韓國斗山大宇發電機發動機維修保養

韓國斗山大宇柴油發動機廢氣渦輪增壓器的正確使用及故障診斷 (廢氣渦輪;增壓器;故障診斷)
　　韓國斗山大宇針對影響增壓器的使用壽命因素，故障和診斷加以分析，并說明使用中的注意事項，意在減少增壓器的故障，延長其使用壽命，降低維護費用。

1 韓國斗山大宇廢氣渦輪增壓器的基本知識及工作原理

　　渦輪增壓器是用來提高發動機功率和減少排放的重要部件。渦輪增壓器本身不是一種動力源，它利用發動機排氣中的剩余能量來工作，其作用是向發動機提供更多的壓縮空氣。它利用發動機排出的廢氣能量，驅動渦輪高速旋轉，帶動與渦輪同軸的壓氣機葉輪高速旋轉，壓力機將空氣壓縮進入發動機氣缸，增加了發動機的充氣量，可供更多的燃油完全燃燒，從而提高了發動機的功率，降低了燃油的消耗，同時由于燃燒條件的改善，減少了廢氣中有害物質的排放，還可降低噪音。

　　柴油機經過增壓以后性能發生了變化，它使柴油機的功率大大得到提高，增壓后發動機的功率可提高20%～40%左右，以WD615機為例，使發動機的機械效率提高，增壓后發動機的輔助系統消耗的功增加很少，雖然因為爆發壓力大，各摩擦表面上的摩擦損失有所增加，但發動機功率增加較多，機械效率提高了近8%左右。燃油消耗降低，增壓后進氣壓力增高，燃燒條件改善，機械效率提高，油耗降低，發動機單位功率質量大大降低，但發動機經增壓后也帶來了新的問題，如：使發動機的機械負荷增加，發動機的熱負荷增加等等。

　　2 影響韓國斗山大宇增壓器使用壽命的因素

　　使用中我們發現，增壓器的損壞和磨損總是在柴油機及其附近出現故障之后發生，柴油機的許多不正常工況都會引起增壓器的損壞。增壓器出現故障，40%是由于潤滑不良造成的，40%是由于外界雜物通過增壓器所造成的，20%是其它原因引起的。

　　2.1潤滑油。潤滑油用來潤滑冷卻增壓器，但當增壓器正常工作時，其轉軸轉速高達每分鐘幾萬轉到十幾萬轉，潤滑油被打成泡沫狀，其冷卻和潤滑性能下降，因此潤滑系統必須保證能提供充足的潤滑油。若當600℃左右的高溫廢氣通過渦輪室時，軸承座得不到足夠的潤滑和冷卻，潤滑油將在其環形油道壁上結焦，逐漸堵塞油道。

　　潤滑油如果不清潔，也會很快損壞增壓器內部零件。如含有灰塵、泥狀沉淀物和金屬微粒的潤滑油會迅速破壞各零件的配合間隙，刮傷和磨損軸承表面。這些都將會引起渦輪軸轉動阻力增大和失掉平衡，使軸的轉速下降，導致柴油機的功率損失增大，且轉動不平衡將很快導致增壓器零件的損壞。

　　如果潤滑油的質量等級老化，油中的各種添加劑不能滿足增壓柴油機大負荷工作的潤滑要求，潤滑油將會加速氧化變質，也會加劇柴油機和增壓器零件的磨損。

　　柴油機的起動、熄火的操作方法不正確也將嚴重影響增壓器的壽命。如果柴油機起動后，就立即將轉速升得很高，潤滑油不能及時到達增壓器軸承而加速磨損。柴油機熄火后，若不首先使增壓器冷卻降溫，而且突然熄火，停止向增壓器供給機油，會導致增壓器內部零件過熱，軸承油道中的機油炭化阻塞油道，將有軸承被咬死的危險。

　　密封環泄露引起的渦輪后部積炭，將使旋轉零件轉動發澀，而損失功率。旋轉零件的不平衡是引起密封環泄露的一個重要原因。曲軸通氣孔或增壓器回油管堵塞或阻力過大，也能引起密封環泄露。

　　2.2韓國斗山大宇進氣系統。增壓器工作的好壞也依賴于進氣系統，只有供給充足、干凈的空氣才能保證增壓器長期無故障工作，使壽命延長。所以應定期檢查所有進氣管接頭和軟管的密封性，防止漏氣。如果壓氣機到柴油機進氣管漏氣，充氣量減少，將導致柴油機冒黑煙。當有較大顆粒的灰塵或沙子進入壓氣機會立刻損壞增壓器。較小的顆粒也會使工作輪葉片彎曲或被割削，并使其失去平衡，引起軸承和密封環的磨損加劇。不平衡的旋轉件與軸承發生碰撞時，使軸承上的油道逐漸縮小，導致潤滑不良。隨著軸承的磨損，配合間隙增大，使壓氣機或渦輪機的工作輪葉片打擊殼體，這種故障的信號是噪音比平常增大很多。

