当前位置:首页 >> 机械/仪表 >>

第4章TROUBLE AND TROUBLE SHOOTING


4JB1 series (diesel generator) maintenance manual

CHARPTER 4 TROUBLE AND TROUBLE SHOOTING
After the diesel engine has run for long time, some parts of diesel engine will wear

or be damaged, which will cause its technical condition get worse. When the technical specifications are not in the limited range, it indicates the diesel engine is in trouble. The failures should be resolved in time when it appeared. If diesel engine works with malfunction, not only the power and economic capability will decrease, but also operation performance will change, even the accessories will wear quickly and diesel engine will be damaged. For some failures, such as air existing in oil system, clog of filter, loose of belt and so on that can be resolved after maintenance or adjustment. But for other failures, such as piston ring is further worn, cylinder gasket is damaged and so on, which cannot be resolved by maintenance or adjust because of the limitation of diesel engine. The operator has to disassemble diesel engine or change accessories to resolve these failures. Note: (1) Usually failure is caused by inappropriate operation or missing maintenance. The operator should check if the engine is operated according to regulated operation and maintenance when failure happening. (2) Resolve failure in time. Firstly, check out the reason of the failure. Then go to service station if need disassemble. (3) For complicated failures, the technician should perform the process with professional instrument and equipment. If the clients are not qualified to adjust or maintain the engine, they should go to service station. (4) It is not allowed for diesel engine to work with "sickness". Engine working with "sickness" will not only damage the parts and decrease the life span of engine, but also cause accident. The following failures and methods of eliminating are just for reference.

4.1 Diesel Engine Is Difficult to Start
Trouble shooting Cause Remedy the trouble Electric system Circuit connect fault or Check electric circle linkage and reconnect it fault link not well if necessary Battery voltage is not Charge the battery enough Starter fault Repair the starter or replace it if necessary

4JB1 series (diesel generator) maintenance manual

Fuel system fault

There is air in fuel system

Fuel system pipe plugged Fuel filter plugged Fuel pump could not pump fuel or fuel supply not continuous

Fuel atomization is not in good condition Chamber pressure Piston ring is low damaged Valve leakage worn or

Check the fuel pipe link for loosing: Loose the return valve of the fuel injection pump and the air release bolt of the fuel filter, pump the fuel by the fuel-water separator pump until there is not air in the fuel. Then tighten the loosed bolt and the fuel-water separator pump Check the fuel pipe Replace the fuel filter Check the fuel intake pipe for air leakage; check the strainer of the fuel intake pipe for plug; make the switch on and off, check the fuel supply magnet valve for moving, if the magnet valve don’t move, replace it Check the injector for atomization quality, remove the injector, clean the needle valve and seat, replace the injector if necessary Replace the piston ring, replace the cylinder liner if necessary Check the valve clearance, check the valve sealing performance, repair or lap the valve if necessary

4.2 Diesel Engine Does Not Work in Full Power
Trouble shooting Fuel system fault: power or speed dose not get higher when open the throttle largely Cause There is air in the fuel pipe Fuel filter or fuel pipe is plugged Fuel supply or fuel inject pump is not enough Fuel atomization is not in good condition Fuel inject pressure is low Injector is damaged Fuel injection advance angle changed Intake and exhaust Air filter is plugged system fault: exhaust Exhaust pipe is plugged or temperature is high exhaust resistance is high and exhaust gas is unusual Diesel engine Cooling liquid temperature overheating is too high Remedy the trouble Drain off the air in fuel pipe as above method Replace the fuel filter or clean fuel pipe Check the fuel injection pump, repair or replace it if necessary Check the injector Adjust the pressure with adjusting gasket Replace the injector Check and adjust the fuel injection advance angle Clean the filter with high pressure air, replace it if necessary Clean the carbon in the exhaust pipe; replace the exhaust pipe with big enough section, the max. number of elbow is 3 Check the cooling system, clear scale, check and adjust the deflection of the belt; check

