What Industry Needs a Standby Diesel Generator Set As the size of the traditional aquaculture industry continues to grow, it is necessary for companies to equip diesel generator sets as backup power suppliers for power outage. This will ensure that the diesel generator set provides the power required for the normal operation of all equipment during a short power outage. Diesel generator set for traditional aquaculture industry The necessary of equipped with diesel generator sets in traditional aquaculture industry. The traditional aquaculture industry is mechanized from the processing of feed, breeding equipment and ventilation and cooling equipment, and the use of mechanical tools determines that the demand for electricity in the aquaculture industry can not be interrupted for one minutes. The most important thing for aquaculture enterprises in the breeding process is ventilation and cooling. In summer, the high temperature weather makes the relatively closed breeding workshops have higher temperature and higher temperature. Once all the equipment stops working, the high temperature and ventilation are not smooth. At this time, if there is no diesel generator set to provide the store to let the ventilation and cooling equipment continue to work, then the high temperature will cause the group to suffer from group death and injury. These losses are far more than the losses of diesel generator set. The cost is more. Therefore, the use of diesel generator sets as backup power sources by aquaculture companies must be considered. The aquaculture industry has a profit, but it has to be said that the risk is very high. The mechanized operation reduces the labor cost and increases the dependence on electricity. Therefore, the backup power supply must be considered in the initial stage of construction to ensure the normal operation of these mechanized equipment. . Diesel generator sets are the best choice as a backup power source, and aquaculture companies can choose the right generator set according to their own needs. Star Hotels The importance of star-rated hotels with diesel generator sets As an important public place, the hotel will have a serious impact on the reputation of the hotel in the event of a power outage, especially for some star hotels. Although the possibility of power outages in the city network is small, no one can rule out such a possibility. This is why more and more star-rated hotels have begun to purchase diesel generator sets backup power sources in recent years. The following emphasizes that diesel generator sets are under. The importance of start hotel applications. Tell everyone a real case, then you can understand the necessity of the hotel equipped with diesel generator sets. A star-rated hotel took on the wedding reception of two couples. On the day of the wedding, the bridegroom smoothly took the bride into the hotel and held a wedding ceremony on the first floor and the second floor. The two couples chose the wedding company to the cloth field. And all the details of the wedding have been done, but the hotel suddenly has a power outage, and the power outage hotel does not have a backup power source such as a diesel generator set to generate electricity, which led to the end of the wedding ceremony. . I believe that through the above example, we already know the importance of star-rated hotels equipped with diesel generator sets. In fact, they are not just star-rated hotels. Most public places, such as shopping malls, cinemas, and residential areas, should be equipped with diesel power. The unit acts as an emergency power source to ensure the normal supply of electricity. Service industry Diesel generator sets are increasingly favored by the service industry The diesel generator set is a power supply device that uses a diesel engine as the prime mover to drive a synchronous generator to generate electricity. It is a power generation device with quick start, convenient operation and maintenance, low investment, and strong adaptability to the environment. Recently, many service industry customers came to our company to purchase Cummins diesel generator sets. Many friends who don't understand the service industry will wonder why the service industry also needs to buy diesel generator sets. There is no production line production, and the demand for electricity is not very large. Why are the power generation equipment frequently purchased? The service industry includes transportation, warehousing and postal services, wholesale and retail, residential services, accommodation and catering, and other industries, which are closely related to people's lives and ensure the normal operation of the economy. In our daily production and life, we often encounter power shortages, the government cuts power limits, and has to stop normal operations. Therefore, many companies will consider the issue of self-purchasing diesel generator sets, and this is also a particularly important issue. On the one hand, some companies will take into account that the purchase of high-powered generators will increase the operating costs of enterprises; on the other hand, during the peak period of power consumption, occasionally several power outages, this is not a rare thing, however, during the power shortage period, enterprises The interruption of normal business due to power outage will bring more losses. If it is accumulated for a long time, the opportunity cost of the enterprise will be greatly increased, and the economic benefits of the enterprise will be greatly reduced. Therefore, it is imperative to purchase a generator set as a backup power source. In the past, the staff once read such a report. The family had a sudden power outage at the hotel, but the hotel was not equipped with emergency power, so it was a pity that everyone had finished eating silently in the candlelight. In order to avoid similar situations, it is also necessary to equip the service industry with diesel generator sets, which is also a convenient means to indirectly improve the quality of service.
