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1、柴油发电机维修维护保养案例分析和故障排除 柴油发电机组维护案例集一、柴油机部分案例、柴油机不能启动柴油机不能启动原因是多种多样的，主要有以下四点：1、启动系统。2、燃油系统。3、压缩冲程压力不足。4、环境温度影响1、启动系统故障分析1启动电池电压低，实际容量不足显示电压为虚电压；2启动电池电缆与马达接线错误；3启动马达电磁开关故障；4康明斯、卡勒比特、威尔逊等型号柴油机启动接触器故障；故障处理1用万用表测量单体电池电压、充电器直流输出是否正常，检查铅酸电池液面高度，适时添加蒸馏水；2拆卸马达，检调电磁开关内触点，如果触点烧坏，更换电磁开关；3检查电池负极电缆是否接地机壳，接线错误，重新连接电缆
2、即可；4用万用表测量康明斯、卡勒比特、威尔逊柴油机启动接触器线圈阻值其阻值一般在几十欧姆，不正常则更换接触器；2、燃油系统故障分析燃油系统中漏入空气故障处理低压油管排空气方法：旋松喷油泵上放气螺塞，压动输油泵的手泵，至柴油溢出不带气泡为止，然后旋紧螺塞，并将手泵旋紧。高压油管排空气方法：逐一旋松喷油泵高压油管接头，启动柴油机，至每缸出油为止，然后旋紧高压油管接头。康明斯柴油机油路排空气方法与其它柴油机的不同之处，是其依靠启动柴油机来完成的。3、压缩冲程压力不足故障分析1气门漏气；2活塞环过度磨损。故障处理1拆卸气缸罩、气缸盖，检查气门间隙、气门弹簧、气门导管及气门座的密封情况，若气门密封线不连
3、续时，可用气门研砂研磨成至一条连续光滑的线；2取出活塞，更换活塞环。4、环境温度低影响故障分析1加热器故障；2柴油过稠。故障处理1拆卸加热器侧盖，检查交流输入端连线、电压是否正常，如果正常，加热器坏，更换加热器；2按比例往柴油添加煤油，或选用10号、20号、35号（数字表示凝点温度，10号轻柴油凝点为10度）轻柴油不等。案例二、 柴油机排气烟色不正常柴油机带负载正常运行时，排气烟色一般为淡灰色，负载略重时，则可能为深灰色。这里排气烟色不正常是指：1、排气冒黑烟；2、排气冒白烟；3、排气冒蓝烟。1、排气冒黑烟表示柴油在燃烧室燃烧不完善故障分析1柴油机超负载运行；2喷油器滴油，雾化不良；3供油时间
4、过早。故障处理1调整负载，使之在额定范围内；2应在柴油机怠速运行时，逐一松开喷油器高压油管接头，以停止喷油器的喷油，观察排气的颜色：喷油器没有故障时，停止喷油后柴油机的转速会显著下降。喷油器有故障时，停止喷油后柴油机的转速变化很小，排气不冒黑烟，检调该喷油器；3按说明书要求，检调供油提前角。维护体会对喷油器有如下要求：要有一定的喷射压力、一定的射程、一定的喷雾锥角、喷雾良好。喷油终了能迅速停油、没有漏油、渗油现象。2、排气冒白烟表示柴油滴在燃烧室未燃烧故障分析1气缸垫损坏；2供油时间过迟；3柴油中有水。故障处理1更换气缸垫；2按说明书要求，检调供油提前角；3安装燃油油水分离器。维护体会为使气缸
5、得到良好密封，气缸盖与气缸体之间必须加气缸垫。气缸盖用螺栓紧固在气缸体上，拧紧螺栓时应有一定次序，即按由中央对称的向四周扩展的顺序分次进行，最后一次扭力扳手按说明书规定的扭矩值拧紧。拆卸螺栓反之。3、排气冒蓝烟表明有机油串入燃烧室燃烧故障分析1油底壳机油油面过高；2油环卡死在环槽内或断裂；3连杆轴瓦与连杆轴颈间隙过大。故障处理1保持油底壳机油位于标尺静满刻度，可适时放掉一些机油；2清理活塞环槽内积碳，更换油环；3拆卸油底壳、连杆螺栓取出轴瓦，直观轴瓦表面是否有烧坏迹象,如果有，更换连杆轴瓦。案例三、柴油机机油压力低故障分析1油底壳内机油平面低；2机油压力调节器弹簧断裂；3机油滤清器橡皮圈垫老化
6、渗油一般为国产柴油机；4机油压力表坏；5油底壳内机油集滤器堵塞。故障处理1保持油底壳机油位于标尺静满刻度，适时添加机油；2更换机油压力调节器弹簧；3更换橡皮圈垫；4更换压力表；5拆卸油底壳，清洗机油集滤器。维护体会机油压力调整方法：拧下调节阀上的油封螺帽，松开锁紧螺母，在用平口起子转动调节螺栓，旋进调节螺栓、压力升高。反之，压力降低，调整到规定范位为止，再紧固螺母和油封螺母。案例、柴油机运行时，油温升到90度以上，排气冒蓝烟故障分析连杆螺栓松动，烧轴瓦的征兆。故障处理检查连杆螺栓是否松动，拆卸连杆轴瓦、直观连杆轴瓦表面是否有烧坏迹象,如果烧坏，更换轴瓦，按说明书要求的扭矩用扭力板手拧紧连杆螺栓
7、。维护体会如遇到以上情况应紧急停机。查明故障原因，防止重大事故发生（如飞车）。柴油机正常运行时，机油油温一般在70-90度之间。案例、柴油机技术保养后，空载试机，三相交流同步发电机输出电压360V故障分析1进、排气门间隙分别调整为0.30MM、0.35MM正常；2更换气缸垫；3校检喷油器、喷油泵；4清理活塞积碳，更换活塞环；5三相交流同步发电机运行正常。案例七、 威尔逊柴油机自动AUTO运行时，出现油压低告警停机故障分析1“606”控制器面板油压低指示灯亮；2油底壳机油位于标尺静满刻度；3检查机油滤清器正常；4检查油底壳内机油集滤器正常。故障处理以上分析：判断是油压感应塞故障。拔掉油压感应塞连
8、线，手动启动柴油机，机组运行正常。油压感应塞坏，更换此组件后，模拟市电停电，断开市电取样空气开关3P，柴油机自动AUTO启动，机组运行正常。维护体会出现此故障：1检查柴油机机油是否溢出，2检查油压感应塞。案例、高压喷油泵常见故障1柴油机运行，喷油分泵不出油或少出油；2柴油机停机后，压动输油泵的手泵，喷油分泵不断有柴油溢出。故障分析1喷油泵柱塞偶件或弹簧故障；2喷油泵出油阀偶或弹簧故障。故障处理1更换喷油泵柱塞偶件或弹簧；2更换喷油泵出油阀偶件或弹簧。维护体会柱塞式喷油泵泵体内有两对精密偶件，一对是柱塞与柱塞套筒，另一对是出油阀与出油阀座。出油阀偶件安装在柱塞偶件的上面，并被压紧，两者之间紧密贴
9、合，不能漏油。喷油泵拆卸时，注意每一个分泵零件应做好记号并放在一起。柱塞偶件及出油阀偶件不能调换，必须成对安置。拆卸后的零件放在柴油中清洗吹净。喷油泵总成在工作1000小时或更换零件装配完毕后，必须进行调整。由于喷油泵的精密程度很高，因此这一工作必须由较熟练的技工在一定设备条件下进行。案例、康明斯柴油机运行时，出现“游车”现象故障分析1检查柴油滤清器正常；2检查空气滤清器滤芯清洁；3更换频率电路板，空载试机，故障仍然。故障处理以上分析：可能是燃油PT泵供油不畅。校检PT泵后，空载试机，故障仍然未排除。根据维护经验，判断是执行器内柱塞偶件轻微磨损所造成，更换执行器PAPT NO3408324，带
