柴油發(fā)電機常見故障維修誘因 工作原理分析
2012/5/17 9:27:43
柴油發(fā)電機常見故障維修誘因 工作原理分析
一.發(fā)電機的故障檢修
為保證機組運行的可靠和性能，進行定期檢查和必要時的維護是重要的，有組織的維護計劃，需制定一按日程或時間排定的定期檢查和測試項目表。必須強調(diào)，以下維護指導(dǎo)僅針對一般情況而言，由于有多種發(fā)電機組機型，任何機組的具體維護要求，需參照機其隨機提供的說明書。
柴油發(fā)電機的常見故障注意以下幾點：
1. 發(fā)電機不能起動的原因
（1）檢查蓄電池電壓是否達到額定電壓DC48V
(2)檢查蓄電池接線柱與連接電纜線是否接觸不良。
(3)起動馬達的正負極電纜線會產(chǎn)生接線不牢，因為在發(fā)電機運行時產(chǎn)生震動使接線松馳造成接觸不良。
(4)燃油系統(tǒng)中有空氣引起。
2. 冷卻水溫度偏高故障
（1）通常是冷卻水箱散熱器表面不清潔引起冷卻水箱內(nèi)冷卻液不足，發(fā)電機在使用較長時間后冷卻風(fēng)扇的皮帶會逐漸老化變得毫無彈性或某條皮帶斷裂造成冷卻風(fēng)扇失去正常的吹風(fēng)能力，這時需重新更換冷卻風(fēng)扇的皮帶，更換時應(yīng)該整組皮帶一起更換而不是只換其中的某一條。
?。?）冷卻水泵故障導(dǎo)致冷卻水不循環(huán)而使水溫升高，是由于節(jié)溫器故障不能張開，使冷卻水水溫變化時不能改變冷卻水的循環(huán)路徑，控制進入散熱水箱冷卻水的流量，達到調(diào)節(jié)冷卻強度目的，此時需要更換節(jié)溫器。
（3）使用不合要求的冷卻液使冷卻水管道積有水垢、鐵銹之類等物阻礙冷卻水的循環(huán)引起水溫升高。
3. 發(fā)電機排氣冒黑煙
?。?）使用燃油的質(zhì)量差，含雜質(zhì)多。
（2）環(huán)境灰塵雜物多，空氣濾芯嚴重堵塞。
?。?）發(fā)動機的噴油正時不對。
4. 發(fā)電機排氣冒藍煙
一般都是濾清器中機油過多（在保養(yǎng)時機油添加過多）引起，減少機油至規(guī)定液位可解決。另外一種情況是：活塞環(huán)卡死或磨損過多，彈性不足使機油泄漏進入燃燒室燃燒所致。這需要清洗活塞環(huán)或更換泄漏部分的活塞環(huán)。
5.發(fā)電機排氣冒白煙
?。?）燃油系統(tǒng)中含有水分引起。可對儲油箱底部進行排放，查看有無水分。
?。?）氣缸氣門磨損后對氣流產(chǎn)生變化這時會排出帶煙圈的白煙。此時必須要更換磨損部件。
?。?）噴油嘴噴油霧化不良，柴油霧滴在燃燒室未燃燒。必須檢查噴油嘴，調(diào)整至規(guī)定的噴油壓力。
二.發(fā)電機的日常維護保養(yǎng)
為了獲得機組最大的運行安全性和使用壽命，對機組定期進行維護保養(yǎng)是必要的，如果能遵守機組維護保養(yǎng)的相關(guān)條例，就可保證機組的性能。
（1）每天保養(yǎng)：
1、檢查柴油發(fā)電機工作日報。
2、檢查柴油發(fā)電機：機油平面，冷卻液平面。
3、日檢柴油發(fā)電機有無損壞、摻漏，皮帶是否松弛或磨損。
（2）每周保養(yǎng)：
1、重復(fù)每日的A級柴油發(fā)電機檢查。
2、檢查空氣濾清器，清潔或更換空氣濾清器芯子。
3、放出燃油箱及燃油濾清器中的水或沉積物。
4、檢查水過濾器。
5、檢查起動蓄電池。
6、起動柴油發(fā)電機并檢查有無影響。
7、用空氣槍及清水冼冷卻器前后端的散熱片。
（3）有組織的維護
有組織的維護使費用和工作量降到最低水平，因為它是有組織的定期進行，而不是在機組處于緊急狀態(tài)時才要求進行的，定期維護的其它好處可能不會被明顯地看見，由于潛在故障可能在其發(fā)展之前發(fā)現(xiàn)，這節(jié)約了大修費用。同時，由于機組總是運行在最佳狀態(tài)，將減少運行費用并增加機組壽命。
