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Excessive Return Oil of Caterpillar Injector 0R-3190 Increases Fuel Consumption
A thermal power plant in Jiangsu found that the fuel consumption of the Caterpillar generator set equipped with 0R-3190 diesel injectors increased significantly recently, and the operating cost increased sharply. After professional testing, the problem was located in the excessive return oil of the 0R-3190 injectors.
The maintenance technicians tested the return oil of the injectors and found that the return oil volume of each 0R-3190 injector reached 80ml/min, which was far higher than the standard value (less than 50ml/min). After disassembling the injectors, it was found that the internal valve plate of the injectors was severely worn, and the spring elasticity was attenuated, leading to poor sealing of the injectors and excessive return oil. In addition, the long-term high-load operation of the generator set also accelerated the wear of the injector components.
The maintenance team replaced the worn valve plate and spring of the 0R-3190 injectors, and carried out pressure testing and adjustment. After maintenance, the return oil volume of the injectors returned to the standard range, and the fuel consumption of the generator set decreased by 8% compared with before. The maintenance personnel reminded that for Caterpillar injectors working under high-load conditions, it is necessary to shorten the maintenance cycle and regularly check the wear of internal components to avoid excessive return oil and increased fuel consumption.