卡特彼勒.奧林匹亞系列發電機組是由美國卡特彼勒(Caterpillar)公司在英國生產的柴油發電機組。該機組發動機采用英國珀金斯(Perkins)，交流發電機采用英國奧林匹亞(OLYMPIAN)，機組由卡特彼勒公司統一設計生產. 柴油發電機組排氣煙色分析故障
柴油機工作溫度正常情況下，
所排出的煙色應該是無色或淡灰色，所謂無色不是完全無色，不能像汽油機那樣無色，而是在無色中伴有淡淡的灰色，這是正常排氣煙色。柴油機在怠速時排氣煙色可能重一些，在高速、高負荷時也可能重一些，要留意觀察正常排氣煙色，才能對非正常的排氣煙色進行判定和分析。柴油機燃料完全燃燒后，正常顏色一般為淡灰色，負荷略重時為深灰色。柴油機在工作中，會經常出現冒煙現象，柴油機排煙有黑煙、藍煙、白煙和灰色四種，它們是判定柴油機故障的條件之一，具體分析如下：
１、活塞環、氣缸套等磨損 氣門、活塞環、氣缸套磨損后，引起壓縮壓力不足以及機油上竄燃燒試冬負氣缸在壓縮行程結束時，混合氣混合的正常比例改變，使燃油在無氧條件下燃燒，燃燒過程輕易產生積炭，排出的廢氣形成大量玄色煙霧。 ２、燃燒室外形改變燃燒室外形因制造質量及長期使用導致技術狀況下降，使壓縮余縫過大、過小以及活塞位置裝錯，都會使燃燒室外形和容積改變，從而影響燃油與空氣混合質量，使燃油燃燒條件變壞。奧林匹亞發電機|奧林匹亞柴油發電機|奧林匹亞發電機維修|奧林匹亞柴油發電機維修|奧林匹亞柴油發電機維修價格|寧波奧林匹亞柴油發電機維修|浙江奧林匹亞柴油發電機維修|寧波日興動力科技有限公司 ３、噴油器工作不良 柴油機排氣煙度與燃油霧化品質的關系密切，在柴油機噴油過程中，每次噴油臨結束時，噴油壓力下降，霧化質量差，使液滴直徑比主要噴射階段的油滴大4—5倍（體積約增大100倍），這些油滴蒸發與燃燒的時間短，四周氧的濃度低，輕易產生碳煙。噴油器不霧化、霧化不良或滴油，使燃料不能充分地與氣缸內的空氣混合，也不能完全燃燒。由噴油器工作不良引起的排黑煙現象在柴油機低速運轉時較為明顯，由于低速運轉時氣缸內進氣渦流較弱，油滴或油束被氣流沖散的可能性減少并且停留的時間較長，更輕易形成碳黑排出。) 
４、供油量過大供油量過大，使進進汽缸內的油量增多，造成油多氣少燃油燃燒不完全。另外，工作負荷過重、燃油質量低劣、工作溫度過低也會引起排氣冒黑煙，柴油機中燃料的高溫裂解反應是不可避免的，特別是在空間混合燃燒的柴油機中，由于高溫氣體包圍著液態的油滴，造成了有利于裂解反應的條件，因此在燃燒初期產生了大量的碳粒，這一點已為燃燒過程的高速攝影所證實。柴油機在正常燃燒時，在排氣門打開以前，燃燒初期所形成的大量碳粒可以基本燒完，排氣基本上是無煙的。只是在某些不利工況下，碳粒不能及時燃燒反而團圓吸附，在氣缸中和排氣過程中形成更大的碳煙粒子或絮團，使排氣冒黑煙。 
５、供油提前角調整不當 （１）供油提前角過大，燃油過早噴進燃燒室內，由于此時氣缸內壓力溫度較低，燃料不能著火燃燒，當活塞上行，氣缸內達到一定壓力和溫度，可燃混合氣燃燒。在直噴式柴油機中，當其它參數不變時，加大噴油提前角可以降低排氣煙度。由于加大噴油提前角會使滯燃期加長，使著火前噴進氣缸的油量增加，預混合量增加，預混合氣增多，加快了燃燒速度，燃燒可較早結束，從而使主燃期的形成碳粒具有較高的溫度和高溫下停留較多的時間，有利于碳粒氧化消失。然而過早的噴油增加了預混燃料量，使柴油機工作粗暴，燃燒噪音增大，并引起較大的機械負荷，以及較多的黑煙（COX）排放。 （２）供油提前角過小，噴進汽缸內的燃油過遲，一部分燃料來不及形成可燃混合氣就被分離或排出，致使部分在排氣管中隨廢氣排出的燃油料受高溫分解、燃燒，形成黑煙隨廢氣一同排出。 二、排氣冒藍煙 排氣冒藍煙，一般情況下是柴油機使用日久，慢慢開始燒機油引起的，隨著藍色煙霧的加重，燒機油越來越多，就應考慮維修柴油機了。有時燃油中混有水分，或有水分漏進燃燒室中，引起燃燒的改變，柴油機會冒淺藍色煙。影響其天生的主要因素為： １、空氣濾清器阻塞，進氣不暢或油盆內油面過高（油浴式空氣濾清器），使進進汽缸內的氣量減少，燃油混合氣正常比例改變，造成油多氣少燃油燃燒不完全，也會引起排氣冒藍煙。 ２、油底殼內潤滑油加進過多，柴油機運行中潤滑油易竄進燃燒室。 ３、長期低負荷（標定功率的40%以下）運轉，活塞與缸套之間的間隙過大，使油底殼內潤滑油輕易竄進燃燒試冬與氣缸中的燃料混合氣混合，改變混合氣正常比例，燃燒不完全，引起排氣冒藍煙。 ４、活塞環卡住或磨損過多，彈性不足，安裝時活塞環倒角方向裝反，使機油進進燃燒試冬潤滑油燃燒后產生藍色水氣煙霧排出。 ５、在機體通向氣缸蓋油道四周的氣缸墊燒毀，活塞、氣缸套磨損以及活塞環對口等狀況將致使潤滑油上竄燃燒試冬并與燃油混合氣一同燃燒。 
