Cummins Generator Fault Maintenance Guide2

Today we will continue to introduce the precautions for troubleshooting Cummins generators.

Valve Components

The valve components include the intake valve, intake valve seat, exhaust valve, exhaust valve seat, valve guide, valve lock, valve spring, upper valve spring cover, and lower valve spring cover.

1.When installing the valves, do not mix up the intake and exhaust valves. Since the exhaust valve endures higher temperatures, incorrect installation can lead to valve burnout.

2.The valve guides of PERKINS engines must be reamed. During reaming, the clearance between the guide and the valve must be properly controlled. Excessive clearance will allow oil to flow into the combustion chamber, while insufficient clearance may cause the valve and the guide to seize. It is recommended to maintain a clearance of 0.03 - 0.05mm between the inner diameter of the guide and the outer diameter of the valve stem.

3.The valve seats of PERKINS engines must be ground and reamed during assembly. After the valve is installed in the seat, the bottom of the valve must be at least 1.25mm below the cylinder head plane; otherwise, the valve may collide with the piston.

4.During major overhauls of Cummins diesel engines, the valve locks must be replaced. For PERKINS diesel engines, the valve locks should be inspected, and those with excessive groove wear or cracks must be replaced.

Piston and Cylinder Components

1.When replacing pistons, refer to the original piston's correct number and check if the combustion chamber shape and valve relief height of the new piston match those of the old one. Incorrect piston installation can lead to piston - valve collisions.

2.If a new cylinder liner needs to be removed after being pressed into the cylinder block and then reinstalled, a new cylinder liner rubber ring must be used. When installing the cylinder liner rubber ring, apply a layer of oil on its outer surface.

3.Inspect the wear of the ring grooves on old pistons. Insert a new piston ring into the groove and use a 0.15mm feeler gauge to measure. If the feeler gauge can be inserted, the wear of the piston ring groove has exceeded the standard, and the piston must be replaced.

4.There should be no fractures or cracks in the ring grooves of old pistons, and no cylinder scoring or cracks on the piston surface.

5.Check the wear of the piston pin holes. Except for the K - series of Cummins engines, the fit between the piston pin and the pin hole in other series is an interference fit. At room temperature, the piston pin cannot be directly inserted into the piston hole. To disassemble or assemble the piston pin, heat the piston in boiling water to expand the pin hole.

6.Inspect the wear of the piston pin circlips. A broken circlip can cause the piston pin to impact the cylinder liner.

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