As we know, diesel engine is very
important for diesel generator set. In generally, engine is not easy to damage
or have faults, but when it has faults, this will be a serious problem. When
the self-diagnosis system does not output fault codes, it is particularly
necessary to rely on operator's inspection and judgment to determine the nature
of fault and the location of the fault. In this article, we mainly shares some
reasons and solutions of common faults of Cummins diesel engine.
1.Diesel engine starts
difficultly or can not start up, a lot of white smoke is discharged from
the exhaust pipe.
When the engine starts, the
exhaust pipe discharges a lot of white smoke, in generally it is not the fault
of fuel supply system.
The reason:
A.There is water in diesel oil.
Water evaporates into steam in cylinder and is discharged from exhaust pipe.
B.Cylinder head bolt becomes less
crowded or air cylinder gasket washout, so that cooling water gets into the
cylinder
C.There is trachoma or crack
somewhere in the cylinder block or cylinder head. Water enters the cylinder and
evaporates and discharges.
Methods of resolution:
A.Approaching the outlet of
exhaust muffler by hand, if there are droplets of water in the wet hands, it is
confirmed that water enters the cylinder.
B.Check whether there is water in
diesel fuel or not. Check whether there is a large amount of water in the
oil-water separator or not, if there is a large amount of water, the fuel
quality is poor. First of all, the water in the high and low pressure oil
pipeline should be removed; then, the discharging screw plug of the tank should
be opened to discharge the water in the tank; finally, the tank should be
washed with clean diesel oil.
C.Open the water tank cover,
press the starter button while observing whether there is bubbles on the water
surface of the nozzle. If there is water in the oil or bubbles on the water
surface of the nozzle, the cooling water enters the cylinder block.
D.Further look for the specific
leak location, can aerate into the tank, pressure is not more than 200 kPa,
open the oil pan, inspect the leak at the bottom of the engine; then open the
cylinder head to inspect the bottom of the cylinder head and the cylinder
gasket and inspect the fault location. For the parts leaking in the directional
cylinder, the method of replacement repair or replacement of new assembly is
adopted.
2.Diesel engine is difficult to
start up in hot tart
The engine is good in cool tart,
but after starting a while, the temperature rises, then quenching, it is
difficult to start again.
The reason:
It is mainly caused by serious
wear and tear of plunger pair and needle valve pair of fuel injection pump.
When the engine starts in hot tart, because the temperature of the fuel injection
pump and fuel filter is higher, the fuel viscosity decreases, and the starting
speed is lower, most of the diesel oil leaks from the wear gap, resulting the
starting oil is insufficient to start.
Methods of resolution:
When the plunger pair or needle
valve pair is seriously worn out, should replace new product after checking and
debugging of the injection pump test bench.
3.There is crackle
on cylinder block and cover or the
cover leaks water
This will
seriously affect the service life of the engine, so should check clearly
for this fault.
The reason:
A.Causing seep through because of
unsuitable operating. For example, adds cooling water into the engine when in
high temperature, or when the engine starts in severe winter, suddenly adds
high temperature water into it, or does not use antifreeze and rust-proof fluid
according to the regulations, which causes cylinder block and cylinder head to
burst, or causes cracks in expansion and extrusion water plug, resulting in
corrosion of water plug cover and leakage of cavitation corrosion.
B.Insufficient disassembly and
repair. Having not tight cylinder head bolts in the prescribed order, method
and moment, causing uneven force or cracks in cylinder block and cylinder head
caused by impact; or inadequate installation and deflection when replacing
water plug cap.
C.If sand holes and aging
treatment is solved unsuitable, concentration of thermal stress or large
residual stress in casting, will cause leakage of cylinder block and head.
Methods of resolution:
A.Check whether there are cracks
in the cylinder block or head, or the leaking part of a water plug
cap. The pressure test of cooling system can be carried out by using the
water pressure of 280kPa to 390kPa, found out the crack location. Different repair
methods are adopted for different parts.
B.Welding repair can be used when
the crack is located near the combustion chamber and valve seat where the
temperature is high and the stress is large.
C.Can use epoxy resin bonding to
repair the cracks when the temperature is not high and the stress is not high.
D.If there are many small cracks
clustered together or small loopholes in the parts with little stress, can use
patching method to repair them.
E.When find water blocking cover
is corrosion and leakage, it is better to change all water blocking cover as
new one. When replacing, pay attention to check whether there are cracks in the
fold corner of the water plug cap. If there are cracks, it should not be
installed.
After any of the above repairs,
should check again to confirm that no leakage, then can install. If there is no
repair condition and technical level, new parts should be replaced.
4.Maintenance method of screw
hole slide wire of cylinder block
The reason:
The fastening bolt is too hard.
Torque is too large.
Repeated disassembly and assembly
resulted in excessive wear and tear.
Improper operation during
installation.
Methods of resolution:
If there is much
excessive slippage or wear on screw hole of cylinder block, can be repaired by
inlay method: expand the damaged screw hole appropriately, then tap out the
thread according to the requirement and load the bolt with the outer thread
sleeve.
In the previous:5. Fault Judgment and Elimination of Cummins Diesel Engine
The next article:3. Common Faults and Troubleshooting of Cummins Engine