（4）維護程序
建議負責(zé)維護的人員，制定發(fā)電機檢查和維護時間或日程表，匯總所有需于適當周期予以注意的部件。這樣減少了相似項目的重復(fù)，以使機組停歇時間最少，更深層優(yōu)點是這些停歇時間可調(diào)整安排在對常規(guī)現(xiàn)場活動影響最小時，通常是引擎或主要運動部件，需要經(jīng)常注意，并建議所有維護周期應(yīng)基于引擎的要求。每家引擎制造商均提供其設(shè)備維護的清楚、詳細的說明，以及其維護所需周期。必須注意，引擎廠家提供的維護周期基于機房環(huán)境為清潔、干燥。如果機組運行在臟和/或潮濕的環(huán)境中，維護應(yīng)該更加頻繁，引擎和發(fā)電機的維護過程分別在其手冊中給出，應(yīng)經(jīng)常觀看這些維護過程和本節(jié)所述內(nèi)容。
為保證機組運行的可靠和性能，進行定期檢查和必要時的維護是重要的，有組織的維護計劃，需制定一按日程或時間排定的定期檢查和測試項目表。必須強調(diào)，以下維護指導(dǎo)僅針對一般情況而言，由于有多種發(fā)電機組機型，任何機組的具體維護要求，需參照機其隨機提供的說明書。
柴油發(fā)電機的常見故障注意以下幾點：
1. 發(fā)電機不能起動的原因
（1）檢查蓄電池電壓是否達到額定電壓DC48V
(2)檢查蓄電池接線柱與連接電纜線是否接觸不良。
(3)起動馬達的正負極電纜線會產(chǎn)生接線不牢，因為在發(fā)電機運行時產(chǎn)生震動使接線松馳造成接觸不良。
(4)燃油系統(tǒng)中有空氣引起。
2. 冷卻水溫度偏高故障
（1）通常是冷卻水箱散熱器表面不清潔引起冷卻水箱內(nèi)冷卻液不足，發(fā)電機在使用較長時間后冷卻風(fēng)扇的皮帶會逐漸老化變得毫無彈性或某條皮帶斷裂造成冷卻風(fēng)扇失去正常的吹風(fēng)能力，這時需重新更換冷卻風(fēng)扇的皮帶，更換時應(yīng)該整組皮帶一起更換而不是只換其中的某一條。
?。?）冷卻水泵故障導(dǎo)致冷卻水不循環(huán)而使水溫升高，是由于節(jié)溫器故障不能張開，使冷卻水水溫變化時不能改變冷卻水的循環(huán)路徑，控制進入散熱水箱冷卻水的流量，達到調(diào)節(jié)冷卻強度目的，此時需要更換節(jié)溫器。
（3）使用不合要求的冷卻液使冷卻水管道積有水垢、鐵銹之類等物阻礙冷卻水的循環(huán)引起水溫升高。
3. 發(fā)電機排氣冒黑煙
?。?）使用燃油的質(zhì)量差，含雜質(zhì)多。
（2）環(huán)境灰塵雜物多，空氣濾芯嚴重堵塞。
?。?）發(fā)動機的噴油正時不對。
4. 發(fā)電機排氣冒藍煙
一般都是濾清器中機油過多（在保養(yǎng)時機油添加過多）引起，減少機油至規(guī)定液位可解決。另外一種情況是：活塞環(huán)卡死或磨損過多，彈性不足使機油泄漏進入燃燒室燃燒所致。這需要清洗活塞環(huán)或更換泄漏部分的活塞環(huán)。
5.發(fā)電機排氣冒白煙
?。?）燃油系統(tǒng)中含有水分引起。可對儲油箱底部進行排放，查看有無水分。
?。?）氣缸氣門磨損后對氣流產(chǎn)生變化這時會排出帶煙圈的白煙。此時必須要更換磨損部件。
?。?）噴油嘴噴油霧化不良，柴油霧滴在燃燒室未燃燒。必須檢查噴油嘴，調(diào)整至規(guī)定的噴油壓力。
二.發(fā)電機的日常維護保養(yǎng)
為了獲得機組最大的運行安全性和使用壽命，對機組定期進行維護保養(yǎng)是必要的，如果能遵守機組維護保養(yǎng)的相關(guān)條例，就可保證機組的性能。
（1）每天保養(yǎng)：
1、檢查柴油發(fā)電機工作日報。
2、檢查柴油發(fā)電機：機油平面，冷卻液平面。
3、日檢柴油發(fā)電機有無損壞、摻漏，皮帶是否松弛或磨損。
（2）每周保養(yǎng)：