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What Is Electronic Diesel Control In this article, we will talk about Volvo TAD engine electronic diesel control. The TAD Series engines are direct injection in-line 4 and 6 cylinder diesel engine equipped with electronically controlled fuel management (EDC 4), turbocharger, thermostatically controlled cooling systems and electronic speed control. All TAD engines are also fitted with charge air-coolers. EDC 4 (Electronic Diesel Control) is an electronic system with CAN (Controller Area Network) or potentiometer communications for diesel engine control. The system includes fuel management and diagnostic functions. Overview The system includes sensors, control unit and an engine speed regulator. The sensors send input signals to the control unit, which in turn governs the injection pump control rack by means of an actuator in the engine speed regulator. Input signals The control unit receives input signals about engine operating conditions from the following components: 1. rpm sensor, camshaft 2. coolant temperature sensor 3. charge pressure sensor 4. oil pressure sensor 5. fuel temperature sensor 6. coolant level sensor (the function is implemented in the control unit as standard, but no sensor is supplied with the engine as a standard feature.) Output signals The control module uses the input signals to control the following components: 1. engine speed regulator (with position sensor for the control rack and actuator) 2. electric air preheating (option) Information from the sensors provides exact information about current operation conditions and allows the processor to calculate the correct fuel volume, check engine status etc. Diagnostics function The task of the diagnostics function is to detect and localize any malfunctions in the EDC 4 system, to protect the engine and to ensure operation in the event of serious malfunction. If a malfunction is detected, notification is made either by the diagnostic function, by warning lamps or via the CAN network. Pressing the diagnostic button will provide the operator with a fault code for guidance in any fault-tracing. Fault codes can also be read off via the CAN interface or using the Volvo VODIA tool (including Penta EDC 4 software) at an authorized Volvo Penta workshop. If there is a serious malfunction, the engine is shut down altogether. Here too, fault codes can be flashed out via the diagnostics connector, the CAN interface or with the Volvo VODIA tool (including th Penta EDC4 software) at an authorized Volvo Penta workshop. Instruments and Controls Gauges The engines are not supplied with instruments and controls. The choice of instruments and controls is up to the customer. Below is a description of the functions available. A. Rpm-potentiometer (Throttle control) B. CAN interface SAE J 1939 C. VODIA input D. Droop switch E. 1500/1800 switch F. Diagnostics button G. Tachometer H. Warning lamp, oil pressure J. Diagnostics lamp K. Warning lamp, coolant temperature L. Fuse15A M. Main switch N. Battery (orange indication) (24/12 V) Description of Marathon MP Series Generator Marathon MP series three phase AC synchronous brushless generator is a new generation brushless generator, which based on MAGNA PLUS generator of Marathon electric co. USA. MP generator may be combined with diesel engine (internal-combustion engine) to make fixed or movable electrical power. It is suited for commercial buildings, hospitals, factories, farms, fields, etc, as power and lighting. The generating set may be used for the prime power or stand by. MP series generators are of unique design, advanced construction, excellent performances, reliable operation, easy use, small volume and light weight. Features: 1. MP series generators are manufactured in accordance with NEM ODP type. It consists of main generator, AC brushless exciter, rotating rectifiers, AVR, conduit box, etc. 2. Class H or Class F insulation system. 3. The frame is made by steel plate. the design of stator lamination is unique. If necessary, 12 lead wires may be supplied. 4. Main rotor apply the single piece 4-pole salient pole lamination, coupled with die cast or welding damping winding, field winding to form a unirotor construction. The field winding is a layer wound with thermo settings epoxy for high mechanical and electrical integrity. Performance: 1. MP series generator may be operated continually at rated load under following conditions: a. Ambient: Air temperature ≤ 40℃, well ventilation, marine use, ≤ 45℃ b. Elevation ≤1000m over sea level 2. Electrical performances a. Steady voltage regulation ≤1.0% b. transient voltage regulations ≤+20%, -15% (60% in, cos= 0.4 lag) c. Adjustable Voltage range 95-105% Un d. Waveform distortion at no-load, ≤5% (line voltage) e. Starting motor ability, (no-load, three phase, 4p, cage motor) Principle of Operation: MagnaPlus generators are a brushless, self excited, extremely voltage regulated, synchronous AC generator. The generator is made of six major components: main stator (armature), main rotor (field), exciter stator (field), exciter rotor (armature), rectifier assembly, and voltage regulator. In understanding the above terminology, note the following: stators are stationary, rotors rotate, a field is an electrical input, and an armature is an electrical output. The generator's exciter consists of a stationary field and a rotating armature. The stationary field (exciter stator) designed to be the primary source of the generator's residual magnetism. This residual magnetism allows the exciter rotor (armature) to produce AC voltage even when the exxciter and fed directly to the main rotor (field). As the generator shaft continues to rotate, the main rotor (field) induces a voltage produced by the residual magnetism of the exciter allows the automatic voltage regulator to function. The regulator provides voltage to the exciter resulting in a build-up of generator terminal voltage. This system of using residual magnetism eliminates the need for a special field flashing circuit in the regulator. After the generator has established the initial residual voltage, the regulator provides a controlled DC field voltage to the exciter stator resulting in a controlled generator terminal voltage. Stroage In the event that the generator is not to be installed on its prime mover immediately, it is recommended that the unit be stored in a cleaned, fry area which is not subject to rapid changes in temperature and humidity. In the event of long term storage, the generator should be tested cleaned and dried as required, before being put into service. See the maintenance section of this manual for further. Installation and adjustment 1. Generator must be mounted at the clean, dry and well ventilation place. The prime mover and generator should be installed on a public frame, never put them on the cement floor, and ensure the public frame underformed. 