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Problems in The Method of Repairing Cummins Generator Sets

Apr. 08, 2022

When a Cummins generator set fails, it must be detected by testing equipment. If there is no testing equipment, the traditional fault judgment method "ask, see, check, test" and means, combined with the structure and working principle of the equipment, can determine the possible fault location. Repairs are performed in the order from simple to complex, exterior first, then interior, first assembly and then component. Here is a summary of some improper methods in the maintenance of Cummins generator sets. Pay more attention to the operation to prevent damage to the generator set.


Cummins 800 kw generator


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


Do not pay attention to detecting the fitting clearance of parts: in the maintenance of common diesel generators, the fitting clearance between the piston and the cylinder liner, the "three clearances" of the piston ring, the piston top clearance, the valve clearance, the plunger clearance, the brake shoe clearance, the master-slave clearance Gear meshing clearance, bearing axial and radial clearance, valve stem and valve guide matching clearance, etc., all types of models have strict requirements, must be measured during maintenance, and parts that do not meet the clearance requirements must be adjusted or replace. In the actual maintenance work, there are many phenomena of blindly assembling parts without measuring the fitting clearance, resulting in early wear or ablation of bearings, burning oil of diesel generators, difficulty in starting or deflagration, broken piston rings, collision of parts, oil leakage, etc. Air leakage, etc. Sometimes even due to improper fitting clearance of parts, serious mechanical damage accidents occur.


Reverse installation of parts during equipment assembly: When maintaining equipment, some parts are assembled with strict direction requirements; only correct installation can ensure the normal operation of parts. The external features of some parts are not obvious, and they can be installed in both positive and negative directions. In actual work, the reverse installation often occurs, resulting in early damage to parts, machinery not working properly, and equipment damage accidents. Such as engine cylinder liners, unequal distance valve springs, engine pistons, piston rings, fan blades, gear oil pump side plates, skeleton oil seals, thrust washers, thrust bearings, thrust washers, oil retaining rings, fuel injection pump plungers , Clutch friction disc hub, drive shaft universal joint and other components are easy to install in reverse if you do not understand the structure and installation precautions. Resulting in abnormal work after assembly, resulting in equipment failure. Therefore, when assembling parts, maintenance personnel must master the structure and installation direction of the parts and requirements for installation.


Irregular maintenance operation methods: When maintaining Cummins generating sets, correct maintenance methods are not adopted, and emergency measures are considered to be omnipotent. Such as the often encountered "repair by welding", is an example. Some parts can be repaired, but some maintenance personnel often use the method of "welding to death" in order to save trouble; in order to make the diesel generator "powerful", artificially increase the fuel supply of the fuel injection pump and increase the fuel injection of the injector. pressure.


The 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 have not carefully analyzed the cause of the fault and not accurately judged the fault location, but the original fault has not been eliminated. , and new problems may arise. These irregular maintenance methods can only be used in an emergency, but cannot be used for a long time. It is necessary to fundamentally find out the cause of the failure and take formal maintenance methods to eliminate the failure.


Starlight Power was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. If you want get more information, please feel free to send email to sales@dieselgeneratortech.com we will pay highly attention on your question.

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