1、柴油發電機維修維護保養案例分析和故障排除 柴油發電機組維護案例集一、柴油機部分案例、柴油機不能啟動柴油機不能啟動原因是多種多樣的，主要有以下四點：1、啟動系統。2、燃油系統。3、壓縮沖程壓力不足。4、環境溫度影響1、啟動系統故障分析1啟動電池電壓低，實際容量不足顯示電壓為虛電壓；2啟動電池電纜與馬達接線錯誤；3啟動馬達電磁開關故障；4康明斯、卡勒比特、威爾遜等型號柴油機啟動接觸器故障；故障處理1用萬用表測量單體電池電壓、充電器直流輸出是否正常，檢查鉛酸電池液面高度，適時添加蒸餾水；2拆卸馬達，檢調電磁開關內觸點，如果觸點燒壞，更換電磁開關；3檢查電池負極電纜是否接地機殼，接線錯誤，重新連接電纜

2、即可；4用萬用表測量康明斯、卡勒比特、威爾遜柴油機啟動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、燃油系統故障分析燃油系統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，啟動柴油機，至每缸出油為止，然后旋緊高壓油管接頭。康明斯柴油機油路排空氣方法與其它柴油機的不同之處，是其依靠啟動柴油機來完成的。3、壓縮沖程壓力不足故障分析1氣門漏氣；2活塞環過度磨損。故障處理1拆卸氣缸罩、氣缸蓋，檢查氣門間隙、氣門彈簧、氣門導管及氣門座的密封情況，若氣門密封線不連

3、續時，可用氣門研砂研磨成至一條連續光滑的線；2取出活塞，更換活塞環。4、環境溫度低影響故障分析1加熱器故障；2柴油過稠。故障處理1拆卸加熱器側蓋，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、20號、35號（數字表示凝點溫度，10號輕柴油凝點為10度）輕柴油不等。案例二、 柴油機排氣煙色不正常柴油機帶負載正常運行時，排氣煙色一般為淡灰色，負載略重時，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柴油機超負載運行；2噴油器滴油，霧化不良；3供油時間

4、過早。故障處理1調整負載，使之在額定范圍內；2應在柴油機怠速運行時，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：噴油器沒有故障時，停止噴油后柴油機的轉速會顯著下降。噴油器有故障時，停止噴油后柴油機的轉速變化很小，排氣不冒黑煙，檢調該噴油器；3按說明書要求，檢調供油提前角。維護體會對噴油器有如下要求：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、沒有漏油、滲油現象。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供油時間過遲；3柴油中有水。故障處理1更換氣缸墊；2按說明書要求，檢調供油提前角；3安裝燃油油水分離器。維護體會為使氣缸

5、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，擰緊螺栓時應有一定次序，即按由中央對稱的向四周擴展的順序分次進行，最后一次扭力扳手按說明書規定的扭矩值擰緊。拆卸螺栓反之。3、排氣冒藍煙表明有機油串入燃燒室燃燒故障分析1油底殼機油油面過高；2油環卡死在環槽內或斷裂；3連桿軸瓦與連桿軸頸間隙過大。故障處理1保持油底殼機油位于標尺靜滿刻度，可適時放掉一些機油；2清理活塞環槽內積碳，更換油環；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、柴油機機油壓力低故障分析1油底殼內機油平面低；2機油壓力調節器彈簧斷裂；3機油濾清器橡皮圈墊老化

6、滲油一般為國產柴油機；4機油壓力表壞；5油底殼內機油集濾器堵塞。故障處理1保持油底殼機油位于標尺靜滿刻度，適時添加機油；2更換機油壓力調節器彈簧；3更換橡皮圈墊；4更換壓力表；5拆卸油底殼，清洗機油集濾器。維護體會機油壓力調整方法：擰下調節閥上的油封螺帽，松開鎖緊螺母，在用平口起子轉動調節螺栓，旋進調節螺栓、壓力升高。反之，壓力降低，調整到規定范位為止，再緊固螺母和油封螺母。案例、柴油機運行時，油溫升到90度以上，排氣冒藍煙故障分析連桿螺栓松動，燒軸瓦的征兆。故障處理檢查連桿螺栓是否松動，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，按說明書要求的扭矩用扭力板手擰緊連桿螺栓