2. Single bearing generators. Single bearing units are provided a SAE flywheel housing adapter and flexible drive discs to match the engine. Close tolerances are maintained in the manufacture of the generator to promote ease of alignment. Special stell drive discs are bolted the shaft. In some case spacer are used to achieve the proper :XG" dimension. Holes are provided in the periphery of the coupling discs which correspond to tapped holes in the engine flywheel. The outside diameter of the drive discs fit in a rabbet in the flywheel so that concentricity is assured. CAUTION: Grade 12.9 place to the flywheel. Do not use split type lock washers, they will cause stress rises, and may result in disc failure. The SAE flywheel housing adapter and the engine flywheel housing are designed to match each other, with no further alignment necessary. Shims may be necessary under the generator feet to insure a solid mounting. Do not force the feet to an uneven mounting surface, serious problems could result. ENDPLAY TEST PROCEDURES: After the generator has been assembled to the engine, check for endplay of the assembled set. Using a suitable lever, force the engine flywheel forward so that the crankshaft is pressed against its thrust bearing. When force is removed, the engine crankshaft should remain in position. Apply force in the opposite direction forcing the crankshaft towards the generator, and observe if the crankshaft remains in the position after force has been removed, refer to the engine manual for proper or recommended endplay. If the crankshaft springs away in either direction after force has been removed. It is an indication that the generator shaft is not moving freely, and normal life of the thrust bearing could be impaired. Probably cause of this problem are: a. Improper "XG" dimension of either the generator or the engine flywheel, or both. Generator bearing may be bottoming out in its bearing bracket. b. Misalignment. a) Improper seating of generator drive discs in the engine flywheel. b) Improper mating of the generator frame to the engine flywheel housing. c) Set sub-base is not true. Generator and or engine feet repair shims. See mounting instructions. 3. Two bearing generators. If generator couples with engine by flange rabbet. It is easy to mount. If it coupled by other way, should pay more attention to installation, it may be necessary to shim the generator feet for proper support and alignment. Aligning the generator and engine as accurately as possible will reduce vibration, increase bearing life, and minimize coupling wear. Common damage characteristics of diesel generator set camshaft The diesel generator set camshaft has a valve train camshaft and a fuel injection pump camshaft. The damage of the fuel pump camshaft in use is similar to that of the camshaft in the valve train, mainly including cam profile wear and camshaft bending. These damages will directly affect the timing of the gas distribution of the diesel generator set and the timing of fuel supply, affecting the normal working quality of the diesel generator set, resulting in overloading of other cylinders and seriously damaging the safety of the diesel generator set. Therefore, it is particularly urgent to timely repair and repair the damage of the cam surface of the diesel generator set and reduce the failure rate. The following is a brief introduction to the main damage characteristics of the diesel generator set camshaft. 1. Diesel generator set cam face wear When the camshaft is at rated speed, the linear speed is up to 1.3 m/s. During the oil supply process of driving the plunger upward, the friction and pressure of the cam surface are quite large due to the compression pressure of the fuel and the spring pressure. When the point of death is turned, the back side of the cam is subjected to the impact of the elastic force. Therefore, there are different degrees of wear on both sides of the cam, especially on the side of the cam lift, in addition to the wear, and a little fatigue pit. When the cam wears up to 0.3 mm, it will obviously affect the accuracy of the oil supply time and the fuel injection continuous angle, resulting in poor engine fire, power and economy. When there is a pit in the surface of the genset cam, the surface roughness will decrease, and if it continues to be used, it will accelerate the wear. 2. Diesel generator set camshaft neck wear The journal and the inner ring of the ball bearing are tightly fitted and generally do not wear. After the individual generator shafts wear out, the radial clearance is increased, which affects the speed regulation performance of the engine. 3. Diesel generator set cam keyway wear Generally, it is not common. In some cases, the installation of the transmission bushing is loose, so that the impact occurs during operation and wear. After wear, the oil supply time will lag behind. 