三、排氣冒白煙 白煙是指排氣煙色為白色，它與無色不同，白色是水蒸氣的白色，表示排煙中含有水分或含未燃燒的燃油成分。白煙呈液珠狀態，和藍煙相比較直徑稍大，一般大于1μm。在光的折射下呈白色，柴油機的白煙是未燃烴（含燃油和潤滑油）、水蒸氣以及不完全燃燒的中間產物（如含氧碳氫），除水蒸氣外，它們也都屬于微粒范疇。柴油機在剛起動時或冷機狀態時，排氣管冒白煙，是由于柴油機氣缸內溫度低油氣蒸發而形成，冬季尤為明顯。柴油機在嚴冷天氣運行時，柴油機溫度低，排氣管溫度也低，有水蒸氣排氣凝聚成水氣形成白色排煙，是正常現象。若當柴油機溫度正常，排氣管溫度也正常時，仍然排出白色煙霧，說明柴油機工作不正常，可判定為柴油機故障。影響其天生的主要因素為： 
６、柴油機剛啟動時，個別氣缸內不燃燒（特別是冬天），未燃燒的燃油混合氣隨其它工作缸的廢氣排出形成水氣煙霧。 ５、活塞、氣缸套等磨損嚴重引起壓縮力不足，造成燃燒不完全。 ４、燃油中有水份和空氣。水和空氣隨著燃油噴射進氣缸形成不均勻燃油混合氣，燃燒不完全，產生大量的未燃烴排出機外。 １、氣缸套有裂紋或氣缸墊損壞，隨著冷卻水溫度和壓力的升高，冷卻水進進氣缸。排氣時形成輕易形成水霧或水蒸氣 ３、供油提前角過小。活塞上行至氣缸頂前噴進氣缸的燃油過少，形成較稀的可燃混合氣，過遲的噴油減少了預混燃料量，預混合量減少。預混合氣減少，降低了燃燒速度，燃燒結束較晚，燃燒形成大量的水氣煙霧。 四、排氣冒灰煙 排氣冒淡灰色煙，柴油機工作還算正常，但煙霧顏色加重呈灰色或接近于玄色就不正常了，除了上述排煙玄色的原因外，還可能有進氣不暢即空氣供給不好的原因。當取下進氣空氣濾清器后，排氣煙色由深變淺甚至變為無色時，就是空氣濾清器堵塞了，應檢查引起進氣不暢的原因。 ２、噴油器霧化不良，噴油壓力過低，有滴油現象。在氣缸中燃油混合氣不均勻，燃燒不完全，產生大量的未燃烴，排氣時輕易形成水霧或水蒸氣。
寧波日興動力科技有限公司柴油發動機/工程機機械發動機/船舶動力/發電機組整體標準維修作業程序
一：按章施工
本公司對整臺發電機的維修，實行程序卡制度，并將整個工作流程分為以下11道工序。
1:發電機拆卸前的檢查項目。2:柴油機的拆卸項目。3:柴油機各部件的清洗。4:柴油機各部件的檢查及測量。5:柴油機所需更換的配件目錄。6:柴油機各部件的裝配。7:柴油機裝配完畢試機前的檢查項目。8:柴油機試機程序的各個檢查項目。9:柴油機返修項目。10:柴油機磨合期的各個檢查項目。11:柴油機磨合后正常運行交付使用。
二：用戶須知
在整個維修過程中，我們要求客戶必須配合以下工作。1:客戶派出一名主管對整個工程進行監督管理。2：每道工序幸均須由工程總監和客戶主管簽名作實。3：監督主管在整個工程中，認為施工者不按程序卡進行操作，必須馬上予以制止，和維修組長進行交涉。4：若意見分岐，請和本公司營業員聯系，直至達到意見統一后方可進行施工。
三：檢修程序
A.機體和曲柄連桿機構：1.氣缸體的損傷/氣缸體常見的損傷有：燒瓦、主軸承孔變形、裂紋、破碎、水道口腐蝕和配合表面磨損等。在外觀檢查時，應無任何的裂紋和損傷，若發現有導致漏水、漏油、漏氣、損傷時，必須予以修理或更換。尤其對氣缸體與氣缸套接觸的密封環帶處有無穴蝕、腐蝕現象予以特別檢查。2.主軸承孔/對有燒瓦現象的缸體，要特別對主軸承孔孔徑予以測量，非標主軸承孔必須予以修正。 3.凸輪軸孔/凸輪軸襯套表面露銅大于120度時，必須更換凸輪軸襯套，如果凸輪軸襯套磨損過度，也必須予以更換，否則會引起機油壓力過低，襯套如在座孔中轉動，則必須檢查座孔的尺寸，超標則修理座孔并換新襯套。4.氣缸套座孔/檢查氣缸廈門座孔的失圓度，不應大于0。025mm，氣缸套座孔肩臺有無裂紋，氣缸套凸出量在0。15-0。20mm之間，新缸套裝入缸體后不應有左右擺動的現象。
B. 活塞、活塞環、活塞銷組件,
活塞的損壞現象有：1:活塞頂面的燒蝕。2:活塞環槽側壁的磨損及環岸斷裂。3:活塞銷孔孔徑變大，失圓。4:銷座部位裂紋。5:活塞初部拉傷。6:活塞初部磨損和馬橢圓。7:活塞環槽內側有脊峰存在。8:活塞磨損過大。
C.連桿組件
連桿組件的主要損傷有：1:小頭襯套磨損。2:小頭襯套座孔和大頭軸瓦座孔磨損與變形。3:連桿的彎曲的扭曲。4:連桿螺釘或螺桿有裂紋、變長、螺紋磨損或滑扣現象。5:連桿身有劃傷現象。6:連桿有燒瓦變形現象。在安裝連桿組件時，必須按正確的扭矩參數及正確的步驟進行操作，而且必須對螺桿螺釘進行復檢。
警告：安裝連桿組件，須由工程總監親自操作。對于損傷的連桿組件，必須予以報廢，否則會引起連桿斷裂，擊破氣缸體，打斷曲軸的危險。
D.曲軸、飛輪組件:由軸的主要損傷有：軸頸磨損，曲軸裂紋和斷裂，燃瓦而造成的燒蝕。如果曲軸軸頸的失圓度大于0.05mm時，則需磨削曲軸軸頸。對于燒瓦嚴重的曲軸，由于其金相組織已發生變化，一般不建議再次使用，有裂紋現象的曲軸必須予報廢，否則會有斷裂的可能。
警告：安裝曲軸、飛輪組件、須由工程總監親自操作，按標準的扭矩和正確的步驟執行，主軸承蓋螺釘必須復檢。
