Minor, Medium and Major Repair of Cummins Generator Sets

With the continuous progress of science and technology, there are more and more applications of domestic and imported diesel generator sets for each unit, especially Cummins is more widely used. Not only depends on the degree of perfection of its own marriage, the quality of the product and the correct use method, but also closely related to whether it can be carefully maintained. It can be divided into three stages: small, medium and major repairs. So what maintenance operations do these maintenance at different time stages refer to?

Diesel generator minor repair (use time: 3000-4000 hours)

1. Check the wear degree of the diesel generator valve, diesel generator valve seat, etc., and repair or replace the diesel generator if necessary;

2. Check the diesel generator PT pump, spray;

3. Check and adjust the torque of the diesel generator connecting rod and each fastening screw; 

4. Check and adjust the valve clearance of the diesel generator;

5. Adjust the diesel generator;

6. Check and adjust the tension of the fan charger belt;

7. Clean the carbon deposits in the intake manifold;

8. Clean the intercooler core;

9. Clean the entire diesel generator oil lubrication system;

10. Clean the rocker chamber, oil pan, sludge and metal iron filings.

Diesel generator mid-repair (use time: 6000-8000 hours)

1. Minor repairs for diesel generators are included;

2. Diesel generator manufacturers disassemble the engine (except the crankshaft) to check the internal structure of the engine;

3. Check the cylinder liner, piston, Piston rings, intake and exhaust valves, and other vulnerable parts of crank connecting rod mechanism, valve train, lubrication system, and cooling system should be replaced if necessary;

4. Check the fuel supply system of diesel generators, and adjust the oil nozzle of the oil pump;

5. Diesel generator electric ball repair and inspection, cleaning oil deposits, lubricating electric ball bearings.

Diesel generator overhaul (use time: 9000-15000 hours)

1.Including diesel generator mid-repair items;

2. Disassemble the engine of all diesel generators;

3.Replace the cylinder block, piston, piston ring, large and small bearing bushes, crankshaft thrust Pads, intake and exhaust valves;

4.Adjust oil pump, injector, replace pump core and injector head;

5.Replace turbocharger overhaul kit and water pump repair kit for diesel generators;

6.Correct connecting rod, crankshaft, Body and other components, repair or replace if necessary; 7.Motor stator and rotor dust removal;

8.Check the insulation characteristics of stator and rotor coils;

9.Check and restore diesel generator engine control circuit;

10. Check diesel generator engine high Water temperature, low oil pressure protection function, replace the damaged parts;

11. Check the instruments on the control panel and start the switch.

In addition, when the following phenomena are found in the Cummins diesel generator set, the user should also overhaul the unit.

1.The inner diameter of the cylinder liner is seriously worn, and its roundness or cylindricity reaches or exceeds the use limit. The conventional roundness reaches 0.05-0.063 mm, and the cylindricity reaches 0.175-0.250 mm. The multi-cylinder diesel engine is based on the cylinder with heavier wear.

2.The crankshaft journal and connecting rod journal are severely worn, and their roundness or cylindricity has reached or exceeded the specified limit.

3.The cylinder pressure drops significantly, lower than 75% of the rated pressure, there is abnormal noise in the cylinder, and the noise does not disappear after the machine heats up.

4.The fuel consumption of fuel and lubricating oil is seriously exceeding the standard, the oil pressure drops, and the exhaust gas emits thick smoke.

5. It is difficult to start, even if it is stopped during operation, it still cannot start smoothly when the water temperature is 60 ℃.

6. The power drops significantly. When the throttle is large, the power emitted by the diesel engine is lower than 75% of the rated power.

7. The temperature in the crankcase rises significantly, the diesel engine vents and oil filling ports emit misty smoke, and the exhaust gas is discharged with oil.

Dingbo Power reminds you that no matter what kind of maintenance is carried out, dismantling and installation should be carried out in a planned and step-by-step manner, and tools should be used reasonably. Do not blindly disassemble and inspect by yourself, otherwise it may be counterproductive. Contact us by email dingbo@dieselgeneratortech.com if you have any questions.