4JB1 series (diesel generator) maintenance manual

Cylinder head unit fault: in this case, not only the power is low, but also there are air leakage, black smoke, and unusual noise Crank and connecting-rod fault

the thermostat and replace it if necessary Oil temperature is too high Check the oil level, fill oil if it is not enough Exhaust gas temperature is Check and adjust the fuel injection advance, too high check the injecting pressure and atomization of injector Cylinder head bolt is Tighten the cylinder head bolt with the loosing or gasket is specification or replace the gasket damaged Intake and exhaust valve Check the intake and exhaust valve, lap the leakage seal face of the valve and seat Valve clearance is not Adjust the valve clearance with the correct specification Injector hole leakage or Disassembly the injector, repair or replace copper washer damaged the damaged parts if necessary Copper bearing of Disassembly oil pump, check if connector connector little end big end could move axial, if could not move, clutched with piston pin disassembly piston connecting-rod unit to check and repair

4.3

Diesel Engine Running with Abnormal Noise
Note: If there are unusual sounds when diesel engine running, do not let diesel engine run with unusual sounds.

Trouble shooting and case Injecting time is very early or injector blocked, there is metal bit sound in cylinder Injecting time is very late, there is a bit sound, and for the same time there are whiff dense smoke exhaust gas The clearance between connecting-rod little end hole and piston pin, there is little and shill sound when diesel engine running, this sound could be heard easy at idling, and get bigger when accelerating The clearance between piston and cylinder liner is very big, bit sound could be heard at outer side of cylinder, and get bigger when accelerating The clearance between bearing and crankshaft, bit sound could be heard at crank case, and big bit sound could be heard at reducing speed suddenly Valve touch the piston when diesel(continue)

Remedy the trouble Adjust the inject timing ( see Part3.8.5), check the injector ( see Part 3.8.4) Adjust the inject timing ( see Part 3.8.5), check the injector ( see Part 3.8.4) Replace the connecting-rod little end copper bearing, make the clearance within the range of specification

Replace the piston, replace the cylinder liner if necessary

Check the bearing, replace it if necessary making the clearance within the range of the specification Find the case, check the valve timing, adjust

4JB1 series (diesel generator) maintenance manual

(continue)engine running, big bit sound rhythm could be heard at cylinder head Transit gear worn, clearance between gears get bigger, there is unusual sound from gear case, and bit sound could be heard when reduce speed suddenly The clearance between valve and rocker arm is very big, so bigger sound with rhythm could be heard at cylinder head

the clearance of valve ( see Part 3.5.4) Check the gear clearance, replace the gear if necessary

Re-adjust the clearance of valve ( see Part 3.5.4)

4.4 Diesel Engine Exhaust Unusual Gas
Trouble shooting Exhaust gas with black smoke Case Diesel engine work with over load Fuel supply to different cylinder is not same Remedy the trouble Reduce the load of diesel engine Adjust the fuel pump, make fuel supply to every cylinder equally Adjust the valve stem clearance, check seal surface of valve( see Part 3.5.4) Adjust fuel supply advance( see Part 3.8.5) Clear air cleaner, replace it if necessary

Valve stem clearance is not correct, so that valve could not seal, exhaust valve leakage Fuel supply is too late, some fuel burn in exhaust manifold Air intake not sufficient, air cleaner blocked or intake manifold blocked Cylinder liner or piston ring Replace the cylinder liner or worn piston ring Exhaust gas with white smoke Water existing in cylinder or Resolve

diesel oil Cylinder temperature is low at Increase speed or load the beginning of start and oil appropriately for certain time not burn in some cylinders Exhaust gas with blue smoke Piston ring is locked, over Check piston ring or replace if wear or deficient flexibility; necessary the piston cutting angle is reverse which cause engine oil enter combustion chamber Running with low load for Increase load appropriately, long time, the clearance check or repair which between piston and cylinder jacket is too big,

4JB1 series (diesel generator) maintenance manual

cause engine oil enter the combustion chamber Too much engine oil in oil pan Supply engine oil according to oil dipstick hole signs