4. Diesel generator set camshaft broken The broken part is mostly on the tapered cylinder of the shaft head. This is because a small number of camshafts have inherent defects during manufacture, fatigue wear during operation, and finally lead to breakage or jamming or breaking of the plunger, causing the camshaft transmission torque to rise significantly, exceeding the permissible stress of the camshaft, due to the conical head taper. The section of the part is small and it is easy to break here. Common damage causes and maintenance methods for camshafts of diesel generator sets Damage to the camshaft of the diesel generator set will directly affect the timing of the valve timing and fuel supply timing of the diesel generator set, and damage the normal operation of the generator set in severe cases. Therefore, it is very important to eliminate the cause of the damage of the cam surface of the diesel generator set and reduce the failure rate. The reasons for the damage of the diesel generator set are analyzed, and the maintenance method of the camshaft is discussed to improve the maintenance quality of the camshaft of the fuel injection pump of the diesel generator set. Common causes of damage to camshafts of diesel generator sets 1. When the oil pump is assembled, if the axis of the push rod is deflected during the assembly process, the roller and the camshaft cam are not in line contact, but a point contact occurs, resulting in uneven force, causing the roller to roll poorly, resulting in the roller and the cam. Work surface wear is intensified. 2. The lower body of the fuel injection pump and the cam are pressure-lubricated, and the oil is supplied to the lower body of the pump through the hollow bolt, the small copper pipe for supplying oil, and the joint body, and the cam and the roller are lubricated, which is often caused by the blockage of the hollow bolt, the small copper pipe and the joint body. The oil is not smooth, the heat generated by the cam and the roller can not be lost in time, initially causing the cam and the roller to be injured. The roller copper sleeve is worn out of excess, and the roller rolling on the cam causes the impact on the roller, which aggravates the wear of the copper sleeve and the positioning pin, sometimes Causes the copper sleeve to lock on the pin. Sliding friction occurs between the roller and the cam, as the roller forms an irregular ellipse and the top of the cam is severely damaged. 3. The clearance between the valve body and the push rod is too large. Due to improper fitting of the push rod, the clearance between the valve body and the push rod is too large, and the clearance between the push rod and the roller pin is too large, which can cause the guide pin to be poorly guided, and the roller axis and the cam axis are deviated, resulting in deviation The gas distribution roller is indexed at a small angle to injure the camshaft valve cam. Diesel generator set camshaft inspection method 1. Check the axial clearance of the camshaft, press the camshaft end, tilt the cam axial side, adjust the hands to "0", and then move the cam shaft to the other side. The indication value of the hands is the axial direction. The gap (0. 05~0. 15 mm is normal). If the axial clearance exceeds the specified value, it can be adjusted by replacing the adjustment spacers of different thicknesses. If the axial clearance is too large, replace the thinner gasket; if the axial clearance is too small, replace the thicker gasket. If the camshaft is left at 0. 05 mm, the right gasket (thickness is also 0. 05 mm) is taken out and placed on the left. 2. Check the camshaft curvature. If the degree of curvature exceeds 0.05 mm, the method of cold pressing should be used for repeated straightening. It is not advisable to use a hammer (hand hammer) to hard-hit. There are only two cases of camshaft bending: one is the bending of the central part of the camshaft; the other is the bending of the end of the camshaft (the end connected to the automatic oil feeder), which is equipped with a gear-driven type of oil supply. When the automatic advancer is used, the front end of the camshaft is most often bent. This kind of bending makes the tapered roller bearing set at the front end of the camshaft the most powerful, which makes the bearing race "out of the circle", the bearing cover loose and outward, the camshaft turbulence increases, the cam, the tappet ball The wear of the timing gears that mesh with each other in the gearbox is accelerated. In severe cases, the bearing roller support frame may be broken, the lubricating oil in the pump may leak from the loose bearing cover edge, the timing gear may be cracked, etc., therefore, the cam The bending of the shaft must be straightened in time. 3. Check the journal at the oil seal of the camshaft. If the depth of the groove is more than 0. 10 mm, repair repair is required. Check the cooperation of the camshaft keyway and the semicircle key. Check the camshaft taper and threads. If it is rough or damaged, use a stone to grind or replace the camshaft. Check the cam on the camshaft and replace the camshaft if it is damaged, deformed or severely worn. The amount of cam wear should not exceed 0.5 mm. Check the radial runout of the camshaft. If it exceeds 0.5 mm, it should be cold-pressed. Check the camshaft axial clearance. If it exceeds 0.15 mm, adjust or replace the camshaft. 4. Grinding the cam profile and roller, the roller and cam profile ensure uniform contact during assembly; the pusher body and the pump lower body should be carefully cleaned before inspection and check whether the roller surface is pocked or scratched, and its rotation and roller axle whether the up and down movement is flexible and whether the gap is too large. How Can We Maintain Oil Filter of Diesel Generator Set Introduction of Oil filter for Diesel Generator set The oil filter of diesel generator sets is used to remove mechanical impurities such as debris, dust and colloidal deposits in oil, so as to reduce the wear of mechanical parts, prolong the life of engine oil, prevent oil road clogging and serious accidents such as burning bearing bush. The performance of the oil filter directly affects the overhaul duration and service life of the diesel engine. The basic requirement of the oil filter effect is good and the resistance is small, and the two are contradictory. In order that the oil can be filtered well without causing excessive resistance, several filters are installed in the lubricating system of the general diesel engine, each in series with the main oil channel (all the circulating oil of the diesel engine passes through it. This filter is called full flow and parallel (this filter is called shunt). Oil filter can be divided into two types, including filter type and centrifugal type. In addition, magnetic core metal wear debris as an auxiliary filter measures. The filter type can be divided into fine filter, coarse filter and collecting filter according to the different filter ability. The oil filter can be divided into screen type, scraper type, wire wound type, sawdust filter type, paper filter core type and compound type according to their different structure. 