7、。維護體會如遇到以上情況應緊急停機。查明故障原因，防止重大事故發生（如飛車）。柴油機正常運行時，機油油溫一般在70-90度之間。案例、柴油機技術保養后，空載試機，三相交流同步發電機輸出電壓360V故障分析1進、排氣門間隙分別調整為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；5三相交流同步發電機運行正常。案例七、 威爾遜柴油機自動AUTO運行時，出現油壓低告警停機故障分析1“606”控制器面板油壓低指示燈亮；2油底殼機油位于標尺靜滿刻度；3檢查機油濾清器正常；4檢查油底殼內機油集濾器正常。故障處理以上分析：判斷是油壓感應塞故障。拔掉油壓感應塞連

8、線，手動啟動柴油機，機組運行正常。油壓感應塞壞，更換此組件后，模擬市電停電，斷開市電取樣空氣開關3P，柴油機自動AUTO啟動，機組運行正常。維護體會出現此故障：1檢查柴油機機油是否溢出，2檢查油壓感應塞。案例、高壓噴油泵常見故障1柴油機運行，噴油分泵不出油或少出油；2柴油機停機后，壓動輸油泵的手泵，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。維護體會柱塞式噴油泵泵體內有兩對精密偶件，一對是柱塞與柱塞套筒，另一對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

9、合，不能漏油。噴油泵拆卸時，注意每一個分泵零件應做好記號并放在一起。柱塞偶件及出油閥偶件不能調換，必須成對安置。拆卸后的零件放在柴油中清洗吹凈。噴油泵總成在工作1000小時或更換零件裝配完畢后，必須進行調整。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備條件下進行。案例、康明斯柴油機運行時，出現“游車”現象故障分析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，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，故障仍然未排除。根據維護經驗，判斷是執行器內柱塞偶件輕微磨損所造成，更換執行器PAPT NO3408324，帶

10、載試機60分鐘，機組運行正常。維護體會柴油在使用之前，首先要靜置并過濾。案例、威爾遜柴油機自動AUTO運行時，出現水溫高告警停機故障分析1“606”控制器面板水溫高指示燈亮，液晶屏顯示水溫100度，交流負載140A負載在額定范圍內；2節溫器開啟冷卻水形成大循環；3檢查水溫感應塞正常；4水箱冷卻水滿。故障處理以上分析：判斷是水箱冷凝器過臟，引起水溫高告警停機。拆下水箱，清洗冷凝器水箱，安裝后，柴油機自動AUTO啟動，機組運行正常。 維護體會清洗冷凝器水箱的水適當添加堿，也就是說，多放些水，少放些堿，以免損傷冷凝器水箱。案例、柴油機自動AUTO運行時，出現油壓低告警停機故障分析1控制器面板油壓低指

11、示燈亮；2油底殼機油位于標尺靜滿刻度；3檢查機油濾清器正常。故障處理以上分析：判斷是機油壓力控制器故障。拆卸機油壓力控制器面板，用萬用表測量交流電壓385V，輸入電壓正常。檢查是機油壓力控制器觸點接觸不良，擦試并調整觸點。柴油機自動AUTO啟動，機組運行正常。案例、柴油機自動AUTO運行時，出現水溫高告警停機故障分析1控制器面板水溫高指示燈亮，水溫表讀數為68度：2水箱冷卻水滿；3檢查風扇皮帶張力在規定范圍之內，水泵運行正常，柴油機沒出現漏水現象。故障處理以上分析：判斷是節溫器未開啟。拆卸節溫器并更換，柴油機自動AUTO啟動，機組運行正常。維護體會柴油機閉式強制循環水冷卻系統中，利用節溫器來改

12、變冷卻水的循環流量，以達到自動控制冷卻強度的目的。節溫器安裝在氣缸蓋出水處。所以在維護過程中，不允許隨便取消節溫器，這樣會影響柴油機的正常使用。節溫器初開溫度68-72度，全開溫度為80-86度，形成冷卻水的大循環。冷卻水一定要用蒸餾水，并且加防銹、防凍液。案例、柴油機怠速運行時，三相交流同步發電機有異常響聲故障分析同步發電機后背輪橡皮圈墊磨損。故障處理考慮到柴油機與同步發電機連接方式為推拔式。所以在拆卸同步發電機緊固螺栓同時，用葫蘆將其調起，拔出同步發電機。發現后背輪六個螺栓分別裝有24個橡皮圈墊磨損無剩。更換其備件，柴油發電機組運行正常。維護體會柴油發電機組運行時，聽到有異常響聲，應立即停