1、重復(fù)每日的A級柴油發(fā)電機檢查。
2、檢查空氣濾清器，清潔或更換空氣濾清器芯子。
3、放出燃油箱及燃油濾清器中的水或沉積物。
4、檢查水過濾器。
5、檢查起動蓄電池。
6、起動柴油發(fā)電機并檢查有無影響。
7、用空氣槍及清水冼冷卻器前后端的散熱片。
（3）有組織的維護
有組織的維護使費用和工作量降到最低水平，因為它是有組織的定期進行，而不是在機組處于緊急狀態(tài)時才要求進行的，定期維護的其它好處可能不會被明顯地看見，由于潛在故障可能在其發(fā)展之前發(fā)現(xiàn)，這節(jié)約了大修費用。同時，由于機組總是運行在最佳狀態(tài)，將減少運行費用并增加機組壽命。
（4）維護程序
建議負責(zé)維護的人員，制定發(fā)電機檢查和維護時間或日程表，匯總所有需于適當周期予以注意的部件。這樣減少了相似項目的重復(fù)，以使機組停歇時間最少，更深層優(yōu)點是這些停歇時間可調(diào)整安排在對常規(guī)現(xiàn)場活動影響最小時，通常是引擎或主要運動部件，需要經(jīng)常注意，并建議所有維護周期應(yīng)基于引擎的要求。每家引擎制造商均提供其設(shè)備維護的清楚、詳細的說明，以及其維護所需周期。必須注意，引擎廠家提供的維護周期基于機房環(huán)境為清潔、干燥。如果機組運行在臟和/或潮濕的環(huán)境中，維護應(yīng)該更加頻繁，引擎和發(fā)電機的維護過程分別在其手冊中給出，應(yīng)經(jīng)常觀看這些維護過程和本節(jié)所述內(nèi)容。
Principle analysis of common faults of diesel generator maintenance work incentives
I. generator troubleshooting
To ensure reliable unit operation and performance, is important to carry out regular inspection and, if necessary, maintenance, organized maintenance plans, need to develop a schedule or time scheduled for periodic inspection and test list. It must be emphasized that following maintenance instructions are only for the General case, because of the variety of generator models, specific maintenance requirements for any unit, required reference the provided instructions.
Common faults of diesel generator note the following several points:
1. the generators not start because
(1) check whether the battery voltage rated voltage DC48V
(2) check the battery post and the connection cable is bad.
(3) positive and negative pole cable starter motor wire be loose wiring because vibrates when the generator is running the wiring loose cause poor contact.
(4) due to air in the fuel system.