6135 diesel engine oil filter, including coarse filter and fine filter two parts. The left component is a coarse filter. The oil is rotated at high speed from the oil duct of the body through the tangential rectangular oil channel on the filter sear into the conical cavity of the coarse filter body. Under the action of centrifugal force, the large impurity and a small part of oil enter the fine filter by squeezing along the wall of the conical cavity towards the lower end of the coarse filter seat. Most of the cleaning oil in the center of the conical chamber enters the main oil channel along the middle oil hole of the filter seat. The coarse filter does not need filter core, simple structure and convenient maintenance. The fine filter consists of a rotor housing, a rotor body, a rotor shaft and a filter base. The oil with impurity separated from the coarse filter enters the rotor, which has two holes in the opposite direction. When the diesel engine is working oil is ejected from two injection holes, under pressure. Due to the reaction of oil ejection, the rotor rotates at thigh speed. Under the action of centrifugal force, the mechanical impurities in the rotor cavity are separated out and thrown to the wall. The clean oil is ejected from the nozzle hole and then flows back to the oil pan. Maintenance of oil filter for diesel generator set Taking 135 series diesel engine as an example, the maintenance method of oil filter is described. The two type filters, except for the fine filter, use the same fine filter, except the winding type and the scraper type. The oil through the coarse filter is directly lubricated into the main oil channel after cooling, and the fine filter is a split flow type, and the fine filter is a split flow type, and the oil after fine filtration is directly returned to the oil bottom. The quality of filter performance directly affects the performance and service life of diesel engine. Therefore, in the use of oil filters should pay more attention to the filter effect. 1. There are two layers of filter net made of copper wire on the filter core of coiled oil filter. The filter clearance is less than 0.09mm. The filter should be removed after every 200 hours of operation of the diesel engine. When removing and washing, first loosen the nut on the lid, remove the filter element from the lid, then loosen the screw on the bottom shaft, remove the filter core and clean it in kerosene or diesel oil, then blow it off with compressed compressed air. En reassembling, the inner and outer filters should be flat at both ends to ensure sealing, the coarse filter shaft should be screwed to the end of the screw hole in the cover. 2. Structure of scraper oil filter. The filter element is assembled from the filter made of thin steel sheet, and the filtration gap between the filter is 0.06-0.10mm. When the diesel engine starts or continuously works for 4 hours, the handle shall be rotated in the direction indicated by the arrow on the filter cover. At this time, because of the rotation of the filter core, the scrape mounted on the locating shaft scraped off the dirt on the outer surface of the filter. After 200 hours of diesel engine work, the filter should be removed, the filter should be placed in diesel oil, and the grime should be scraped off by turning the handle. If there is too much dirt, you can loosen the nut at the lower end of the shaft, remove the filter in turn, soak it into diesel oil and wash it one by one, but you must be careful to keep the filter flat, then assemble it in order and number of pieces, otherwise the filter effect will be affected. After loading, pay attention to the sealing performance of the two ends of the filter element, and rotate the handle to rotate freely. 3. Oil filter is also called centrifugal oil filter. When HCA-11 lubricating oil is used, the oil temperature is 85 ℃ and the oil inlet pressure is 294KPa (3kgf/cm2), the rotor speed of the oil filter should be above 5500/min. Because of the high speed rotation of the rotor, the fine impurities in the coil are separated by centrifugal force, and collected on the inner wall of the rotor body. The filtered oil flows directly back to the oil pan through the return hole. This repeated cycle of the entire system of oil to achieve the purpose of filtering. Troubleshooting for Diesel Engine Temperature, Injection and Governor This is the part II of Yuchai YC4108D/YC4108ZD diesel engine troubles and troubleshooting. It contains the examples of normal troubles that users will encounter during operating diesel engine and many remedies are provided to different troubles. The problems include high oil pressure, much diluted oil, excessive oil consumption, high water outlet temperature, engines stop automatically, engine over-speeding and other troubles like injection and governor. I. Too High Oil Pressure, Much Diluted Oil, Excessive Oil Consumption Possible causes Remedies 1. Too high diesel engine load Be careful not to pull out the lead seal on the injection to avoid engine operating forepart,which will damage the engine forepart. 2. Incorrect engine oil grade Select oil according to the brand prescription. 3. Piston ring stuck or seriously worn causing gas blow - by and oil pumping - up. Dismantle, check and clean the piston an piston ring, replace the piston ring and cylinder sleeve if necessary. 4. Oil groove and bore of piston and piston ring clog. Dismantle and clean, and then reinstall it. 5. Oil cooling plug clog Clean,replace if necessary. 