4.5 Diesel Engine Oil Over-consumption or Lower Oil Pressure
Trouble shooting High oil consumption Cause regulation Sealing gasket and oil seal out Replace sealing gasket and oil of work or leak groove Worn of valve guide tube seal, Replace oil seal, valve or valve guide tube valve guide tube or valve lever Worn of cylinder Repair or replace cylinder jacket PCV valve leakage Wash or replace the PCV valve Engine oil not comply with Replace engine oil the regulation Safety valve is locked Replace safety valve Engine oil pump filter is Clean or replace filter clogged Worn of driving gear and driven gear of oil pump Oil tube is cracked or coupling is loose Failure of oil pump Over worn of main bearing and connecting-rod bearing Oil pressure gauge is damaged Replace oil pump Check or replace seal Worn of piston ring and Replace piston ring or piston Remedy the trouble Oil not comply with the Replace oil

Low engine oil pressure

Replace oil pump assembly Replace main bearing or connecting-rod bearing Repair or replace Engine oil cannot reach to The oil hole on the cylinder Clean or repair valve system block and cylinder head is clogged Oil hole on rocker arm shaft is Clean or repair clogged Oil hole on rocker arm bracket Clean or repair seat is clogged

4JB1 series (diesel generator) maintenance manual

Oil hole on rocker arm is Clean or repair clogged

Note: If there is not oil pressure in the lubrication system or oil pressure is very low, diesel engine could not work continuously. In these cases, you should first stop the diesel engine to check what happened.

4.6 Diesel Engine Cooling System with Unusual Temperature
Trouble shooting Overheat of diesel engine Case Cooling fluid level is too low Remedy the trouble Supply cooling liquid, check if there is leakage, repair if necessary Fan belt is loose or ruptured Adjust or replace fan belt

Thermostat main valve cannot Replace thermostat assembly be opened Failure of water pump Incorrect oil supply timing Radiator core is clogged Overcool of diesel engine Replace water pump assembly Adjust oil supply timing Clean the radiator

Thermostat valve cannot be Replace thermostat closed entirely Water temperature instrument Gauge coolant temperature or out of work replace water temperature instrument Radiator leakage Repair or replace the radiator Radiator hose coupling is Tighten the coupling or loose or the hose is damaged replace the hose Water pump leakage Replace water pump assembly Heater hose coupling is loose Tighten or replace hose or the hose is damaged

Lack of water

Note : (1) When the diesel engine is overheat, do not stop it suddenly or supply cooling fluid immediately. The operator should keep engine run with no load for a while; after coolant temperature decrease, stop engine and check. (2) When the diesel engine is still hot, do not touch the water inlet cover. Adding cooling fluid, the operator should be careful. (3) If the clients cannot find the reason of overheat, they should go the professional service station immediately, otherwise, other accessories will be damaged.

4JB1 series (diesel generator) maintenance manual

4.7 Starter Can Not Run, Starts Powerless and Noise
Trouble shooting Starter not working Cause Remedy the trouble Start switch or other control Check to make sure circuit is circuits break tight Bad contact of carbon brush Adjust carbon brush spring and commutator pressure and clean commutator Inside circuit of starter is Check starter broken or short out Deficient battery capability Charge the battery Tighten the wire connection Bad wire connection Burning loss of commutator Grinding the commutator surface or clean the stain surface Over wear of carbon brush Replace carbon brush or adjust cause bad connection with spring pressure commutator Main contact of brush solenoid Use “0” nonmetal sand paper of carbon

Starter cannot drive the engine

switch burning loss or bad grind contact Serious worn of bearing Replace bearing After diesel engine start, The copper plate stick with Cut off power immediately, starter still working and make two contacts check circuit and adjust noise electric contact Cut off power immediately Starter armature axle is bent or broken Gear is locked Cut off power immediately and adjust gear surface and replace starter

4.8 Alternator Runs without Output, Charging Not Engine
Trouble shooting Not working Cause Incorrect connection, Rotor coil is broken Commute diode is damaged Bad contact of carbon brush Regulator is damaged connection or bad connection Repair or replace generator assembly Change commute diode Clean or replace carbon brush Repair or replace regulator Remedy the trouble broken Check the circuit