　　韓國斗山大宇進氣系統的進氣阻力應很小，如果空氣濾清器堵塞，進氣阻力增大，充氣量減少，增大功率損失，同時，壓氣機一側的密封環將會由于壓力差太大而泄露，引起潤滑油消耗量過大，這種故障的標志是在壓氣機工作輪葉片后面出現一層暗色的潤滑油膜。

　　2.3排放的廢氣。廢氣中很小的顆粒進入渦輪機，與顆粒進入壓氣機后果一樣，將導致增壓器的損壞。

　　韓國斗山大宇柴油機燃油供油量過大，進氣阻力大，會使燃燒室內可燃混合氣過濃而引起廢氣過熱，造成渦輪機殼體和油道過熱，廢氣從排氣管到渦輪室的通道泄露會降低渦輪機渦輪的轉速，增加冒煙，也會使渦輪機殼體過熱。這些都會導致渦輪室內積炭及渦輪葉片的腐蝕。

　　潤滑油壓力過高，潤滑油將通過密封環滲入渦輪機也會造成渦輪室積炭。

　　3 韓國斗山大宇廢氣渦輪增壓器使用注意事項

　　廢氣渦輪增壓器經常處于高溫下工作，進入廢氣渦輪端的溫度在600℃左右。增壓器轉子以每分鐘幾萬轉到十幾萬轉的高速旋轉，為了保證增壓器的正常工作，使用中應注意以下幾點： (1)使用正確牌號的潤滑油，并定期更換。對渦輪增壓柴油機至少應使用CD級增壓機油。

　　(2)韓國斗山大宇發動機發動以后，特別是在冬季，發動機點火后，應怠速運轉幾分鐘，千萬不能轟油門，以防止損壞增壓器油封。

　　(3)韓國斗山大宇火前，發動機也應怠速運轉幾分鐘，讓發動機、增壓器轉子的轉速降下來以后再熄火，以防止猛轟油門，增壓器轉速很高，突然熄火，機油泵不打油，增壓器轉子仍在高速慣性運轉，干磨損壞軸承。

　　(4)由于經常處于高溫下運轉，到增壓器的潤滑油管線由于高溫，內部機油容易有部分的結焦，這樣會造成增壓器軸承的潤滑不足而損壞。

　　(5)檢修發動機時，應注意千萬不能讓雜物進入增壓器，以防損壞轉子。

　　(6)WD615機經增壓后，空氣進入中冷器，有幾道橡膠管連線，要求在出車前、修車中檢查其連接情況，防止松動、脫落，以免造成增壓器失效和空氣短路進缸。

　　(7)禁止柴油機長時間急速運轉(一般不超過5min)因怠速時機油油壓較低，不利于增壓器的潤滑，容易使軸承過早磨損。

　　4 韓國斗山大宇廢氣渦輪增壓器常見的故障及排除

　　增壓器出現故障，不要匆忙的更換增壓器，應該尋找和判斷故障原因和部位，并盡可能地加以排除。這樣可以避免換上增壓器后同樣的故障重復出現。

　　4.1壓氣機喘振。如果增壓器在工作過程中向氣缸內輸送空氣量不足，空氣壓力將產生極大的波動，在壓氣機端發出異響，如氣喘的響聲，這就是喘振。由于喘振，發動機工作不平穩，功率下降，排氣冒黑煙。

　　產生喘振的原因是進氣系統堵塞，如空氣濾清器濾芯嚴重阻塞，進氣管內油污太多阻塞。增壓器的噴嘴環流通道發生變形也會造成喘振。最好是每次二級保養更換空氣濾芯，車運行十萬公里左右，清洗進氣通道。

　　4.2增壓器在運轉中發出雜音，發出金屬的撞擊，摩擦聲、或者產生振動，是增壓器轉子和渦殼之間發生了變化，應拆卸轉子檢修、調整。

　　4.3增壓器在運轉中出現了強烈的震動。這是由于轉子組不平衡，軸承損壞造成的，應更換軸承及進行轉子組的動平衡校驗。

　　4.4增壓壓力下降。該故障的主要原因是進氣道堵塞，并進入中冷器的進氣道連接軟管松脫，破裂造成。

　　4.5增壓器突然停止運行，發動機功率下降。這是增壓器軸承損壞，轉子組燒死所致。應更換軸承，如損壞嚴重應更換增壓器總成。油封漏油也應及時檢修更換。

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。

South Korea Doosan Daewoo diesel engine exhaust gas turbocharger correct use and fault diagnosis ( exhaust gas turbine supercharger; fault diagnosis; )

The effect of turbocharger life factors, fault and diagnosis are analyzed, and the points for attention in use, is intended to reduce the supercharger failure, prolong the service life, reduce maintenance cost.