13、機，找出故障原因并排除。案例、柴油機噴油提前角的調整為了獲得良好的燃燒，使柴油機運行正常，并得到最經濟的燃油耗量，噴油泵校檢后在安裝時都必須進行噴油提前角的調整供油提前角2831度、噴油提前角20-23度。調整時，盤動飛輪的齒圈，使飛輪上的定時零度線對準飛輪殼上檢視窗的指針，第一缸活塞位于膨脹沖程始點用手捻推桿左右活動自如，第一缸的進、排氣門處于關閉狀態。拆下噴油泵側蓋板，轉動接合器接盤使第一缸柱塞彈簧處于剛剛壓縮狀態。然后將飛輪反方向順時針轉動約23度即可，緊固噴油泵螺栓調整調速器柴油機轉速偏低，可松開接合器接盤上的螺栓進行微調傳動軸接頭上刻有分度線，每格3度，然后緊固螺栓。在實際維護工作中

14、，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，活塞距離壓縮沖程上止點前的曲軸轉角。因為檢查供油提前角比噴油提前角方便而準確。如果查出柴油機供油提前角，若再想知道該機的噴油提前角，只須將供油提前角的數值減去8度，就是噴油提前角。維護體會柴油機供油時間過早或過遲都是有害的。柴油機供油時間過早，即供油提前角過大。當活塞距離上止點不遠時，噴油泵就開始供油。這時，由于氣缸氣體的壓力和溫度都較低，使著火延遲期拖長。造成柴油機不易啟動，運行粗暴，產生敲缸，功率下降，排氣管冒黑煙，并導致機件早期磨損。供油時間過遲，即供油提前角太小，由于燃燒是在工作沖程活塞已經下行之后進行，這就使柴油機功率下

15、降，燃油耗油率增加，容易引起機體溫度過高，冷卻水沸騰，排氣管冒白煙或冒黑煙。柴油機噴油提前角是不同的，調整時應按說明書進行。二、柴油機控制部分案例一、康明斯柴油機正常運行時，三相交流同步發電機輸出電壓95V故障分析用萬用表測量勵磁部分定子、轉子繞阻阻值均正常，判斷為自動調壓AVR板故障。故障處理Maintenance of diesel generator maintenance case analysis and troubleshooting            

16、60;                        Diesel generator set maintenance case setA, diesel engine part of the case, the diesel engine can not startThe diesel engine can not start a variety of r

17、easons, mainly the following four points: 1, start the system. 2, the fuel system. 3, the pressure of the compression stroke. 4, the ambient temperature1, start the systemFailure Analysis<1> to start the battery voltage is low, the actual capacity of less than <display the voltage of the vi

18、rtual voltage><2> start battery cable and motor wiring error;<3> to start the motor electromagnetic switch failure;<4> Cummins, Kalebite, Wilson, model engine start contactor failure;Troubleshooting<1> with a multimeter to measure the cell voltage, the charger DC output is

19、 normal, check the fluid level of lead-acid batteries, timely add distilled water;<2> and then remove the motor, prosecutors electromagnetic switch contacts if the contacts burn out, replace the solenoid switch;<3> Check the negative battery cable is grounded to the "chassis" w

20、iring error, reconnect the cables can be;<4> measured with a multimeter Cummins, Kalebite, Wilson diesel start contactor coil resistance <its resistance is usually in the tens of ohms> not normal, replace the contactor;2, the fuel systemFailure AnalysisLeakage into the air in the fuel sy

21、stemTroubleshootingThe low-pressure tubing to exhaust air: Loosen the injection pump to put gas plug, pressure to move the fuel pump the hand pump to diesel overflow without bubbles so far, and then tighten the plug, and hand pump tightened. The high-pressure tubing to exhaust air: one by one Loosen

22、 the injection pump high-pressure tubing connector, start the engine until the oil per cylinder, and then tighten the high pressure tubing connector. Cummins diesel engine oil row air method and other diesel engines, is completed to start the engine.3, the pressure of the compression strokeFailure A

23、nalysis<1> valve leakage;<2> excessive piston ring wear.Troubleshooting<1> Remove the cylinder cover, cylinder head, check the valve clearance, valve springs, valve guides and valve seat seal, valve seal line is not continuous, available valve research sand ground into a continuous

24、 smooth line;<2> Remove the piston, replace the piston rings.4, ambient temperature, low-impactFailure Analysis<1> heater failure;<2> diesel too thick.Troubleshooting<1> Remove the heater side of the cover, check the AC input connection, the voltage is normal, if normal, bad

25、heater, replace the heater;<2> pro rata to add kerosene to the diesel, or selection on the 10th, the 20th, No. 35 (the numbers indicate the pour point temperature, on the 10th, light diesel oil solidifying point of -10 degrees) light diesel ranges.Case 2, diesel exhaust smoke color is not norm