E.氣缸蓋和配氣機構,1、氣缸蓋/氣缸蓋和氣缸體接合平面，氣門導管孔，氣門座圓孔，噴油器孔，冷卻水套壁等處，易產生裂紋，可用目檢，水壓試驗進行檢查。氣缸蓋與氣缸體接合平面不平時，建議上磨床修理，每次加工量為0.10mm左右，加工極限為1.00mm。噴油器缸套有滲漏或損傷會引起漏水，應對噴油器銅套予以換新。有裂紋的缸蓋建議予以報廢，否則會引起漏水現象。2、配氣機構: 1)氣門座圈和氣門導管/個別機組的氣門座圈和氣門導管需予以磨削，磨削量必須正確，否則會引起氣門碰撞活塞，氣門和氣門導管卡死，機油耗量劇增等故障。此工作須由工程總監親自操作.2）氣門彈簧/檢查氣門彈簧的長度和彈力，彈簧太軟會造成氣門跳動，使氣門和氣門座加劇磨損，也會破壞氣門正時,氣門和活塞發生碰撞。不合格的彈簧必須予以報廢。3）氣門和氣門座圈的研磨/采用研磨膏研磨氣門，使氣門和氣門座圈呈線性接觸，所有氣門研磨完畢，必須將研磨膏清洗干凈（特別注意要將氣門導管內的研磨膏清洗干凈）。4）氣門上下蓋/檢查有無裂紋，不合格則予以報廢。5）凸輪軸/檢查凸輪軸的凸輪型面積軸頸處有無裂紋、凹坑、腐蝕、擦傷，檢查齒輪有無裂紋、齒斷裂或齒面凹坑，不合格則予以報廢，否則會引起冒黑煙、功率虧損、擊破缸體的危險。6）凸輪從動件/檢查從動軸外有無超標，不合格則予以報廢。檢查滾輪表面有無麻點，轉動是否靈活，是否磨損過度，不合格則予以報廢。檢查滾輪銷及銷孔是否磨損過度，超標則予以報廢。檢查隨動臂有無裂紋，如有則予以報廢。7）氣門及噴油器推桿/球頭端有無磨損過度，推桿是否失圓，有無彎曲，不合格則則予以報廢。8）播臂/檢查有無裂紋，與丁字壓板的接觸凸面有無磨損或損傷，搖臂襯套內徑有無超標。檢查搖臂軸的磨損，超標則。予以報廢9）丁字壓板/檢查丁字壓板孔徑有無超標，丁字壓板的螺紋是否磨損和損傷，為合格則予以報廢。
警告：凸輪從動件為最關鍵而且容易出問題的配件，需予以特別檢查，否則會出現冒黑煙，功率虧損，擊破氣缸體曲軸的危險。
Diesel generating set exhaust smoke analysis fault
Diesel engine operating temperature under normal circumstances, the exhausted smoke should be colorless or pale gray, called is not totally colorless colorless, not as a petrol engine as colorless, but with a touch of gray colorless, it is normal for exhaust smoke. Diesel engine when idling exhaust smoke may be heavier, at a high speed, high load can be heavier, to observe the normal exhaust smoke, to a normal exhaust smoke determination and analysis. Diesel fuel after complete combustion, the normal colour is generally pale gray, negative Helve heavy and dark grey. Diesel in the work, will often smoke, diesel exhaust with black smoke, smoke, white and grey four, they are judging fault of diesel engine is one of the conditions, concrete analysis is as follows:
One, black smoke exhaust ( soot )
Black smoke and Chi Gu smoke, black smoke of diesel exhaust is the major cause of fuel rich mixture, combustible gas mixture formed bad or combustion is not perfect wait for a reason to cause. Diesel engine at high temperature, high pressure combustion conditions, local hypoxia, cracking and dehydrogenation and the formation of carbon as the main component of the solid particles of fuel in the combustion chamber, is incomplete combustion performance. Because