Plungers, oil valves and injectors are three precision parts of a diesel engine. Its state of technology directly affects the dynamics and economy of the diesel engine. Keeping the three precision parts always in good technical condition is an important part of maintenance.
The normal service life of the three precision parts is generally more than 2 500 h. However, according to the survey, there are few people whose service life exceeds 1 500 h, usually about 500 h, and some even use dozens of hours. In addition to manufacturing quality and the reasons for improper storage, the reasons for the destruction of the three major components, such as disassembling and disassembling, incorrect assembly adjustment, improper cleaning, and use of inferior fuel, are more common.
1 Reasons for the damage of the three precision parts
(1) Dismantling a lot of engines indiscriminately Because diesel engine oil supply system failures are more common, once a diesel engine malfunctions, it is often not analyzed carefully. After finding the cause of the failure, it is targeted to check and eliminate, but it is to the fuel supply system one by one. Perform disassembly inspection and replacement. The processing precision and assembly accuracy of the three precision parts are very strict and cannot be disassembled. Disassembly and installation can shorten the service life by tens or even hundreds of hours. In addition, the technical state may be further deteriorated due to bumps, dirt, scratches or even deformation due to disassembly and improper installation.
(2) Improper cleaning When cleaning the three precision parts, mix them with other parts and use unclean cleaning fluid. The newly purchased three precision parts are not thoroughly cleaned of anti-rust oil. Even before cleaning, it is not legal to clean it. Some cloths and cotton yarns are used to wipe the surfaces of the couplings directly; some cleanly cleaned couplings are placed in dirty places. The results of these practices all caused scratches on their work surfaces, adhesion of mechanical debris, and destruction of the assembly gap, resulting in stuck and burned-out failures.
(3) Poor fuel quality or unclean use of poor quality fuel (kerosene and oil, diesel oil, etc.), its lubricating performance, sealing performance and viscosity can not meet the requirements of use, will cause the pump pump oil pressure is insufficient, increased wear
And fuel injector coke and other faults. In addition, the fuel is not purified, the use of fueling tools is not clean, fuel filter damage, missing or incorrectly installed seal ring, remove the filter, so that the oil line "clear" and other wrong practices will make the three precision The life of the coupling is shortened.
(4) Improper assembly. In order to prevent oil leakage, some operators tighten the tight seat of the outlet valve and the injector cap too tightly, resulting in excessive stress on the injector body, plunger sleeve and outlet valve seat, resulting in deformation. The accuracy of coordination was destroyed, and the motion of the coupling was blocked and damaged.
Some operators also use asbestos ropes instead of copper pads. Asbestos is a heat-insulating material. Winding with asbestos ropes will seriously affect the heat dissipation of the injectors, causing the needle valve of the injector to be overheated and burned.
There are also some operators who have used thin, thick copper pads when they are installed in the injector assembly. This will change the distance the fuel is injected into the combustion chamber, thus affecting the formation of the mixture, making the engine less powerful and less likely to start. In direct-injection engines, too thin copper pads can also cause the piston top to hit the injector head.
(5) Improper adjustment of fuel injection pressure When replacing the fuel injection nozzle or adjusting the fuel injection pressure, the fuel injection pressure is adjusted too low or too high, which will shorten the life of the fuel injector coupling. If the fuel injection pressure is too low, it will lead to high-pressure gas backflow in the cylinder, so that the needle valve even stuck; if the injection pressure is too high, not only will the wear of the nozzle joint increase, but also increase the plunger pair and the oil valve Wear and tear.
(6) Failure to maintain diesel engine oil in time, poor combustion, if not timely troubleshooting, remove the carbon deposition, the nozzle will be damaged early.
(7) Arbitrary increase in engine speed Some operators increase the engine speed at random in order to make the locomotive run fast. Some pump the gear rack to 2 to 3 teeth in the direction of the small throttle; some use the control arm to directly control the throttle, and some will remove a few pellets from the timing ball. In fact, this will not only accelerate the wear of the three precision parts, but also cause serious accidents such as flying.
The above reasons that caused the shortened service life of the three precision parts are caused by improper use and maintenance. Only the operator pays attention and takes active measures. The service life of the three precision parts will be prolonged and the failure of the fuel supply system will be greatly reduced. .
2 preventive measures
(1) Select the fuel that meets the requirements and strictly implement the fuel precipitation and filtration system. Precipitate at least 48 h before the fuel is filled. The tank is cleaned once every 500 h. The refueling device must be cleaned. When refueling, it should be filtered with a silk cloth. It is best to use a closed refueling device with a filter to refuel. Release the sediment according to the maintenance regulations during work. Precipitated oil in the tank and tank, timely cleaning and replacement of the diesel filter, filter installation to ensure effective filtration, to prevent short-circuit; should be based on the season, the temperature changes in the use of the required standard grade fuel, do not use mixed oil; fuel storage must ensure seal.
(2) It is necessary to pay attention to the dismantlement of the coupling parts. Cleaning should be carried out separately and not mixed with other parts to avoid bumps and scratches.
(3) Assembly should be tightened according to the specified torque to ensure that the coupling is in good technical condition. If you install the injector pressure cap, you must check the state of the pressure cap, and replace the pressure cap with long deformation. The tightening torque for installing the pressure cap should be appropriate (0.5886 to 0.7848 MPa). Do not use excessive force, otherwise it is easy to damage the fuel injector. When using old pressure caps, the coke inside must be carefully removed. In addition, the tight tightening torque of the outlet valve must also comply with regulations.
(4) Improve fault analysis and judgment capabilities to avoid disassembly and adjustment. If there is no disassembly and adjustment of the equipment, do not troubleshoot it yourself. Go to the repair station or ask for repairs.
(5) The diesel engine cannot be overloaded and over-speeded for a long time.
Because the overload operation will cause the engine temperature to be too high, the injector needle valve will be stuck.
Overspeed operation will cause the machine to lose oil, wear and tear, speed is too high or even speed, the consequences are very dangerous.
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