26、alThe diesel engine load during normal operation, the exhaust smoke color is generally light gray, slightly heavier load, it may be dark gray. Exhaust smoke color is not normal:1, the exhaust black smoke;2, exhaust, white smoke;3, the exhaust take the blue smoke.1, the exhaust black smoke <said t

27、he diesel combustion chamber imperfect>Failure Analysis<1> diesel engine super-load operation;<2> injector drop of oil, poor atomization;<3> oil too early.Troubleshooting<1> to adjust the load, so that within the rated range;<2> diesel engine idle running one high-pr

28、essure tubing connector, loosen the injector and injector to stop fuel injection to observe the exhaust Color: injector without a fault, stop fuel injection diesel engine speed decreased significantly. Injector failure to stop the fuel injection diesel engine speed change is very small, not black sm

29、oke exhaust, the prosecutors of the injector;<3> the instructions, prosecutors fuel supply advance angle.Maintenance experienceInjector has the following requirements: to have a certain injection pressure, a certain range of the spray cone angle, spray well. The end of the injector can quickly

30、 stop the oil, no oil leakage, oil leakage phenomenon.2, the exhaust white smoke <said diesel fuel droplets in the combustion chamber unburned> Failure Analysis<1> cylinder head gasket is damaged;<2> oil too late;<3> diesel water. Troubleshooting<1> replace the cylinder

31、 head gasket;<2> the instructions, prosecutors fuel supply advance angle;<3> Install the fuel oil and water separator.Maintenance experienceThe cylinder to get a good seal between the cylinder head and cylinder block, cylinder head gasket must be added. The cylinder head bolted on the cy

32、linder block and tighten the bolts should have a certain order, that is, according to the order of expansion by the central symmetry around the time the last torque wrench according to the instructions prescribed torque value tighten. Demolition of bolts and vice versa.3, exhaust take Lanyan <tha

33、t the oil string into the combustion chamber>Failure Analysis<1> the sump oil level is too high;<2> oil ring stuck in the ring slot or fracture;<3> rod bearing and rod journal gap is too large.Troubleshooting<1> to keep the sump oil is located in the scale static full-scal

34、e, may be timely to let go of some of the oil;<2> to clean up the carbon deposition of piston ring slot, replace the oil ring;<3> Remove the oil pan, connecting rod bolts to remove the bearing, intuitive bearing surface burn signs, if any, replace the connecting rod bearing.Three cases,

35、low engine oil pressureFailure Analysis<1> sump oil flat;<2> oil pressure regulator spring break;<3> oil filter rubber ring pad aging oil leakage <general domestic diesel><4> bad oil pressure gauge;<5> the oil sump set of filter clogging.Troubleshooting<1> k

36、eep the sump oil in the scale static full-scale, timely add oil;<2> to replace the oil pressure regulator spring;<3> to replace the rubber ring pad;<4> replace the pressure gauge;<5> and then remove the oil pan, oil cleaning set filters.Maintenance experienceOil pressure adju

37、stment method: Remove the control valve on the oil seal nut, loosen the lock nut, turn the adjusting screw with the flat screwdriver, precession of the adjusting bolt, the pressure increased. On the contrary, the pressure is reduced, the adjustment to the required range of bit far, then tighten the

38、nut and seal nut.Case, the diesel engine running, the oil temperature rose to 90 degrees above, take the blue smoke exhaustFailure AnalysisThe connecting rod bolt is loose, and burning bush signs of.TroubleshootingCheck the connecting rod bolt is loose, the demolition of connecting rod bearings, int

39、uitive connecting rod bearing surface burn signs, if burned, replace the bearing, according to the instructions of torque with a torque wrench, tighten the connecting rod bolt.Maintenance experienceCase of the above should be an emergency stop. To identify the cause of the failure to prevent major a

40、ccidents (eg, Speed). Normal operation of the diesel engine, engine oil oil temperature between 70 - 90 degrees.Case, the maintenance of diesel technology, no-load test machine, three-phase AC synchronous generator output voltage of 360VFailure Analysis<1> into the exhaust valve clearance adju

41、stment 0.30MM, 0.35MM normal;<2> to replace the cylinder head gasket;<3> checksum injector, fuel pump;<4> to clean up the piston carbon deposition, replace the piston rings;<5> three-phase AC synchronous generator is operating normally.Case seven, Wilson diesel the automatic