In recent years, along with the motor vehicle replacement, some heavy duty diesel vehicles generally used a turbocharger, but in the use of often occurs in the exhaust gas turbine supercharger damaged early fault, analyse its reason, is mainly used for turbocharger, improper maintenance caused by. The influence of turbocharger life factors, fault and diagnosis are analyzed, and the points for attention in use, is intended to reduce the supercharger failure, prolong the service life, reduce maintenance cost.

The 1exhaust gas turbocharger of the basic knowledge and principle of work

Turbocharger is used to increase engine power and reduce emissions of major parts. Turbocharger itself is not a kind of power supply, it uses the residual energy in the exhaust of the engine to work, its role is to provide more compressed air engine. It uses the engine exhaust gas energy, driving the turbine rotating speed, driving the coaxial with turbine compressor impeller rotating speed, press the compressed air into the engine cylinder, increases the engine's air volume, for more complete combustion of the fuel, thereby increasing the power of the engine, reduce fuel consumption, at the same time as the combustion conditions improve, reduce exhaust emissions of harmful substances, capable of reducing noise.

Diesel engine performance through the pressurization later changed, it makes the power of diesel engine is greatly improved, turbocharged engine power can be increased by 20%～ 40%, WD615 machine as an example, the engine mechanical efficiency, turbocharged engine auxiliary system of the power consumption is increased a little, although because of an outbreak of pressure, the the friction surface of the friction loss has increased, but the engine power increased, the mechanical efficiency is increased by about 8% or so. Reduced fuel consumption, after the booster inlet pressure, improve combustion conditions, mechanical efficiency, reduce oil consumption of engine unit, power quality is greatly reduced, but the engine after pressurization also brought new problems, such as: the engine so that the mechanical load is increased, the heat load of an engine to increase and so on.

2Influence Factors of service life of turbocharger

Use we found, turbocharger damage and wear always in diesel engine and its nearby after a failure occurs, diesel engine with many abnormal conditions will cause the damage of turbocharger. Turbocharger failure,40% is due to poor lubrication caused,40% is the result of external impurities through the turbocharger caused by other reasons,20%.

The 2.1lubricating oil. Lubricating oil used for lubricating and cooling the supercharger, but when the turbocharger when in normal work, the rotating speed of up to the minute tens of thousands to ten rotates, lubricating oil is hit into foam, its cooling and lubricating performance, therefore lubrication system must guarantee to provide sufficient lubrication oil. When600℃high temperature of exhaust gas through the turbine chamber, the bearing seat can not get enough lubrication and cooling, lubricating oil in the annular oil on the wall of coking, gradually blocked oil.

Lubricating oil if not clean, will soon damaged turbocharger internal parts. Such as containing dust, mud sediment and metal particles in the lubricating oil can quickly destroy the parts fit clearance, scratching and wear of bearing surface. All these will cause the turbine shaft resistance and lose balance, so that the rotational speed of the shaft down, resulting in engine power loss increases, and the rotational imbalance will soon lead to a turbocharger parts damage.

If the oil quality grade aging, oil additives can not meet the large work load of turbocharged diesel engine lubrication requirements, lubricating oil will be accelerated oxidation metamorphism, also aggravate the diesel engine and turbocharger parts wear.

Diesel engine starting, flameout operation method is not correct it will seriously affect the life of turbocharger. If the starting of the diesel engine, once the speed to rise too high, the lubricating oil can not be timely arrival of turbocharger bearing and accelerated wear. Diesel engine flameout, if not the first to make turbocharger cooled, and all of a sudden flameout, to stop the supply of oil will cause the turbocharger, turbocharger internal parts overheat, bearing oil passage oil carbonization blocking oil, would have killed risk bearing.

Seal ring leakage caused by turbine rear carbon deposit, will make the rotating parts rotation of Shibuya, and loss of power. Rotating parts unbalance is caused by the seal ring leakage is one of the important reasons. The crank vent or supercharger oil return pipe plug or the resistance is too large, can also cause the seal ring leakage.