2. high cooling water temperature fault
(1) usually is cooling water box radiator surface does not clean caused cooling water box within cooling liquid insufficient, generator in using more long time Hou cooling fan of belt will gradually aging became without elastic or a article belt fracture caused cooling fan lost normal of hair dryer capacity, then needed again replaced cooling fan of belt, replaced Shi should whole group belt together replaced and not only for which of a a article.
(2) cooling water cooling water pump failure will not cycle and increase the water temperature, is because of a thermostat failure can not open, circular path of cooling water does not change when cooling water temperature, control entry to the radiator cooling flow, achieve adjusting cooling strength of purpose, need to replace the thermostat.
(3) the use of unqualified cooling water pipes of cooling liquid product such as scale, rust, and so impede the circulation of cooling water temperature caused by.
3. generator exhaust black smoke
(1) use poor-quality fuel, containing impurities.
(2) environmental dust debris, serious air filter clogging.
(3) fuel injection timing of the engine does not.
4. the generator exhaust to risk blue smoke
Are generally too much oil in the filter (adding too many maintenance timing oil) caused reduced oil to provide liquid can be resolved. Another situation is that stuck or excessive wear of piston rings, elastic due to the lack of oil leaking into the combustion chamber the burning. This needs to be cleaned or replace the leaking part of piston ring piston rings.
5. the generator exhaust white smoke risk
(1) contains water in the fuel system causing. Can storage Department of bottom emission, viewing with or without water.
(2) the cylinder valve worn on air change now white smoke exhaust smoke rings. You must to replace worn parts.
(3) poor injector fuel injection spray, diesel fuel droplets in the combustion chamber is not burning. Nozzle must be checked, adjusted to the provisions of fuel injection pressures.
II. the daily maintenance of the generator maintenance
In order to get maximum operational safety and the use of unit life, regular maintenance is necessary on unit, if they can comply with the regulations unit maintenance, you can guarantee the performance of the unit.
(1) daily maintenance:
1, check the diesel generator working daily.
2, check the diesel generator: engine oil plane, cooling liquid plane.
Day 3, found mixed with diesel generators for damage, leakage, the belt is loose or worn.
(2) the weekly maintenance:
1, repeat class a diesel generator to check on a daily basis.
2, check the air filter, clean or replace the air filter element child.
3, release the water in the fuel tank and fuel filter or sediment.
4, check the water filter.
5, check the starter battery.
6, starting of diesel generators and check for effect.
7, wash with air gun and water cooler before and after the end of the heatsink.
(3) the organization maintains
Organized maintenance workload and costs to a minimum level, because it is organized regularly, rather than request only if the unit is in a State of emergency, other benefits of regular maintenance may not be clearly seen, due to potential failures may be found to its development, which saves repair costs. At the same time, since the unit always running in an optimal state, will reduce operating costs and increase machine life.
(4) maintenance program
Recommends that the persons responsible for the maintenance, inspection and maintenance time, or schedule of developed generator, summarizing all the appropriate cycle parts of the attention. This reduces duplication of similar projects, so that the unit stop time at least, deeper advantage is that these dead time arrangements can be adjusted at the time of least impact on regular on-site activities, usually the engine or the main moving parts, require constant attention, and recommends that all maintenance cycle should be based on the engine's requirements. Each manufacturer of engines provide clear, detailed descriptions of the equipment maintenance, as well as necessary for its maintenance cycle. It must be noted that engine manufacturers to provide maintenance intervals based on the room environment clean and dry. If the unit is running in dirty and/or humid environments, maintains should be more frequent, engine and generator maintenance procedures at its shown in the manual, should watch these maintenance procedures, and content in this section.
Principle analysis of common faults of diesel generator maintenance work incentives
I. generator troubleshooting
To ensure reliable unit operation and performance, is important to carry out regular inspection and, if necessary, maintenance, organized maintenance plans, need to develop a schedule or time scheduled for periodic inspection and test list. It must be emphasized that following maintenance instructions are only for the General case, because of the variety of generator models, specific maintenance requirements for any unit, required reference the provided instructions.