the diesel engine is non homogeneous combustion, combustion chamber in various regions of the chemical reaction conditions are not consistent, and changes over time, so the black smoke is likely to be composed of many different approaches to natural. Diesel is a complex hydrocarbons, spray into the combustion chamber without burning diesel by high temperature decomposition, formation of carbon black, the exhaust gas discharged together with formation of black smoke. Black smoke is incomplete combustion products, is a hydrocarbon combustion in a high temperature anaerobic condition cracking process and polymerization of the release. In some cases the fuel injection on the combustion chamber wall surface, to form a liquid film, the oil film is finally the evaporation part, it depends on the speed of evaporation and combustion of fuel vapor and oxygen mixing speed. If the ambient gas oxygen concentration is too low, or a mixture of fast enough, from the oil film evaporation of the fuel gas will be decomposed, and bring unburned hydrocarbon, incomplete oxidation products and black smoke.
Diesel engine combustion process the natural black smoke can be summarized into three stages -- the nucleation stage, single stage, single particle combustion disappear or agglomerated into larger floc. Effects of the natural raw due:
1, piston rings, cylinder sleeve valve, piston ring wear, cylinder wear, causing compression pressure and oil channeling combustion test negative winter cylinder at the end of the compression stroke, mixture proportion change, so that the fuel in the anaerobic condition combustion, combustion process easy to produce coke, exhaust gas formation large black smoke.
In 2, the combustion chamber shape combustion chamber shape for manufacturing quality and long-term use of LED technology status decline, the compression I sewed is too large, too small and the position of the piston installed the wrong, will make the combustion chamber shape and volume change, thus affecting the fuel mixed with air quality, so that the fuel combustion conditions addle.