6. Diluted oil due to diesel or water in it Check the cylinder sleeve seal ring, oil cooler, injection pump, injector, cylinder head, and cylinder head washer, replace them if necessary. II. Too High Water Outlet Temperature Possible causes Remedies 1. Insufficient cooling water or too small water flow Check the level of cooling water, add water to adequacy if necessary; check for looseness of the belt, adjust it if necessary; check for leakage of the water pump, repair it in time if necessary; check and replace the damaged thermostat. 2. Too much scale in water passage and tank Clear it. 3. Thermostat failure Check and replace the damaged thermostat 4. Water temperature indicator damaged and transmitter failure. Check and compare the actual temperature with the indication, if they are not same, replace the transmitter or water temperature indicator. 5. Cooling fan damage Repair or replace. 6. Water pump damage Repair or replace. III. Engine Stops By Itself Possible causes Remedies 1. Fuel is used up Check and add fuel, and remove the air in the oil line 2. Oil line clogged or much air entering Check and clear the oil line; remove the air in the oil line; determine the location of the intake and then remove it. 3. Bushing burned due to the blockage in lubrication oil line. When the water temperature is normal, will lead to engine to stop immediately. Dismantle the sump, check and repair it and then replace the damaged parts. 4. Overheat piston scraping due to lack of water or too high water temperature. At first,make engine cool naturally(make sure not to add cold water or wash engine with it),then try to rotate the crankshaft. If it is jammed, start engine after adding cold water, or else move engine, check and repair it, then replace the damaged parts. IV. Engine over-Speed (Speed Rises Sharply) Possible cause Remedies 1. Injection pump ( governor) is in trouble Pull the stop handle when engine over speeding, if the engine is fail to stop, brake it with engaging a gear in transmission,or other measures should be taken to force it to stop, such as sealing off the in let, cutting off the fuel pipe and etc. After engine has stopped, adjust and repair it, replace the damaged parts if necessary. V. Common Trouble And Troubleshooting Remedies For Injection Possible causes Remedies 1. Injection failure: A. No oil in oil tank. B. Air or leaks in oil line. C. Oil line clogged. D. Fuel pumps failure. E. Plunger precision pair worn out, snapped or spring cracked. Check and add oil to adequacy. check and remove air, block up the leakage. Check and remove the blockage. Determine the location of the trouble and repair it. Determine the location of the damaged part and repair it. 2. Insufficient or uneven outlet A. Insufficient inlet oil pressure. B. Leaky oil outlet valve or spring crack. C. Plunger precision pair is out of order due to dirty or much wear. D. Loose plunger control gear. Check the condition of fuel pump and blockage of oil line, if necessary, remove it. If there is leakage, lap in pair; if there is damage, replace parts. Check and wash the oil line and precision pair, and replace the much worn one. Check for the looseness of the plunger control gear, tighten to the signal if necessary; regulate the injection pump on test bench better. VI. Common Trouble And Troubleshooting Remedies For Governor Possible causes Remedies 1. Unsteady speed (engine hunting): A. Inflexible flyweight or fly weight holder of governor. B. Improper idle adjustment C. Governor components worn out Determine the location of the troubles, and then repair it,replace parts and wash it if necessary. Readjust the idle adjusting screw. Check and repair it(By specialist manufactures) 2. Speed always lower than calibrated speed. A. Adjusting spring deflection. B. Control handles mis - positioning. C. Adjusting rack and pull bar jammed or loose. Regulate properly and replace the spring by professionals, do not do it without authorization. Determine the location the blockage, and then regulate and remove it. Check and adjust it, then ensure the rack slides flexibly arid the gear ring is not loose, otherwise readjust and repair it. 3. Speed rising promptly to abnormal state( runaway). A. Adjusting rack or throttle pull bar stuck. B. The pin connecting adjusting rack and pull bar drops. C. Governor spring crack. Regulate and repair it. Reinstall it and, if necessary, replace the damaged parts. Replace it and then readjust the injection pump on test bench. VII. Common Trouble For Fuel Supply Pump Possible causes Remedies 1. Check valve and piston wear or spring crack Check and repair, replace it if necessary. 2. Oil leak around joints Tighten or replace the seal gasket. 3. Outlet screen clog Check and clean it. 4. Oil and air leak around hand pump Dismantle and repair, replace it if necessary. VIII. Common Trouble And Troubleshooting Remedies For Injector Possible causes Remedies 1. Bad atomization of injector and insufficient or without fuel injection. A. Needle precision pair stuck and injection orifice clogged. B. High pressure pipe joints leakage C. Dirt on surface of needle Clear the carbon deposit and dirt. Clean and grind it,replace if it cannot be recondition. Determine the location of the troubles, and then recondition or replace it. Clean it. 2. Low injection pressure A. Pressure adjusting screw looseness B. Pressure adjusting spring crack C. Pressure adjusting spring deflection D. Spring seat and stem damage E. Needle stuck Readjust and tighten the stud. Check and replace. Check and replace. Repair or replace the damaged parts. Clean and grind it 3. Injector oil leak: A. Bad seal of needle precision pair. B. Needle stuck C. Nozzle retaining nut damage and deflection D. Sealing surface of injector body and needle body damage. Grind it after cleaning, replace it if ineffective. Clean and grind, replace it if ineffective. Replace it. Lap in pair after cleaning, replace it if it can not be reconditioned. Diesel generator set oil oil surface height increase and oil pump noise inspection method The oil level increase and the oil pump noise are common faults in the diesel generator set lubrication system. 