10、载试机60分钟，机组运行正常。维护体会柴油在使用之前，首先要静置并过滤。案例、威尔逊柴油机自动AUTO运行时，出现水温高告警停机故障分析1“606”控制器面板水温高指示灯亮，液晶屏显示水温100度，交流负载140A负载在额定范围内；2节温器开启冷却水形成大循环；3检查水温感应塞正常；4水箱冷却水满。故障处理以上分析：判断是水箱冷凝器过脏，引起水温高告警停机。拆下水箱，清洗冷凝器水箱，安装后，柴油机自动AUTO启动，机组运行正常。 维护体会清洗冷凝器水箱的水适当添加碱，也就是说，多放些水，少放些碱，以免损伤冷凝器水箱。案例、柴油机自动AUTO运行时，出现油压低告警停机故障分析1控制器面板油压低指
11、示灯亮；2油底壳机油位于标尺静满刻度；3检查机油滤清器正常。故障处理以上分析：判断是机油压力控制器故障。拆卸机油压力控制器面板，用万用表测量交流电压385V，输入电压正常。检查是机油压力控制器触点接触不良，擦试并调整触点。柴油机自动AUTO启动，机组运行正常。案例、柴油机自动AUTO运行时，出现水温高告警停机故障分析1控制器面板水温高指示灯亮，水温表读数为68度：2水箱冷却水满；3检查风扇皮带张力在规定范围之内，水泵运行正常，柴油机没出现漏水现象。故障处理以上分析：判断是节温器未开启。拆卸节温器并更换，柴油机自动AUTO启动，机组运行正常。维护体会柴油机闭式强制循环水冷却系统中，利用节温器来改
12、变冷却水的循环流量，以达到自动控制冷却强度的目的。节温器安装在气缸盖出水处。所以在维护过程中，不允许随便取消节温器，这样会影响柴油机的正常使用。节温器初开温度68-72度，全开温度为80-86度，形成冷却水的大循环。冷却水一定要用蒸馏水，并且加防锈、防冻液。案例、柴油机怠速运行时，三相交流同步发电机有异常响声故障分析同步发电机后背轮橡皮圈垫磨损。故障处理考虑到柴油机与同步发电机连接方式为推拔式。所以在拆卸同步发电机紧固螺栓同时，用葫芦将其调起，拔出同步发电机。发现后背轮六个螺栓分别装有24个橡皮圈垫磨损无剩。更换其备件，柴油发电机组运行正常。维护体会柴油发电机组运行时，听到有异常响声，应立即停
13、机，找出故障原因并排除。案例、柴油机喷油提前角的调整为了获得良好的燃烧，使柴油机运行正常，并得到最经济的燃油耗量，喷油泵校检后在安装时都必须进行喷油提前角的调整供油提前角2831度、喷油提前角20-23度。调整时，盘动飞轮的齿圈，使飞轮上的定时零度线对准飞轮壳上检视窗的指针，第一缸活塞位于膨胀冲程始点用手捻推杆左右活动自如，第一缸的进、排气门处于关闭状态。拆下喷油泵侧盖板，转动接合器接盘使第一缸柱塞弹簧处于刚刚压缩状态。然后将飞轮反方向顺时针转动约23度即可，紧固喷油泵螺栓调整调速器柴油机转速偏低，可松开接合器接盘上的螺栓进行微调传动轴接头上刻有分度线，每格3度，然后紧固螺栓。在实际维护工作中
14、，一般都是检查供油提前角，供油提前角是指喷油泵出口处刚刚冒油时，活塞距离压缩冲程上止点前的曲轴转角。因为检查供油提前角比喷油提前角方便而准确。如果查出柴油机供油提前角，若再想知道该机的喷油提前角，只须将供油提前角的数值减去8度，就是喷油提前角。维护体会柴油机供油时间过早或过迟都是有害的。柴油机供油时间过早，即供油提前角过大。当活塞距离上止点不远时，喷油泵就开始供油。这时，由于气缸气体的压力和温度都较低，使着火延迟期拖长。造成柴油机不易启动，运行粗暴，产生敲缸，功率下降，排气管冒黑烟，并导致机件早期磨损。供油时间过迟，即供油提前角太小，由于燃烧是在工作冲程活塞已经下行之后进行，这就使柴油机功率下
15、降，燃油耗油率增加，容易引起机体温度过高，冷却水沸腾，排气管冒白烟或冒黑烟。柴油机喷油提前角是不同的，调整时应按说明书进行。二、柴油机控制部分案例一、康明斯柴油机正常运行时，三相交流同步发电机输出电压95V故障分析用万用表测量励磁部分定子、转子绕阻阻值均正常，判断为自动调压AVR板故障。故障处理Maintenance of diesel generator maintenance case analysis and troubleshootingDiesel generator set maintenance case setA, diesel engine part of the case,
16、 the diesel engine can not startThe diesel engine can not start a variety of reasons, 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 to start the battery voltage is lo
17、w, the actual capacity of less than ; start battery cable and motor wiring error; to start the motor electromagnetic switch failure; Cummins, Kalebite, Wilson, model engine start contactor failure;Troubleshooting with a multimeter to measure the cell voltage, the charger DC output is normal, check t
18、he fluid level of lead-acid batteries, timely add distilled water; and then remove the motor, prosecutors electromagnetic switch contacts if the contacts burn out, replace the solenoid switch; Check the negative battery cable is grounded to the chassis wiring error, reconnect the cables can be; meas
19、ured with a multimeter Cummins, Kalebite, Wilson diesel start contactor coil resistance not normal, replace the contactor;2, the fuel systemFailure AnalysisLeakage into the air in the fuel systemTroubleshootingThe low-pressure tubing to exhaust air: Loosen the injection pump to put gas plug, pressur