In 3, the fuel injector is bad
Diesel engine exhaust smoke and fuel atomization quality are closely related, on the fuel injection process of diesel engine, fuel injection at the end of each pro, injection pressure drop, the atomization quality difference, the droplet diameter than the main injection stage of oil droplet in4- - 5 times ( volume increases about 100times ), the oil droplet evaporation and burning time is short, around the oxygen concentration is low, easy to produce the carbon smoke. A fuel injector atomization, atomization adverse or drop of oil, so that the fuel can not be fully with the air in the cylinder is mixed, also cannot complete combustion. By the fuel injector is caused by the phenomenon of black smoke exhaust in diesel engine at low speed operation when the more obvious, because of a low speed cylinder swirl is weak, oil droplets or oil beam by the airflow to reduce the possibility of broken up and stay longer, more easily to form carbon black discharging. )
4, the large amount of fuel oil supply amount is too large, so that the inlet cylinder oil increases, resulting in less fuel oil gas incomplete combustion. In addition, work overload, poor quality, low working temperature of the fuel will cause the black smoke exhaust, diesel engine fuel pyrolysis reaction is unavoidable, especially in the mixed combustion in diesel engines, due to the high temperature gas surrounded by a liquid droplet, a conducive to the cleavage reaction conditions, therefore, in the initial stage of combustion to generate a large number of carbon particle, this point has been confirmed by the combustion process of high speed photography. Diesel engine under normal combustion, in the exhaust valve opens before combustion, the early formed a large number of carbon particles can burn, basically is smokeless exhaust. Only in some unfavorable conditions, carbon cannot seasonable combustion instead reunion adsorption www.zfdjz.com, on the cylinder and the exhaust process to form larger carbon smoke particle or floc, the black smoke exhaust.
