Maintenance of Cummins diesel generator
1. Maintenance of new Cummins diesel generator:
1. Run for 20 hours under light load (generally 2~3 horsepower).
2. After 20 hours of operation. Check and tighten the cylinder head nuts (check when the unit is cold)
3. After the new Cummins diesel generator has been running for 50 hours, the following work should be done.
(1) Use a clean Cummins diesel generator and a brush to flush the crankcase and replace the engine oil.
(2) Brush the engine oil Fleetguard filter with clean diesel or kerosene (only for R170F).
2. 8-hour maintenance:
1. After the Cummins diesel generator has been running for 8 hours, the unit should be stopped to check the oil level. If it is insufficient, add more.
2. Check whether there is any oil leakage or loose screws outside the machine. If any, they should be eliminated.
3. Clear the debris blocked between the air inlet and the heat sink.
4. Make sure the appearance of the machine is clean.
5. Remove the valve cover and add a small amount of engine oil to the oil holes of the intake valve rocker arm and exhaust valve rocker arm (only for 170F).
3. 100-hour maintenance:
1. Clean the fuel tank filter ring.
2. Clean the diesel filter element components and air filter element components, and blow air from the inside out (or use an air pump), or use a soft brush to remove surface dirt. If the filter paper is damaged or the filter end cover is degummed, it should be replaced. When operating in harsh environments, the frequency of cleaning and replacement should be increased.
3. Check and adjust valve clearance.
4. Clean the crankcase: (1) After stopping the unit, drain out the engine oil as it gets hotter. (2) Clean the crankcase with clean diesel fuel.
5. Remove the gear chamber cover and oil pan, clean the oil collector with clean diesel or kerosene, and replace the filter if it is damaged. (Only for R170F)
6. Install the oil pan, gear chamber cover and observation hole cover, and add new engine oil.
4. 500-hour maintenance:
In addition to completing the 100-hour maintenance project, the following work needs to be performed.
1. Clean the diesel tank and fuel tank switch, and clean the oil passage in the crankcase.
2. Remove carbon deposits from the exhaust pipe.
3. (A) Clean the oil throw ring and the lubricating oil hole on the crankshaft connecting rod (for 170F) (B) Unscrew the crankshaft oil plug and clean the crankshaft oil passage in the inner neck of the connecting rod. (For R170)
4. Clean the bearing seat and oil passage. (For 170F)
5. Clean the untubed oil line, use a pump to inflate the oil line or use a lead wire to barrel the oil line. (For R170F)
6. Clean the oil lines of the cylinder head, rocker arm seat, rocker arm shaft and exhaust rocker arm. (For R170F)
7. Check and clean the fuel injector: (1) Check the spray quality of the fuel injector. If the fuel sprayed is not in the form of fine mist or the nozzle hole has carbon deposits and the fuel nozzle is stuck, etc., answerClean the fuel injector parts. If the fuel injection nozzle couple is too loose, it should be replaced. (2) Remove the fuel injection nozzle assembly and pull out the needle valve from the needle valve body. If the fuel injection nozzle assembly cannot be removed from the tight cap, first pull out the needle valve, place a wooden block on it, and knock out the needle valve body. When the needle valve is difficult to pull out, you can use wire pliers lined with cloth to clamp the needle valve and pull it out gently to prevent lint. (3) If the nozzle hole of the needle valve body is blocked, use a needle to clear it. (4) Remove carbon deposits on the needle valve. (5) Clean the needle valve and needle valve body with clean diesel. (6) When there is oil dripping from the fuel injection nozzle, pull out the needle valve, apply a small amount of engine oil (or toothpaste) on the cover and grind it back and forth a few times. Then wash it again. (7) Check the fuel injection quality of the fuel injection nozzle. The fuel injection should be in the form of mist, with no oil dripping around the nozzle.
8. Check the sealing of the valve and valve seat: (1) Remove the cylinder head. (2) Inject diesel or kerosene into the intake and exhaust ducts. If there is leakage between the valve and the valve seat, remove the valve and grind it. (3) Scrape off the carbon deposits on the valve and cylinder head. (4) Apply some abrasive paste on the cone surface of the grinding valve and grind it with a valve grinding tool. When grinding, rotate the valve back and forth on the valve seat and tap it up and down until a matte full-circle sealing line appears on the contact surface.
9. Check the piston rings: (1) Remove the piston connecting rod assembly and piston rings. Scrape off the carbon deposits on the top of the piston and the bottom of the ring groove, and clean them with detergent and diesel. (2) Scrape off the carbon deposits on the piston rings and clean them with clean diesel. (3) Scrape off the carbon deposits on the front of the cylinder liner, and then clean it in clean diesel. (4) Push the piston ring into the rear end of the cylinder liner, and use a thickness gauge to measure the opening gap. If the opening gap exceeds the maximum allowable value of 2.5mm, replace it with a new ring.
