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The Shortcomings of The Generator Set in The Maintenance Process

Jul. 20, 2021

It is very important to correctly determine the fault of the generator set. It not only save time, puts the set into normal operation quickly, but also save costs and avoid blind replacement of the wrong components. In this article, Starlight Power has sorted out several deficiencies in the overhaul of generator sets.

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1. Unit maintenance cannot correctly judge and analyze the fault

Some maintenance personnel disassemble and repair the equipment because they are not clear about the mechanical structure and principle of the equipment. They did not carefully analyze the cause of the fault not accurately determine the fault location. As a result, not only the original fault could not be eliminated, but there might be new problems. Therefore, when the generator set fails, it must be detected by the testing equipment; if there is no testing equipment, the traditional fault judgment method "ask, see, check, test" and etc., combined with the structure and working principle of the equipment, determine the most The part where failure may occur. Follow the order from simple to complex, exterior first, interior first, assembly first, then parts.


2. Blind replacement parts

It is relatively difficult to judge and eliminate the fault of the generator set, but it can not be large or small. As long as the parts that may cause the fault are considered, replace them one by one. As a result, not only the fault was not eliminated, but also the parts that should not be replaced were replaced at will. Some faulty parts can be repaired to restore their technical performance, such as generators, gear oil pumps, etc., which are faulty and can be repaired without complicated repair techniques. During maintenance, the cause and location of the failure should be carefully analyzed and judged based on the failure phenomenon, and repair methods should be taken to restore the technical performance of the repairable parts.


3. Do not pay attention to detecting the clearance of parts

In the maintenance of common generator sets, the matching clearance between the piston and the cylinder liner, the "triple clearance" of the piston ring, the piston head clearance, the valve clearance, the plunger clearance, the brake shoe clearance, the meshing clearance of the driving and driven gear, the axial and diameter of the bearing All types of models have strict requirements on the clearance, the clearance between the valve stem and the valve guide, etc., which must be measured during maintenance, and the parts that do not meet the clearance requirements must be adjusted or replaced. In actual maintenance work, there are many phenomena of blindly assembling parts without measuring the fit clearance, which leads to early wear or ablation of bearings, oil burning in the generator set, difficulty in starting or deflagration, broken piston rings, mechanical impacts, oil leakage, and leakage. Gas and other failures. Sometimes even due to improper fit clearance of parts, serious mechanical damage accidents may occur.


4. Parts are reversed during equipment assembly

When servicing equipment, some parts have strict orientation requirements; only the correct installation can ensure the normal operation of the parts. The external features of some parts are not obvious, and they can be installed positively and negatively. In actual work, the installation is often reversed, resulting in early damage to parts, mechanical failure, and equipment damage accidents. Such as engine cylinder liners, unequal-space valve springs, engine pistons, piston rings, fan blades, gear oil pump side plates, skeleton oil seals, thrust washers, thrust bearings, thrust washers, oil retainers, fuel injection pump plungers , When installing the clutch friction plate hub, drive shaft universal joint and other parts, if you don't understand the structure and installation precautions, it is most easy to install the reverse. Resulting in abnormal operation after assembly, resulting in equipment failure. Therefore, when assembling parts, maintenance personnel must grasp the structure and installation direction of the parts and require installation.


5. Irregular repair methods

When servicing generator sets, the correct maintenance method is not adopted, and emergency measures are considered to be omnipotent. There are many phenomena that "emergency" is used instead of "maintenance" and "treatment of the symptoms but not the root cause" is still common. For example, the frequently encountered "repair by welding" is an example. Some parts could have been repaired, but some maintenance personnel tried to save trouble, but often adopted the method of "welding to death"; in order to make the generator set "strong", artificially increase the fuel supply of the fuel injection pump and increase the fuel injection pressure of the fuel injector. . These irregular maintenance methods can only be used as an emergency, but cannot be used for a long time. The cause of the failure must be found fundamentally, and regular maintenance methods must be adopted to eliminate the failure.


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