In 5, fuel supply advance angle adjusting improperly
(1) the fuel supply advance angle is too large, the fuel injected into the combustion chamber of premature, as the cylinder pressure at a lower temperature, fuel combustion, when the piston, cylinder reaches a certain pressure and temperature, combustible gas mixture combustion. In a direct injection diesel engine, when the other parameters are constant, increase the injection advance angle can reduce exhaust smoke. Due to increased fuel injection advance angle makes the ignition delay period is lengthened, so that the sprayed into the cylinder before ignition oil quantity increase, premixing volume increase, premixed gas increase, accelerate the combustion rate, combustion can be ended earlier, so that the main combustion period for the formation of carbon particle with higher temperature and stay more time, in favor of soot oxidation disappear. However early injection increased premixed fuel quantity, make the crude operation of diesel engine, combustion noise increasing, and due to the mechanical load, as well as more black smoke emission ( COX ).
(2) the fuel supply advance angle is too small, sprayed into the cylinder fuel too late, a portion of the fuel will not form a combustible mixture can be separated or discharge, resulting in the exhaust pipe with the exhaust from the fuel material by high temperature decomposition, combustion, producing black smoke with gas discharges.
In two, blue smoke exhaust
Exhaust emit blue smoke, under normal circumstances is diesel engine with long, slowly began to burn oil induced, with the blue smoke of burning oil increased, more and more, it should be considered for repair of diesel engines. Sometimes the fuel oil mixed with water, or water leakage into the combustion chamber, combustion caused the change, opportunity to take light blue smoke of diesel. Effects of the main factors for the natural:
In 1, the air filter inlet obstruction, or poor tank oil level is too high ( oil bath air filter ), which entered the cylinder volume reduction, fuel mixture proportion change, resulting in less oil gas fuel combustion is not complete, it will cause the exhaust emit blue smoke.
In 2, the oil sump lubricating oil adding too much, operation of diesel engine lubricating oil in easily penetrates into the combustion chamber.
In 3, long-term low load ( rated below 40% ) operation, clearance between the piston and the cylinder is too large, so that the oil bottom shell lubricants easily running into the combustion in the cylinder and fuel mixture, change the mixture proportion, incomplete combustion, cause the exhaust emit blue smoke.
In 4, the piston ring stuck or wear too much, lack of flexibility, installation of piston ring chamfering direction reversed, so that the oil into the combustion in the oil smoke exhaust gas generated after burning blue.
In5, the body to the cylinder head oil passage around the cylinder pad burnt, piston, cylinder wear and piston ring and other conditions will cause the lubricating oil flow combustion in and mixed with fuel gas combustion together.
