the fault is in the starter.
Usually the excitation coil short circuit, armature coil short circuit, etc., should be removed and repaired.
If there is no spark after the switch short circuit, it may be that the carbon brush is in bad contact with the armature converter after wear. At this time, the carbon brush should be replaced.
3.The Starting Motor Run But Diesel Generator Set Stop
Please check the circuit first to see if the brush is badly worn. If so, replace it immediately.
If the brush spring pressure is insufficient, grease makes brush contact bad, commutator loosens, friction disc clutch slips, switch contact is bad, storage battery capacity is insufficient, and the armature and stator coil friction due to bearing loosens, etc., the motor will start weak.
In addition, due to the oil viscosity in winter caused by the increase in dynamic resistance, is also the cause of the starting motor starting weak.
This can also occur if there is a wire or conductive metal on the battery, resulting in a short circuit inside the battery.
4.The Diesel Generator Still Idles When Grive Gear Engages with The Flywheel Gear Ring
This situation is due to a severe slip of the friction plate clutch.
This situation to disassemble the starter, as long as the friction plate clutch slip, the diesel engine can not start.
The maintenance of diesel generator should always check whether the connection of the starter and its switch is firm, whether the wire contact and wire insulation is good, always keep the starter’s parts clean, especially the brush holder and converter clean.
When the diesel generator is maintained at all levels, the dust belt should be disassembled and compressed air should be used to blow up the dust inside the starter to check the contact of the starter commutator.
In addition, you should always pay attention to the lubrication of starter bearings, check whether the carbon brush elastic meet the requirements, whether the carbon brush and commutator contact is good, whether the steering wheel out of circle, if more than 0.05mm, should be removed and repaired.
In addition, the transmission control mechanism should also be frequently checked.
5.There is a Crash Between The Drive Gear and The Fly Gear Ring of Diesel Generator Set
After the start of the generator set, if you hear the sound of the driving gear and the flying gear tooth ring crash, this is mainly because the electromagnetic switch stroke is wrong, the cause of premature closure, gear has not been in place meshing in, and the starter’s main loop has been closed, so that the armature high speed idling.
In a similar situation, the eccentric screw can be adjusted.
In addition, due to the failure of the driving gear of the flywheel gear ring and the starter, or the axis of the flywheel gear ring and the starter is not parallel, will be such a situation.
