Diagnosis and Repair of Crankshaft Failure in Cummins Diesel Generator Set

Crankshaft is one of the most important high-speed running parts in Cummins diesel generator, which plays a vital role in the reliable operation of Cummins diesel generator. However, when the starting system of the generator is far from damaged, press the starting switch, and the starter makes a noise but the crankshaft cannot rotate, it is a mechanical failure of the crankshaft. The user should timely diagnose and correct the failure.

The reason why the crankshaft cannot rotate when Cummins diesel generator is started

1. The starter and flywheel teeth are poorly meshed. The ring gear and starter gear will collide when starting Cummins generator, causing tooth damage or unilateral tooth wear. If more than three consecutive teeth are damaged or seriously worn, the starter gear and ring gear teeth will be difficult to mesh.

2. Sticking cylinder. When the temperature of Cummins diesel generator is too high, the engine will stop and shut down. The heat is difficult to dissipate. The piston ring and cylinder are stuck under high temperature and cannot be started after cooling.

3. The crankshaft is locked. Due to the lubrication system failure or lack of oil, the sliding bearing dry friction, resulting in locking the crankshaft and unable to start.

4. The plunger of the fuel injection pump is stuck.

Diagnosis and repair method of crankshaft failure when Cummins diesel generator is started

1. If more than three consecutive teeth of the flywheel are damaged and are opposite to the starter teeth, the two gears will not mesh. In this state, only use a crowbar to pry the flywheel to an angle, and then press the start button to start it smoothly. The damaged flywheel teeth can generally be repaired by welding.

2. When the gear ring is loose, it can be confirmed from the flywheel housing starter installation port. If the gear ring is loose, replace it with a new one. During installation, put the gear ring in the heating box for heating, then press it on the flywheel while it is hot, and then fasten it on the flywheel after cooling.

3. When the unilateral wear of the ring gear teeth is serious, the ring gear can be pressed down, the front and rear end faces turned over, and then installed on the flywheel for use.

4. After inspection, if the gear mesh is normal and the flywheel does not rotate when starting, it should be considered as internal fault of Cummins generator, such as crankshaft locking, piston sticking cylinder, clutch sticking, etc., which should be further observed. Check whether the clutch is damaged or stuck, and then check whether the plunger of the fuel injection pump is stuck and whether there are foreign matters in the Cummins generator.

During the working process, the diesel generator crankshaft often fails to work normally, so timely diagnosis and repair can restore the service performance of the crankshaft and extend the service life of the crankshaft.