In three, an exhaust white smoke
White smoke exhaust smoke is white, it is different with colorless, white water vapor white, said smoke contains water or containing unburned fuel composition. White smoke was liquid beads, and blue smoke compared with a slightly larger diameter, generally larger than 1μ M. The reflected light is white, the white smoke of diesel engine is unburned hydrocarbons ( including fuel and lubricants ), water vapour and incomplete combustion of intermediate products ( such as oxygenated hydrocarbon ), in addition to water vapor, they all belong to the category of particles. Diesel engine in starting or cold, white smoke, is due to low temperature in the cylinder of diesel engine oil gas evaporation and form, especially in winter. Diesel engine in cold weather operation, diesel engine exhaust pipe low temperature, low temperature, water vapor condenses into water to form white exhaust smoke, is a normal phenomenon. If the engine temperature is normal, exhaust temperature is normal, still exhaust white smoke, description of diesel engine is not working properly, can be judged to be the fault of diesel engine. Effects of the main factors for the natural:
In 6, when an engine is started, the individual cylinder does not burn ( especially in the winter ), unburned fuel mixture with other working cylinder exhaust gas out of formation water smoke.
In 5, the piston, cylinder liner, wear caused by compressive force is insufficient, resulting in incomplete combustion.
In 4, the fuel in the water and the air. Water and air with fuel injection in the cylinder form a uniform mixture of fuel oil, complete combustion, resulting in a large number of unburned hydrocarbon discharge machi, , , ne.
1, cylinder liner crack or damage of cylinder pad, along with the increase of temperature and pressure of cooling water, cooling water into the cylinder. The exhaust is formed easily form water fog or water vapor
In 3, fuel supply advance angle is too small. Piston to cylinder top front spraying into the cylinder fuel too little, forming a dilute mixture, later injection reduces the premixed fuel quantity, premixing volume reduction. Premixed gas reduction, reduced the rate of combustion, the combustion end later, the formation of a large number of water vapor smoke combustion.
Four, exhaust smoke ash
His pale gray smoke exhaust, diesel engine work is normal, but the smok, e increase was the color gray or close to black is not normal, in addition to the above smoke black reasons, may also have poor air supply inlet is not good reason. When the intake air filter, exhaust smoke from deep shallow even becomes colorless, is the air filter is clogged, should be checked by the intake not the reason of free.
2, atomization of fuel injector is poor, injection pressure is too low, a drop of oil , , phenomenon. In the cylinder fuel mixture is not uniform, incomplete combustion, produce large amounts of unburned hydrocarbons, exhaust easily form water fog or water vapor.
Nikko Ningbo power science and technology limited company diesel engine / engineering mechanical engine / ship power / power unit standard repair procedures
A: according to construction
The company of the whole generator repair, execute program card system, and the whole process is divided into the following11 procedures.
1: generator removing before the examination project. The 2: diesel engine disassembly project. 3: diesel engine parts cleaning. 4: diesel engine parts inspection and measurement. 5: diesel engine replacement parts catalog. 6: assemblage of parts of a diesel engine. 7: diesel engine assembly line test before the examination project. 8: diesel engine test procedures of various examination items. 9: diesel engine repair project. 10: diesel engine running-in period various examination items. 11: diesel engine running-in normal work after delivery.
Two: User guidelines
In the repair process, we request the customer to cooperate with the following work. 1: customer sent a supervisor on the project supervision and management. 2: each process shall be required by the director of engineering and to charge customers signed for confirmation. 3: Supervision of the supervisor in the whole project construction, that does not press a program card operation, must immediately be stopped, and repair group representations. 4: if the opinion divergence, and the company please contact the clerk, until it reaches the agreement before construction.