4JB1 series (diesel generator) maintenance manual

Deficient charge

Adjust pulley Bad contact of carbon brush or Adjust and clean stain on the ring Replace regulator Regulator is damaged Lack of electrolyte or serious Supply electrolyte to regulated sulfidation of pole plate level or replace battery

Pulley is loose

4.9 Battery Capacity Is Not Enough, Starts Difficultly, Self-discharges Excessively
Trouble shooting Cause Electrolyte is not enough and Electrolyte level is too low engine is difficult to start Remedy the trouble Supply distilled water or dilute sulfuric acid with density of 1:1 Pole plate short Sulfidation of pole plate Clean out the deposit or replace electrolyte Repeat charging and discharging the battery to clean the sulfidation Bad contact of circuit Tighten the contact and clean coupling, too much oxide on the oxide terminal and deficient charge Impurity existing in Use regulated electrolyte electrolyte Check circuit and resolve Battery wire is short Electrolyte overflowing from Use alkali water or warm water clean the terminal end battery cause anode and and keep battery clean cathode is short Metal lever or tool cause Do not place metal lever or anode and cathode are short tool on the battery Coming off much active Repair or replace battery substance cause the pole plate to be short; damaged clapboard cause pole plate to be short ; bended pole cause anode and cathode to be short circuit

Excessive battery discharged


相关文章:
第4章TROUBLE AND TROUBLE SHOOTING
第4章TROUBLE AND TROUBLE SHOOTING_机械/仪表_工程科技_专业资料。福田ISUZU 柴油动力英文说明书4JB1 series (diesel generator) maintenance manual CHARPTER 4 TROUB...
LD3249 Trouble Shooting
ProWind-trouble shooting 4页 免费 044CI02 TROUBLE SHOOTING 4页 20财富值 HS Trouble Shooting 53页 5财富值 第4章TROUBLE AND TROUBLE... 8页 2财富值喜...
patch trouble shooting
HS Trouble Shooting 53页 5财富值 第4章TROUBLE AND TROUBLE... 8页 2财富值如要投诉违规内容,请到百度文库投诉中心;如要提出功能问题或意见建议,请点击此处进...
Eagle60 Trouble shooting menu rev b
ProWind-trouble shooting 4页 免费 044CI02 TROUBLE SHOOTING 4页 20财富值 HS Trouble Shooting 53页 5财富值 第4章TROUBLE AND TROUBLE... 8页 2财富值喜...
trouble-shooting
trouble-shooting_家具家电_生活休闲。DR.COM 客户端常见上网故障解决办法 目录一...将 IP 中的第四位地址修改到 200-249 之间, 然后在本地连接 (无线网络) ...
pcb design problem and trouble shooting
Trouble Shooting Problem... 79页 免费 第4章TROUBLE AND TROUBLE... 8页 ...pcb design trouble shootingpcb design trouble shooting隐藏>> Copper to hole ...
第一章和第三章
07 第五章 阀门检修 51页 免费如要投诉违规内容,请到百度文库投诉中心;如要提出...4 TROUBLE AND TROUBLE SHOOTING 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 ...
MTX_Trouble_Shooting
0925220922 EVENT = SETUP_AND_WAIT TIME = 2004/04/23 15:33:46.849 FRI...Trouble Shooting Guide 24页 免费 ProWind-trouble shooti... 4页 免费 ...
DGP4灌注机总线故障报警解决Trouble shooting
第 1 页共 4 页 Classified - Internal use Page 3 of 5 Trouble shooting...Trouble cost analysis/故障损失分析(原料、备件、人工) : 连续停机,合计 1320 ...
电控专业用语
收藏指正 4.Design of radial and multiple-lay core gripper 径向多层岩心夹持器设计收藏指正 5.ANALYSIS AND TROUBLE SHOOTING OF EAF ELECTRODE ARM CLAMPER ...
更多相关标签:
trouble shooting | trouble shooting应用 | in love and trouble | 兽人的资源trouble4 | 徐小婷shooting | shooting star | shooting | cls shooting brake |