20、e 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 the injection pump high-pressure tubing connector, start the engine until the oil per cylinder, and then tig
21、hten 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 Analysis valve leakage; excessive piston ring wear.Troubleshooting Remove the cylinder cover, cylinder head, c
22、heck 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 smooth line; Remove the piston, replace the piston rings.4, ambient temperature, low-impactFailure Analysis heater failure; diesel too
23、thick.Troubleshooting Remove the heater side of the cover, check the AC input connection, the voltage is normal, if normal, bad heater, replace the heater; 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
24、, light diesel oil solidifying point of -10 degrees) light diesel ranges.Case 2, diesel exhaust smoke color is not normalThe 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, t
25、he exhaust black smoke;2, exhaust, white smoke;3, the exhaust take the blue smoke.1, the exhaust black smoke Failure Analysis diesel engine super-load operation; injector drop of oil, poor atomization; oil too early.Troubleshooting to adjust the load, so that within the rated range; diesel engine id
26、le running one high-pressure 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 ve
27、ry small, not black smoke exhaust, the prosecutors of the injector; 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 injecto
28、r can quickly stop the oil, no oil leakage, oil leakage phenomenon.2, the exhaust white smoke Failure Analysis cylinder head gasket is damaged; oil too late; diesel water. Troubleshooting replace the cylinder head gasket; the instructions, prosecutors fuel supply advance angle; Install the fuel oil
29、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 cylinder block and tighten the bolts should have a certain order, that is, according to the order of expansion b
30、y 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 Failure Analysis the sump oil level is too high; oil ring stuck in the ring slot or fracture; rod bearing and rod jou
31、rnal gap is too large.Troubleshooting to keep the sump oil is located in the scale static full-scale, may be timely to let go of some of the oil; to clean up the carbon deposition of piston ring slot, replace the oil ring; Remove the oil pan, connecting rod bolts to remove the bearing, intuitive bea
32、ring surface burn signs, if any, replace the connecting rod bearing.Three cases, low engine oil pressureFailure Analysis sump oil flat; oil pressure regulator spring break; oil filter rubber ring pad aging oil leakage ; bad oil pressure gauge; the oil sump set of filter clogging.Troubleshooting keep