1. Increased oil level Cause: 1. The fuel leaks into the oil basin, the plunger of the diesel engine fuel injection pump wears too much, the injector needle is not closed tightly or the needle valve is stuck in the open position; the clearance between the piston, the piston ring and the cylinder is too large, so that Fuel leaks under the cylinder wall to the oil sump. 2. The water seeps into the oil basin, and the cylinder head gasket is damaged; the cylinder wall comunicating with the water jacket is cracked; the rubber sealing ring between the wet cylinder liner and the cylinder block is not installed correctly or damaged. Method of exclusion First, take out the oil gauge to check if the oil is too thin. If you find that the oil level is high and very thin, you should further find the reason to see if there is water or fuel leaking and dilute the oil. The inspection method is as follows: Draw out the oil gauge and drop a few drops of oil on the paper to observe the oil color and smell. If the oil is milky yellow and has no other odor, it means that the water has entered the crankcase. Check whether the cylinder head gasket is damaged, whether there is crack in the cylinder water channel, whether the rubber sealing ring between the wet cylinder liner and the cylinder block is installed correctly or damaged. . If there is fuel smell in the oil, start the engine to see if it is working well. If the exhaust pipe emits black smoke after starting the diesel engine, check whether the needle valve of the injector is properly closed. If there is dripping, it should be repaired. If the engine is underpowered at normal operating temperature, check whether the plunger of the fuel injection pump leaks diesel, and whether the clearance between the piston, piston ring and cylinder is too large, and replace or repair. After checking the repair, release the old oil, clean the lubrication system, and re-add the specified amount of new oil. Oil pump noise Phenomenon: When the diesel engine is running, there is noise coming out at the oil magnetic device. Cause: The oil pump drive gear and the driven gear are excessively worn or improperly gapped. Inspection and elimination: If there is noise in the oil pump, check it after the diesel engine reaches normal temperature. Touch the screwdriver head near the oil pump, stick the wooden handle to the ear, and repeatedly change the speed of the diesel engine. If you hear a special noise and vibrate very much, it means that the oil pump is noisy. If the sound is not loud and even, it is normal. After long-term use of the oil pump, the gear wear is too large, not only has noise, but also can be observed from the reading of the oil meter. At this time, the reading of the oil pressure gauge is generally low. How to inspect and repair diesel generator oil pump Whether the lubrication system in the diesel generator set can ensure good lubrication conditions when the internal combustion engine is working. Although it is related to factors such as whether the oil passage is unblocked and the filter is functioning, the most important and decisive factor is the performance of the oil pump. Is it good? Therefore, during the maintenance of diesel engines. It is reminded that you should repair and repair the oil pump. 1. Common faults of oil pumps (1) The pressure limiting valve spring is broken and the ball valve is worn. (2) Wear of the main and passive gear tooth surfaces, gear shafts, and pump body and pump cover. (3) The tooth surface is peeled off, and the teeth are cracked and broken. 2. Inspection of the main and passive gear meshing clearance The increase in gear meshing clearance is caused by the friction between the gears of the oil pump gears. The inspection method is as follows: the pump cover is removed, and the gap between the two teeth is measured by the thickness gauge at three points of the main and passive gear meshing at 120°. Inspection of the main and passive gear meshing clearance The normal value of the meshing clearance between the driving gear and the driven gear of the oil pump is generally 0.15-0.35mm. Each model has clear regulations. For example, the 4135 diesel engine is 0.03-0.082, the maximum is not more than 0.15mm; the 2105 diesel engine is 0.10-0.20mm. The maximum is no more than 0.30mm. If the gear meshing clearance exceeds the maximum allowable limit, the new gear should be replaced in pairs. 3. Inspection and repair of gear end clearance The gap between the main and passive gear end faces of the oil pump and the pump cover is the end face clearance. The increase in the end face clearance is mainly due to the friction of the gear in the axial direction with the pump cover. 4. Inspection and repair of the working face of the oil pump pump cover The working surface of the oil pump pump cover will be sunken after being worn. The recess cannot exceed 0.05mm. The inspection method is as follows: the thickness gauge is matched with the steel ruler. The steel ruler is placed on the working surface of the pump cover, and then the gap between the working surface of the pump cover and the steel ruler is measured by a thickness gauge. If the specified value is exceeded, place the oil pump pump cover on a glass plate or flat plate and sand it with a valve. There are two ways to check it. (1) Fuse method Place the fuse on the gear surface, install the pump cover, tighten the pump cover screw and then loosen it. Take out the flattened fuse and measure the thickness. This thickness value is the end face clearance. This gap is generally 0.10-0.15mm, such as 0.05-10.11mm for 4135 diesel engine and 0.05-0.15mm for 2105 diesel engine. (2) Measuring with a thick gauge and a steel ruler Gear end face clearance = pump cover recession + gap between gear end face and pump body joint surface. If the end face clearance exceeds the specified value, there are two repair methods. (1) Grinding the pump body joint surface and the pump cover plane. (2) Adjust with a thinner gasket. 