Common faults of diesel generator note the following several points:
1. the generators not start because
(1) check whether the battery voltage rated voltage DC48V
(2) check the battery post and the connection cable is bad.
(3) positive and negative pole cable starter motor wire be loose wiring because vibrates when the generator is running the wiring loose cause poor contact.
(4) due to air in the fuel system.
2. high cooling water temperature fault
(1) usually is cooling water box radiator surface does not clean caused cooling water box within cooling liquid insufficient, generator in using more long time Hou cooling fan of belt will gradually aging became without elastic or a article belt fracture caused cooling fan lost normal of hair dryer capacity, then needed again replaced cooling fan of belt, replaced Shi should whole group belt together replaced and not only for which of a a article.
(2) cooling water cooling water pump failure will not cycle and increase the water temperature, is because of a thermostat failure can not open, circular path of cooling water does not change when cooling water temperature, control entry to the radiator cooling flow, achieve adjusting cooling strength of purpose, need to replace the thermostat.
(3) the use of unqualified cooling water pipes of cooling liquid product such as scale, rust, and so impede the circulation of cooling water temperature caused by.
3. generator exhaust black smoke
(1) use poor-quality fuel, containing impurities.
(2) environmental dust debris, serious air filter clogging.
(3) fuel injection timing of the engine does not.
4. the generator exhaust to risk blue smoke
Are generally too much oil in the filter (adding too many maintenance timing oil) caused reduced oil to provide liquid can be resolved. Another situation is that stuck or excessive wear of piston rings, elastic due to the lack of oil leaking into the combustion chamber the burning. This needs to be cleaned or replace the leaking part of piston ring piston rings.
5. the generator exhaust white smoke risk
(1) contains water in the fuel system causing. Can storage Department of bottom emission, viewing with or without water.
(2) the cylinder valve worn on air change now white smoke exhaust smoke rings. You must to replace worn parts.
(3) poor injector fuel injection spray, diesel fuel droplets in the combustion chamber is not burning. Nozzle must be checked, adjusted to the provisions of fuel injection pressures.
II. the daily maintenance of the generator maintenance
In order to get maximum operational safety and the use of unit life, regular maintenance is necessary on unit, if they can comply with the regulations unit maintenance, you can guarantee the performance of the unit.
(1) daily maintenance:
1, check the diesel generator working daily.
2, check the diesel generator: engine oil plane, cooling liquid plane.
Day 3, found mixed with diesel generators for damage, leakage, the belt is loose or worn.
(2) the weekly maintenance:
1, repeat class a diesel generator to check on a daily basis.
2, check the air filter, clean or replace the air filter element child.
3, release the water in the fuel tank and fuel filter or sediment.
4, check the water filter.
5, check the starter battery.
6, starting of diesel generators and check for effect.
7, wash with air gun and water cooler before and after the end of the heatsink.
(3) the organization maintains
Organized maintenance workload and costs to a minimum level, because it is organized regularly, rather than request only if the unit is in a State of emergency, other benefits of regular maintenance may not be clearly seen, due to potential failures may be found to its development, which saves repair costs. At the same time, since the unit always running in an optimal state, will reduce operating costs and increase machine life.
(4) maintenance program
Recommends that the persons responsible for the maintenance, inspection and maintenance time, or schedule of developed generator, summarizing all the appropriate cycle parts of the attention. This reduces duplication of similar projects, so that the unit stop time at least, deeper advantage is that these dead time arrangements can be adjusted at the time of least impact on regular on-site activities, usually the engine or the main moving parts, require constant attention, and recommends that all maintenance cycle should be based on the engine's requirements. Each manufacturer of engines provide clear, detailed descriptions of the equipment maintenance, as well as necessary for its maintenance cycle. It must be noted that engine manufacturers to provide maintenance intervals based on the room environment clean and dry. If the unit is running in dirty and/or humid environments, maintains should be more frequent, engine and generator maintenance procedures at its shown in the manual, should watch these maintenance procedures, and content in this section.
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