33、 the sump oil in the scale static full-scale, timely add oil; to replace the oil pressure regulator spring; to replace the rubber ring pad; replace the pressure gauge; and then remove the oil pan, oil cleaning set filters.Maintenance experienceOil pressure adjustment method: Remove the control valve
34、 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 nut and seal nut.Case, the diesel engin
35、e 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, intuitive connecting rod bearing surface b
36、urn 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 accidents (eg, Speed). Normal operation
37、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 into the exhaust valve clearance adjustment 0.30MM, 0.35MM normal; to replace the cyl
38、inder head gasket; checksum injector, fuel pump; to clean up the piston carbon deposition, replace the piston rings; three-phase AC synchronous generator is operating normally.Case seven, Wilson diesel the automatic run-time, low oil pressure alarm shutdownFailure Analysis 606 controller panel, low
39、oil pressure indicator light; sump oil in scale static full scale; Check the oil filter is normal; Check sump oil set a normal filter.TroubleshootingThe above analysis: to determine the oil pressure sensor plug failure. Unplug the oil pressure sensor plug connection, manually start the engine, the u
40、nit is operating normally. Bad oil pressure sensor plug, replace this component, simulate a mains power failure, disconnect the mains sampling air switch , diesel automatic the start, the unit is operating normally.Maintenance experienceThis failure occurs: Check engine oil overflow, check the oil p
41、ressure sensor plug.Case, high pressure common injection pump failure diesel engine running, the injector Fenbeng no oil or less oil; diesel engine shutdown, the pressure action pump, hand pump, injector wheel cylinder diesel constantly overflow.Failure Analysis injection pump plunger or spring fail
42、ure; injection pump outlet valve or spring failure.Troubleshooting replace the injection pump plunger or spring; 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
43、 of the oil valve and the oil. Oil delivery valves installed 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 replac
44、ement, must be paired with placement. After the demolition 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 cer
45、tain device conditions.Case, the Cummins diesel engine running, the free ride phenomenonFailure Analysis Check diesel fuel filter is normal; Check the air filter is clean; the frequency of replacement circuit boards, no-load test machine, the fault persists.TroubleshootingThe above analysis: It may be poor fuel PT pump oil. School inspection PT pump, no-load test machine, the fault is still not excluded. Maintenance