威爾信柴油發電機組發動機維修保養

⑴P30E機組

⑵P50E1機組

⑶ P330E機組

⑷ P系列防音型

⑸ P系列拖車型

3、威爾信柴油發電機配件功能介紹

㈠控制屏

1001控制屏：⑴儀表：電壓表、電流表、頻率/轉速表、運行時間表、冷卻水溫表、潤滑油壓力表、電池電壓表

⑵有報警燈的故障停機保護( 高水溫、低油壓）

⑶控制：開關停機運行/預熱/啟動、急停按鈕、告警測試

2001系列：允許通過遙控信號，自動控制發電機組，因而適用TI系列自動負載切換屏組成市電/發電機組全自動切換系統。

2001控制屏⑴ 儀表：電壓表、電流表、頻率/轉速表、運行時間表、冷卻水溫表、潤滑油壓力表、電池電壓表。

  ⑵控制：開關停機運行/預熱/啟動、急停按鈕、告警測試

  ⑶故障停機保護： 啟動失敗、高水溫、低油壓、超速/緊急停機

  ⑷控制屏遙控信號/觸點：遙控急停連接線端、故障警報信號干觸點

  Access4000控制屏：提供開放的通訊協議具有遠程監控，能提供多種操作和保護功能的自啟動系統。

  Access4000：

   ⑴  全數字具有4行超寬的LCD顯示發電機組相關工作數據。

   ⑵  各種故障報警及停機功能

   ⑶ 開放通訊接口（R422或R485)

   ⑷ 失電數據自動存儲

   ⑸ 故障歷史數據

   ⑹ 分級保護控制密碼

6200系列控制屏：具有自動并機功能的自啟動數碼式  控制屏，配合市電失壓檢測模塊(AMF)實現全自動的并車。能做到自動分配有功功率和無功功率，即使機組型號不同，自動負載分配程序也同樣能夠根據機組的輸出能力自動按比例分配負載。

 6200控制屏：

  ⑴  全數字2×4行LCD顯示發電機組相關工作數據

   ⑵  各種故障報警及停機功能

   ⑶ 開放通訊接口（R422或R485)

   ⑷ 相關系統控制

   ⑸ 相關操作控制

4、威爾信機組其它功能介紹

威爾信機組配置2001控制屏及TI/TX的ATS雙機備用自動系統（－）

4、威爾信機組其它功能介紹

   威爾信機組并機系統功能（二）

 1.手動和自動控制單臺機組的啟停及輸出空氣開關；

 2.LCD寬屏液晶參數顯示：油壓、水溫、電池電壓、運行時間等油機參數，三相相電壓、線電壓、線電流、頻率、功率因數、有功功率、無功功率、電度等電參數，并聯匯流母線電壓、母線與發電機電壓、頻率、相位差等同步參數；

 3.發電機組低油壓、高水溫、超速、超頻、速度信號丟失、起動失敗、過流、電壓過高或過低、逆功率保護停機；

 4.發電機組充電失敗、水溫高、油壓低、電池電壓低、傳感器故障報警；

 5.類似黑匣子的歷史事件記錄；

 6.參數設置授權控制；

 7.方便功能擴展。

威爾信機組并機系統功能（三）

1.自動并車，自動按設定的比例實現有功和無功負載的無差分配，自動根據負載波動投入和撤出機組，即當負荷較輕時會自動退出部分機組，當負荷較重時會自動投入部分機組 ；

2.實現多臺備用時不停電負載轉移；

3.啟動負載儲備及運行負載儲備的設定功能。當負荷在任意點反復波動時都不會造成機組   頻繁投切，可保證在負載變動時提供穩定的電力；

4.啟動優先順序可編程設定；

5.機組之間通過CAN工業控制器高速總線進行通訊；

6.具有可編程輸入/輸出口；

7.易于實現單臺手動機組擴容為多臺監控并機；

8.根據需要方便擴展并機單元，最多可達8臺。

9.通過精確設置參數、優化負載管理來達到可靠和經濟運行的目的。

威爾信機組并機系統功能（四）

   用于并車的機組必須裝有電子調速器及自動電壓調節裝置(AVR),每臺并

  車機組為一個單元,當負載擴容時可根據需要任意增加并機單元,每個并

  機單元包含:

   ● 6200控制屏

   ● 自動斷路器（MCCB）整個并機系統可以有如下可選配量:

   ● 輸出空氣開關柜（ACB柜）（可選）

   ● 自動電源切換柜（ATS柜）（可選）

1． 噴油泵的速度特性
噴油泵每個工作循環的供油量主要取決于調節拉桿的位置。此外，還受到發動機轉速的影響。在調節拉桿位置不變時，隨著發動機曲軸轉速增大，柱塞有效行程略有增加，而供油量也略有增大；反之，供油量略有減少。這種供油量隨轉速變化的關系稱為噴油泵的速度特性。
2． 柴油機上為什么要安裝調速器
噴油泵的速度特性對工況多變的柴油機是非常不利的。當發動機負荷稍有變化時，導致發動機轉速變化很大。當負荷減小時，轉速升高，轉速升高導致柱塞泵循環供油量增加，循環供油量增加又導致轉速進一步升高，這樣不斷地惡性循環，造成發動機轉速越來越高，最后飛車；反之，當負荷增大時，轉速降低，轉速降低導致柱塞泵循環供油量減少，循環供油量減少又導致轉速進一步降低，這樣不斷地惡性循環，造成發動機轉速越來越低，最后熄火。
要改變這種惡性循環，就要求有一種能根據負荷的變化，自動調節供油量。使發動機在規定的轉速范圍內穩定運轉的自動控制機構。移動供油拉桿，可以改變循環供油量，使發動機的轉速基本不變。因此，柴油機要滿足使用要求，就必須安裝調速器。
3． 調速器的功用、形式
調速器是根據發動機負荷變化而自動調節供油量，從而保證發動機的轉速穩定在很小的范圍內變化。
型式：按功能分有兩速調速器、全速調速器、定速調速器和綜合調速器；按轉速傳感分有氣動式調速器、機械離心式調速器和復合式調速器。
4． 機械離心式調速器的工作原理
機械離心式調速器是根據彈簧力和離心力相平衡進行調速的，工作中，彈簧力總是將供油拉桿向循環供油量增加的方向移動；而離心力總是將供油拉桿向循環供油量減少的方向移動。當負荷減小時，轉速升高，離心力大于彈簧力，供油拉桿向循環供油量減少的方向移動，循環供油量減小，轉速降低，離心力又小于彈簧力，供油拉桿又向循環供油量增加的方向移動，循環供油量增加，轉速又升高，直到離心力和彈簧力平衡，供油拉桿才保持不變。這樣轉速基本穩定在很小的范圍內變化。
反之當負荷增加時，轉速降低，彈簧力大于離心力，供油拉桿向循環供油量增加的方向移動，循環供油量增加，轉速升高，彈簧力又小于離心力，供油拉桿
又向循環供油量減小的方向移動，循環供油量減小，轉速又降低，直到離心力和彈簧力平衡。
5． 兩速調速器
兩速調速器適用于一般條件下使用的汽車柴油機，它只能自動穩定和限制柴油機最低與最高轉速，而在所有中間轉速范圍內則由駕駛員控制。

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 generator governor 's basic principle and type

The 1fuel injection pump speed characteristics

Fuel injection pump oil supply amount of each working cycle depends mainly on the control rod position. In addition, but also by the effects of engine speed. In the control rod position unchanged, with the engine crankshaft speed increases, the plunger effective stroke increases slightly, and the amount of oil also slightly increased; conversely, amount of oil was slightly reduced. The oil supply quantity changes with the rotating speed relationship called fuel injection pump speed characteristic.

On 2 diesel engine why install a speed governor

Fuel injection pump speed on multivariate working diesel engine is very bad. When the engine load is changed slightly, resulting in engine speed change. When the load is reduced, high speed, high speed causes the plunger pump the fuel cycle fuel cycle increased, leading to more speed increases further, the vicious spiral, causing the engine speed is more and more high, the last coaster; conversely, when the load is increased, reducing speed reduces speed, causes the plunger pump the fuel cycle reduced, the fuel cycle and leads to further reduction to reduce speed, this constant vicious spiral, causing the engine speed is more and more low, finally stalling.

To change this vicious spiral, requires a according to the change of load, automatically adjust the amount of oil. To keep the engine at given speed range of stable operation of the automatic control mechanism. Mobile fuel rod, can change the cycle of oil production, the rotation speed of the engine is basically unchanged. Therefore, the diesel engine must meet the requirements for use, you must install the governor.

3 governor function, form

The governor is according to engine load changes automatically regulate oil supply, so as to ensure the engine speed is stable in a very small range.

Type: divided by function two speed governor, full speed regulator speed governor, and governor speed sensing; according to a pneumatic governor, mechanical centrifugal governor and compound type speed governor.

4the working principle of mechanical centrifugal governor

Mechanical centrifugal speed governor is according to the spring force and the centrifugal force is balanced speed, work, the force of the spring will always pull rod to supply fuel cycle of increasing direction; and the centrifugal force will always tie rods to reduce oil fuel cycle to move in the direction of. When the load is reduced, rising of rotating speed, the centrifugal force greater than the force of the spring, to reduce fuel rod fuel cycle in the direction of movement, the fuel cycle is reduced, to reduce speed, centrifugal force is less than the force of the spring, and the fuel cycle fuel rod to increase in the direction of movement, the fuel cycle speed increase, rise, until the centrifugal force and the force of the spring balance, fuel rod will remain unchanged. This speed is stabilized basically in a very small range.

Conversely when the load increases, the rotational speed is reduced, the spring force is larger than the centrifugal force, the fuel cycle fuel rod to increase in the direction of movement, the fuel cycle increased, rising of rotating speed, the spring force is smaller than the centrifugal force, fuel rod

And to the fuel cycle decreases in the direction of movement, the fuel cycle is reduced, speed and reduce, until the centrifugal force and spring force balance.

5two speed governor

Two speed governor for general use under conditions of vehicle diesel engine, it can automatic stability and limit of minimum and maximum speed of diesel engine, and in all the intermediate speed range by the pilot control.

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 surfa, ce 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 a black smoke, power loss, the risk of breaking cylinder. 6) the cam follower / check the driven shaft and not exceed the standard, unqualified will be scrapped. Check the wheel surface is pitted, rotation is flexible, whether the excessive wear and tear, unqualified will be scrapped. Check the wheel pin and a pin hole is worn, exceed the standard will be scrapped. Check with the boom has no cracks, such as there is to be scrapped. 7) valve and fuel injector push rod / ball end without excessive wear and tear, the push rod is losing a round, there is no bending, unqualified then will be scrapped. 8) an arm / check for cracks, and the T-shaped plate contact convex are worn or damaged, rocker arm bushing diameter not exceed the standard. Check the arm shaft wear, exceed the standard criterion. Be scrapped9) T-shaped plate / check T-shaped plate aperture having no exceed the standard, the T-shaped plate thread for wear and damage, as qualified will be scrapped.

Warning: the cam follower is the key and difficult parts, need to be special examination, otherwise there will be a black smoke, power loss, breaking cylinder crankshaft risk.