5. 1000~1500 hours of maintenance: (1) Do all the 500 hours of maintenance. (2) Check the fitting clearance and wear limit table of main parts in Chapter 7. Parts that exceed the wear limit should be replaced. (3) Replace the paper filter element of the diesel Fleetguard filter
Car generator, also called car alternator. It plays an important role in automotive components - power generation. \x0d\ During use, non-charging and minor charging failures often occur, causing serious power loss to the car battery and making it difficult to start the car. At this time, the car alternator needs to be replaced or repaired. \x0d\Disassembly and assembly of automobile silicon rectifier generator\x0d\ 1. Inspection before disassembly\x0d\ (1) Clean the appearance of the generator; \x0d\ (2) Hold the pulley to check the bearing axial and radial clearance before testing;\x0d\ x0d\(3) Rotate the rotor and check the bearing resistance, noise and whether there is any friction\x0d\ and abnormal noise between the rotor and stator. When the resistance is found to be large, you can remove the brush and try again to determine whether the resistance comes from the brush or the bearing; (4) Turn the rotor shaft to visually check the swing difference of the pulley to judge the rotor Is the shaft \x0d\ bent? \x0d\ (5) Check whether there are cracks or damage in the shell, hanging feet, etc. \x0d\ 2. Breakdown of silicon rectifier generatorSolution \x0d\ (1) Remove the rear bearing cover and oil seal, and unscrew the rotor shaft fastening nut; \x0d\ (2) Remove the fastening screws of the front and rear end covers to make sure that the front end cover with the rotor is in contact with the stator. \x0d\ Separate the rear end cover, and make a mark on the front and rear end covers and the stator core for easy reassembly; \x0d\ (3) Remove the pulley fastening nut, and remove the pulley, fan, and semicircular key , separate the rotor from the \x0d\ front end cover, be careful not to break the stator coil lead; \x0d\ (4) Remove the front bearing cover, and take out the front bearing; \x0d\ (5) Remove the protection on the rear end cover cover; \x0d\ (6) Remove the connecting nut of the stator coil line end on the component board and the connection nut of the neutral wire end \x0d\ to separate the stator from the component board (heat sink), and take out the stator assembly; \x0d\ (7) Remove the nuts that fasten the component plate assembly on the rear end cover and the fastening nuts of the armature terminals, and \x0d\ remove the component board assembly. \x0d\3. Assembly of generator\x0d\ (1) First, add No. 1 to No. 3 calcium-sodium composite grease to the bearing. However, the amount of grease filled in the bearing should not be too much to avoid overflow and splashing in the bearing. on the slip ring, causing poor brush contact; \x0d\ (2) Assemble the bearings of the front and rear end covers (201#203#); \x0d\ (3) Install the rectifier component plate onto the rear end cover (10 million Do not miss the insulating pad); \x0d\ (4) Install the stator assembly on the rear end cover and connect it to the rectifier component board (the four terminals (pieces) on the stator winding should be allowed to flow naturally, do not pull them forcefully, Forcefully fold to prevent the rotor from being scratched); \x0d\ (5) Install the rotor assembly onto the stator and rear end cover; \x0d\ (6) Combine the front and rear end covers (note that the nuts of the connecting bolts face the fan, and the connecting bolts should not While tightening, turn the rotor to ensure that it does not scratch the stator, so as not to cause burning of the rotor and stator. If the rotor scratches the stator, use a wooden hammer to tap the generator shell to adjust it); \x0d\ (7) Assemble the semicircle. Key, fan, pulley, and front and rear fixing nuts of the rotor shaft; \x0d\ (8) Assemble the brush holder assembly (note that the brush holder and the copper slip ring on the rotor shaft should be aligned. Never eat two brushes with one brush. Slip ring, so it cannot generate electricity); \x0d\(9) The assembled generator should rotate flexibly, without jamming, no scratching sound, and no movement of the rotor shaft. \x0d\ (4) Maintenance of silicon rectifier generator 1. Maintenance of generator casing \x0d\ The casing should have no cracks, the hanging feet should be intact, and the matching gap between the socket hole on the casing and the outer ring of the bearing should not be greater than 0.1mm. \x0d\2. Maintenance of generator carbon brushes and springs\x0d\The carbon brush should move freely in the carbon brush holder without sticking. There should be no oil on the carbon brush. The length should not be too short. The elastic force of the carbon brush spring should meet the regulations. Require. \x0d\ 3. Detect the rectifier diode \x0d\ Use the resistance R×1 level of the multimeter to detect the diode. The forward resistance value is 8~10Ω and the reverse resistance value is more than 10ΚΩ. \x0d\4. Rotor coilDetection \x0d\ Use the R×1 scale of the multimeter to detect the resistance of the magnetic field connection post to the ground. The resistance of the 12V generator should be 5 to 7Ω, which means the coil is normal. If the resistance is too low or too much, it means there is a short circuit in the magnetic field winding. Or there is an open circuit, and the connection between the winding and the slip ring is faulty. \x0d\5. Detection of stator coil\x0d\ Use multimeter R×1 to measure the resistance of the three connecting ends of the stator coil. The resistance values should be consistent. If the measured resistance value is too large or too small (close to zero), then Indicates that there is an open circuit or short circuit inside the coil. \x0d\6. Check the slip ring\x0d\ The surface of the slip ring should be clean, flat and smooth, without ablation scars, and the surface roughness should not be greater than 1.6 microns. Oil stains are not allowed on the surface of the slip ring, and there are slight burn marks on the surface. It should be polished with fine sandpaper, and the thickness of the copper ring of the slip ring should be no less than 2mm.