2.2air intake system. Turbocharger working stand or fall is also dependent on the intake system, only supplies enough, clean air to ensure the supercharger long-term trouble-free, prolonging life. Therefore, should be regularly checked all the inlet pipe and hose seal, to prevent leakage. If the compressor to diesel engine intake pipe leakage, reduce the amount of air, will cause the black smoke for diesel engine. When the larger particles of dust or sand into opportunity immediately damaged turbocharger compressor. The smaller particles will also make the work wheel blades bending or cutting, and make it out of balance, causing a bearing and seal ring wear intensifies. Unbalanced rotor and bearing when a collision occurs, the bearing oil passage is gradually reduced, leading to poor lubrication. As the bearing wear, with increasing gap, so that the compressor or turbine blade against shell, the fault signal is a lot more noise than usual.

Air intake system and the intake resistance should be small, if the air filter is clogged, the intake resistance increases, the inflatable amount is reduced, increasing the power loss, at the same time, the compressor side of the seal ring will be due to the pressure difference is too big and leaked, causing lubricating oil consumption is too large, the fault is marked in the compressor work wheel blades appear behind a layer of dark lubricating oil film.

2.3emissions. Very small particles in the exhaust gas into the turbine, and the particles into the compressor as a result, will lead to the damage of turbocharger.

Diesel fuel amount is too large, the intake resistance, will make the combustion chamber combustible mixed gas exhaust overheating caused by too strong, causing the turbine casing and oil overheating, the exhaust gas from the exhaust pipe to the turbine chamber passage leak will reduce the turbine turbine speed, increasing the smoke, also can make the turbine housing overheating. All these will lead to the interior carbon deposit and turbine blade corrosion.

Lubricating oil pressure is too high, the lubricating oil through the sealing ring into the turbines will result in the turbine chamber, carbon deposition.

The 3exhaust gas turbochargers use matters needing attention

Exhaust gas turbine supercharger often works under high temperature, into the exhaust gas turbine end at the temperature of 600℃. Supercharger Rotor with tens of thousands to ten per minute to rotate at high speed, in order to ensure the normal work of the supercharger, the use should pay attention to the following points: (1) use the correct grade of lubricating oil, and the regular replacement. For turbocharged diesel engine should be at least CD stage supercharged engine.

(2) engine, especially in the winter, after engine ignition, should be idle a few minutes, ten million cannot banging accelerator, to prevent damage to the turbocharger oil seal.

(3) before the engine flameout, should also be idle a few minutes, let the engine, turbocharger rotor speed down later to prevent stalling, bombarded the throttle, the turbocharger speed is very high, all of a sudden flameout, machine oil pump not nonsense, Supercharger Rotor in high-speed inertial movement, dry bad bearing wear.

(4) due to the frequent under high temperature operation, to the turbocharger lubricating oil pipeline due to high temperature, the internal oil easy to have part of the coke, which will cause the supercharger bearing lubrication and damage.

(5) as part of the engine, should pay attention not to let the debris into the supercharger, to prevent damage to the rotor.

(6) WD615by pressurized, air enters the intercooler, a couple of rubber pipe connection, requirements, before driving car check their connections, to prevent loosening, fall off, so as to avoid the turbocharger failure and short circuit of air cylinder.

(7) prohibit the diesel engine for a long time racing ( less than 5min ) for idle speed oil pressure is low, is not conducive to the turbocharger lubrication, easy to cause premature bearing wear.

The 4exhaust gas turbocharger of common breakdown and eliminate

Turbocharger failure, not to rush to replace supercharger, should seek and fault reasons and positions, and as far as possible to exclude. This can be avoided in the supercharger the same fault repeated.

4.1compressor surge. If the turbocharger in the working process to the cylinder air volume, air pressure will produce great volatility, in air compressor end sends out the different bang, such as wheezing sound, this is the surge. Since the surge, the engine working is not stable, power down, black smoke exhaust.

Surge is the cause of the intake system blockage, such as air cleaner element severe obstruction, air intake pipe oil too much congestion. Turbocharger nozzle circulation channel deformation will cause surge. It is best for each two maintenance replacement air filter, car runs one hundred thousand kilometers, cleaning air inlet passage.

4.2 supercharger in operation emits a sound, making the metal bump, friction sound, or vibration, the turbocharger rotor and the volute are between changed, should remove rotor maintenance, adjustment.

In the operation of the4.3turbocharger appeared strong shock. This is due to the rotor group imbalance, bearing damage, replace the bearing and rotor dynamic balancing.

4.4pressure drop. This is the main reason of failure of inlet plug, and into the cooler inlet port connected to the hose loose, caused by ruptured.

4.5 supercharger suddenly stopped running, engine power is reduced. This is the turbocharger rotor beari, ng damage, caused by the group. Should replace the bearings, such as serious damage to replace the turbocharger assembly. Seal leak should also be timely maintenance and replacement.

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 within the conduit