5. Inspection of the tip clearance The gap between the top end of the oil pump gear and the inner wall of the pump casing is called the tip clearance. There are two reasons for the increase in the tip clearance. (1) The gap between the center hole of the driven gear and the shaft pin is too large, causing friction between the top end of the gear and the inner wall of the pump cover, resulting in excessive tooth gap. (2) The clearance between the oil pump shaft and the bushing is too large. The inspection method is as follows: a thick gauge is inserted between the top surface of the gear and the inner wall of the pump casing for measurement. The tip clearance is generally 0.05-0.15mm, and the maximum is not more than 0.50mm, such as the 4135 diesel engine is 0.15-0.27mm, and the 2105 diesel engine is 0.03-0.15mm. If the specified allowable value is exceeded, the gear or pump body should be replaced. The uneven speed of diesel generator set is mostly caused by the abnormal resistance of the parts of the injection pump and governor and the slow response of the governor. Generally, there are two kinds of performance. One is a large swing, the voice is clearly identifiable, commonly known as gasp or tour car. The other is that the speed fluctuates in a small range, the sound is not easy to appear at low speed, which will lead to the diesel engine flameout. The following are eight reason for the uneven speed of diesel generator sets. When the wear gap at the joints of the governor increases, the movement parts such as steel ball or air hammer are blocked and the speed regulating spring fails, then the governor must overcome the resistance or eliminate the clearance first before the governor can move to adjust the increase or decrease of the fuel supply of the tooth rod or the fork pull rod. As the speed regulation is not in time, speed fluctuates high and low. For 135 or 105 type of combined fuel injection pump, it can be seen that the regulating rod moves repeatedly regularly by opening the side cover of the fuel injection pump. If the diesel engine swims slightly, then you can see the pull rod will jitter. Importance of reasonable rotational speed range of diesel generator set. It is important for diesel generator to maintain a reasonable working speed range. The reason is that it can reduce wear and tear effectively, and extend the service life or the genset. Especially when the diesel generator set starts, the crankshaft speed is low, the oil supply of the genst oil pump is not timely, and the oil temperature is low, the oil viscosity is high, the friction surface is difficult to establish liquid lubrication, so the wear is very serious. The friction of diesel generator increases with the increase of speed and load. As the load increases, the unit pressure on the friction surface increases and the thermal condition is poor. With the increase of rotational speed, the number of friction times per unit time is half plus, and at the same power, the increase of rotational speed is larger than the wear when load is increased. However, too low rotational speed can not guarantee good liquid lubrication conditions, also increase wear. In addition, when diesel generator sets work unsteadily, such as acceleration, deceleration, stopping and starting, the lubricating condition of diesel generator sets is poor, the thermal state is unstable, and the wear will increase due to the frequent changes of rotational speed and load. Generally speaking, there are two kinds of rotating speed of normal generator sets. One is 1500 rpm, the other is 1800 rpm. It is wrong to artificially turn down or raise the speed of the generator. Adjusting skill of speed controller before and after starting of diesel engine. In order to understand the adjustment of engine speed controller before and after starting, we must first understand how the speed controller works. Adjustment before starting diesel engine Observe a potentiometer that regulates gain and stability. In a general case factory set at 12:00 position (that is middle position red dial code open). The controller has already been set up when it is out of the factory, so it is not necessary to adjust the controller before starting the diesel engine, and the user only needs to start the diesel engine to make fine adjustment. Adjustment of controller after starting The actuator should supply the maximum amount of fuel until the diesel engine starts, and the controller should be controlled in the idle position. If the engine is unstable after starting, adjust the gain and stability potentiometer counterclockwise until the engine is stable. The external high/low speed switch is disconnected and the diesel engine enters the rated speed. Adjust the rated speed potentiometer or the external micro=adjustable potentiometer to adjust the forehead fixed speed precisely. The clockwise rotation frequency of the rated speed setting point is increased. After starting, the following adjustments are made when the diesel engine s no longer loaded. Rotate the gain potentiometer clockwise until it is unstable, then fine tune it counterclockwise until the system is stable, and then progress counterclockwise to adjust a portion of the nozzle to ensure stability. Rotate the stability potentiometer clockwise until instability occurs, then adjust counterclockwise to stability, and then further fine-tune part of the counter-clickwise to ensure that the engine rotates steadily. After the adjustment of gain and stability, the rated speed is adjusted by trimming potentiometer to meet the design requirements of the generator set. If the engine needs to introduce idle operation, the high/low speed switch is closed, and then adjust the speed of the potentiometer to the required speed, and adjust clockwise to increase the frequency (usually 50% of the rated speed). If the diesel engine can not be stabilized by the above adjustment, it is necessary to adjust the dial up switch at this time, as follows, the gain and stability potentiometer are adjusted again after each trimming, until the engine is stable. |
作者
dieselgenerator 存档
July 2022
类别 |