Three: maintenance program
A. body and a crank and connecting rod mechanism:1 cylinder body damage / cylinder common injury: burn tile, main bearing hole deformation, crack, breakage, the mouth of the water channel matching surface corrosion and abrasion. On visual inspection, should be no crack and damage, if found to have lead to water leakage, oil leakage, leakage, damage, it must be repaired or replaced. Especially for the cylinder body and the cylinder sleeve contacts the sealing ring has no pitting, corrosion phenomenon to be special inspection. 2main bearing hole of burning tile / phenomenon of the cylinder, particularly on the main bearing hole of aperture to be measured, non-standard main bearing hole must be corrected. The 3cam shaft hole and the camshaft bushing surface exposed copper is greater than 120 degrees, must be replaced if the camshaft bushing, camshaft bushing wear is excessive, also must be replaced, otherwise it would cause the engine oil pressure is too low, such as in the base hole bushing rotate, it must be checked seat hole size, exceed the standard, repair seat hole and renewed bush. 4cylinder block bore / check cylinder Xiamen seat hole non roundness, should not be greater than 0. 025mm, cylinder sleeve hole shoulder have no crack, cylinder liner projection in 0. 15-0. Between 20mm, new cylinder is sheathed in the cylinder should not swing phenomenon.
B. piston, piston ring, piston pin assembly,
Piston damage phenomena are: 1: piston top surface ablation. The 2: piston ring groove side wall wear and ring fracture. 3: piston pin hole aperture greatens, out of round. The 4: pin base crack. 5: piston initial strain. 6: early wear and horse ellipse piston. The 7: piston ring groove medial ridge peak exists. 8: piston wear too large.
C. connecting rod assembly
Connecting rod assembly of major injury are: 1: head liner wear. 2: small end bushing seat hole and the big end bearing saddle bore wear and deformation. 3: rod bending distortion. Connecting rod bolt or screw4: crack, variable length, thread wear or slipping buckles. 5: connecting rod body scratch phenomenon. 6: connecting rod has a tile deformation phenomenon. In the installation of connecting rod assembly, must press the correct torque parameters and the correct procedure, and must be inspected for screw screw.
Warning: installing a linkage assembly, shall be determined by the project manager to operate personally. For the damage of connecting rod assembly, must be scrapped, otherwise it will cause the connecting rod fracture, break the cylinder block, crankshaft and the risk of break.
Crankshaft, flywheel assembly: D. from the axis of the main shaft neck injury: abrasion, crack and fracture, burning tile resulting ablation. If the crankshaft out of roundness is greater than 0.05mm, will be grinding crankshaft. For tile serious crankshaft, due to its metallographic structure has changed, is generally not recommended to use again, crack phenomenon of the crankshaft must be scrapped, or there will be the possible fracture.
Warning: installing crankshaft, flywheel assembly, shall be determined by the project director in person operation, according to the criteria of the torque and the correct steps, main bearing cover screws must recheck.
E. cylinder cover and a gas distribution mechanism,1, cylinder head and cylinder cover and the cylinder body joint plane, valve guide hole, the valve seat hole, the injector hole, water cooling wall, easy to crack, available visual inspection, pressure test check. The cylinder cover and the cylinder body joint planes are not usually, advice on grinding machine repair, each processing capacity of around 0.10mm, processing limit is 1.00mm. The injector cylinder leakage or damage will cause the water leakage, deal with the fuel injector copper sets to be renewed. Cracked cylinder head suggested to be scrapped, otherwise it will cause the water leakage phenomenon. 2, gas distribution mechanism:1) the valve seat and the valve guide / individual units of the valve seat and the valve guide should be grinding, grinding amount must be correctly, otherwise it will cause impact piston valve, valve and valve catheter blocked, oil consumption increases fault. This work is required by the project director personally operation .2) valve spring / check valve spring length and elastic, soft spring will result in valve beating, the valve and valve seat exacerbates wear, will also destroy the valve timing, valve and piston collisions. Unqualified spring must be scrapped. 3) valve and valve seat ring polishing / grinding paste grind the valve, the valve and valve seat ring a linear contact, all valve grinding is finished, must be grinding paste clean (with particular attention to the valve catheter within the grinding paste clean ). 4) valve upper cover and a lower cover / check have no crack, failure will be scrapped. 5) the camshaft / check camshaft type cam shaft neck area of any crack, dent, corrosion, abrasion, check the gear has no cracks, tooth fracture or tooth surface pits, unqualified will be scrapped, otherwise it will cause
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