42、<AUTO> run-time, low oil pressure alarm shutdownFailure Analysis<1> "606" controller panel, low oil pressure indicator light;<2> sump oil in scale static full scale;<3> Check the oil filter is normal;<4> Check sump oil set a normal filter.TroubleshootingThe ab

43、ove analysis: to determine the oil pressure sensor plug failure. Unplug the oil pressure sensor plug connection, manually start the engine, the unit is operating normally. Bad oil pressure sensor plug, replace this component, simulate a mains power failure, disconnect the mains sampling air switch &

44、lt;3P>, diesel automatic <AUTO> the start, the unit is operating normally.Maintenance experienceThis failure occurs: <1> Check engine oil overflow, <2> check the oil pressure sensor plug.Case, high pressure common injection pump failure<1> diesel engine running, the inject

45、or Fenbeng no oil or less oil;<2> diesel engine shutdown, the pressure action pump, hand pump, injector wheel cylinder diesel constantly overflow.Failure Analysis<1> injection pump plunger or spring failure;<2> injection pump outlet valve or spring failure.Troubleshooting<1>

46、replace the injection pump plunger or spring;<2> replace the fuel injection valves of the spring.Maintenance experiencePlunger injection pump in the pump body precision coupling two pairs, a pair of plunger sleeve, the other is the seat of the oil valve and the oil. Oil delivery valves install

47、ed on top of the plunger, and pressed close fit between the two, can not spill. Injection pump disassembly, pay attention to each wheel cylinder parts should be well marked and put together. Even parts of the plunger and delivery valve replacement, must be paired with placement. After the demolition

48、 of parts on diesel cleaning blowing. The fuel pump assembly must be adjusted to work 1000 hours or replacement parts assembled. Due to the high precision of the injection pump, so this work must be performed by the skilled craftsmen in a certain device conditions.Case, the Cummins diesel engine run

49、ning, the "free ride" phenomenonFailure Analysis<1> Check diesel fuel filter is normal;<2> Check the air filter is clean;<3> the frequency of replacement circuit boards, no-load test machine, the fault persists.TroubleshootingThe above analysis: It may be poor fuel PT pum

50、p oil. School inspection PT pump, no-load test machine, the fault is still not excluded. Maintenance experience, judgment is caused by the actuator plunger slightly worn replacement actuator <PAPT NO3408324>, with a load testing machine 60 minutes, the unit is operating normally.Maintenance ex

51、perienceDiesel oil prior to use, we must first put it aside and filter.Case, Wilson diesel automatic <AUTO> run-time, high water temperature alarm stopFailure Analysis<1> "606" controller panel water temperature indicator light, LCD display temperature of 100 degrees, the AC lo

52、ad 140A <load within the rated range><2> the thermostat to open the cooling water to form a large circle;<3> Check the water temperature sensor plug is normal;<4> full tank of cooling water.TroubleshootingThe above analysis: to determine the water tank condenser is too dirty,

53、 caused by high water temperature alarm shutdown. Remove the tank, cleaning the condenser <tank> After installation, the diesel engine automatically <AUTO> start, the unit is operating normally.    Maintenance experienceCleaning condenser water tank> water is appro

54、priate to add the alkali, that is, put some more water and less to put some alkali, so as not to damage the condenser <tank>.Case, the diesel engine automatically <AUTO> run, a low oil pressure shutdown alarmFailure Analysis<1> controller panel, low oil pressure indicator light;<

55、;2> sump oil in scale static full scale;<3> check the oil filter properly.TroubleshootingThe above analysis: the judgment is that the oil pressure controller failure.Remove the oil pressure controller panel with a multimeter to measure AC voltage 385 V, the input voltage is normal. Check th

56、e oil pressure controller contacts poor contact, wipe, and adjust the contact. Diesel Engine Automatic <AUTO> start, the unit is operating normally.Case, the diesel engine automatically <AUTO> run, high water temperature alarm shutdownFailure Analysis<1> controller panel water temp

57、erature indicator light, water temperature readings of 68 degrees:<2> cooling water tank is full;<3> Check fan belt tension within the specified range, normal pump operation, the diesel engine is no water leakage.TroubleshootingThe above analysis: the judgment is that the thermostat is n

58、ot turned on.Remove the thermostat and replace, diesel automatic <AUTO> the start, the unit is operating normally.Maintenance experienceDiesel engine closed forced circulation water cooling system, the use of the thermostat to change the flow of cooling water circulation in order to achieve the purpose of the automatic control of cooling intensity. The outlet thermostat installed in the cylinder head. In the maintenance process, not allowed to arbitrarily cancel the thermostat, it will affect