斯堪尼亞柴油發電機組發動機維修

卡特彼勒柴油發動機3406C 操作與保養

正確的操作和保養是發動機獲得最長使用壽命和最大經濟效益的關鍵因素。

 按照操作和保養手冊中的說明去做，可以使發動機的使用費用最低，且發動機的使用壽命最長。

發動機起動前

進行每日和其它的定期保養。

檢查發動機室，這樣可以防止以后的重大故障。

圍繞發動機的檢查

圍繞發動機的檢查

       為使您的發動機得到最長的使用壽命，在起發動機以前，進行一次徹底檢查。

  察看潤滑油或冷卻液有無泄漏、有無松動的              螺栓和臟物堆積，清除任何臟物。

      護罩必須正確就位，修理損壞的護罩、更換           丟失的護罩。

      確保轉動零件周圍無障礙物。

進排氣系統

      確保進氣管道和空氣濾清器安裝就位。

      確保所有的管夾箍和接頭擰緊。

      察看空氣濾清器保養指示器。當黃色膜片進    入紅色區域或紅色柱塞定在可見位置內時，    應保養空氣濾清器。

冷卻系統

檢查冷卻系統有無泄漏或接頭是否松動。

檢查冷卻系統軟管有無綻裂，及管夾箍是否松馳。

檢查水泵有無泄漏的跡象。

檢查風扇驅動皮帶是否松馳及有無損壞。

檢查冷卻液液位。如有必要，添加冷卻液。

被驅動設備

進行被驅動設備所需的任何保養。

如果需要，檢查被驅動設備的潤滑油油位。

如果發動機與被驅動設備之間有離合器，確保離合器已脫開。

如果發動機驅動的發電機，確保發電機輸出端的主斷路器已斷開。

電氣系統

檢查線路的下列狀況：

連接有無松動

線路有無磨損或損壞

檢查交流發電機皮帶有無綻裂和損壞。

確保接地是牢靠的。

燃油系統

在發動機運轉前或運轉中，燃油回油管路中的所有閥門都必須是打開的，以防止高的燃油壓力。

檢查燃油管路的接頭是否松動和有無泄漏。

確保向發動機供給燃油。

如果已有幾個星期沒有起動發動機，燃油可能已從燃油系統中泄出，所以在起動前首先用手動注油泵給發動機注油。

潤滑系統

檢查發動機曲軸箱機油油位，保持機油油位在機油油尺“發動機停車”側上的“加”和“滿”的標記之間 。

檢查下列零部件處有無泄漏：曲軸密封、曲軸箱、機油濾清器、機油油道堵頭、傳感器和氣門室蓋。

檢查曲軸箱呼吸器上的管子、T形管和管夾箍。

起動系統

拆開那些對起動馬達嚙合時產生的大電流沒有防護作用的電池充電器。

檢查蓄電池電纜的連接是否良好和有無腐蝕。

檢查儀表和控制面板狀態是否良好。

將停機裝置和報警器復位。

自動起動

       要實現自動起動，發動機控制開關必須在“自動 ” 位置。當遠程的起動/停車觸點閉合時，發動機自動地起動。

  警告：當發動機處于“自動 ” 模式時，發動機可能在任何時刻起動。為避免人身傷害，當發動機處于“自動 ” 模式時，人員必須遠離發動機。

手動起動

       警告： 如果有“不準操作”（DO NOT OPERATE）的警告標簽或類似標簽掛在起動開關或操縱機構上時，不要起動發動機或扳動任何操縱機構。

       1.    執行“發動機起動前”部分所敘述的步驟。

       2.    如果發動機與被驅動設備之間有離合器，確保       離合器已脫開。

       3.    將發動機控制開關轉到“手動起動”　　　　       （MAN.START）位置，手動起動發動機。

空氣起動馬達

把壓縮空氣壓力調到最大。

       注意：壓縮空氣壓力最大不能超過 1030 kPa (150 psi)

額外的壓縮空氣量。

電起動馬達

維持蓄電池中正確的電解液液位。

保持蓄電池中充滿電。

加熱蓄電池室或把蓄電池存放在較溫暖的地方。

用跨接電纜起動發動機,斯堪尼亞發電機組,斯堪尼亞發電機組維修,斯堪尼亞柴油發電機組維修,寧波斯堪尼亞柴油發電機組維修,浙江斯堪尼亞柴油發電機組維修,斯堪尼亞柴油發電機組維修保養,斯堪尼亞柴油發電機組維修報價,當使用外部電源起動發動機時，只能使用電壓與起動馬達的額定電壓相同的電源。

使用更高的電源電壓或電焊機的輸出電壓會損壞發動機的電氣系統。 電源沖擊會導致發動機電子控制模塊的損壞。

最好是使用一組備用的蓄電池，不推薦使用外部電源來起動發動機 。

發動機起動后

暖機

       1.　在提高發動機轉速到額定轉速前， 讓發動機在      低怠速下運轉2到3分鐘，以使缸套水溫開始上升。

       2. 　在暖機期間，檢查所有儀表上的讀數。

       3. 　再一次圍繞發動機進行檢查 ，檢查發動機有無液體和空氣泄漏。

       注意：當發動機在額定轉速和小負荷下運轉時，將較快地達到正常工作溫度。

接合被驅動設備

1. 確保各種儀表都處于相應發動機轉速的正常范圍內。

2. 增加發動機轉速到額定轉速。在加負荷以前，必須將發動機轉速增加到額定轉速。

3.    接合離合器以給發動機加負荷。

4. 繼續檢查所有儀表的讀數和被驅動設備。

儀表

當發動機在運轉時，要頻繁地觀察儀表。

定期地將儀表上的數據記錄下來 。

將記錄下來的數據與標準數據相比較，以確保發動機在正常運轉。 比較這些數據有助于知道發動機性能的變化。

確定并糾正儀表上任何明顯的讀數變化。

部分負荷運轉

延長在低怠速或較少負荷下的運轉時間會引起機油消耗量的增加和氣缸中積炭。

積炭會造成功率損失和性能變壞。

如有可能，至少每小時加滿負荷運轉一次，這樣能燒掉氣缸中過多的積炭。

警報器和停機裝置

為防止發動機損壞，警報器和停機裝置都設定在臨界工作溫度、壓力或轉速下。

當出現不正常的工作狀況時，警報器報警，以警告操作者。

當出現更危急的不正常工作狀況時，停機裝置起作用，停止發動機的運轉。

停機裝置有助于防止設備的損壞。

       如果一種發動機保護裝置使發動機停機，則必須確定停機的原因。在再次起動發動機之前，進行必要的修理。

       應熟悉下列項目：

警報器和停機裝置的類型

警報器和停機裝置的位置

使各種保護裝置起作用的各種工作狀態

起動發動機之前所需的復位步驟

手動停機

在發動機停機前，應使其逐漸冷卻。

發動機已在負荷下運轉后，立即使發動機停機會造成過熱和發動機零部件的加速磨損。

渦輪增壓器中心殼體中的過高溫度會造成機油焦化問題。

使用以下的步驟作為發動機的一般停機程序：

1.  脫開發動機與被驅動設備之間的離合器

2.  在使發動機停機前，讓發動機有一段時間冷卻：

a. 如果啟用了發動機的冷機功能，則把發動機控制開關轉到“冷機/停機”（COOLDOWN/STOP） 位置。

b.如果沒有啟用發動機的冷機功能， 則讓發動機運轉在高怠速大約五分鐘，然后再讓發動機停機。

3.  把發動機控制開關轉到“關機/復位” （OFF/RESET）位置。

自動停機

當發動機運轉在自動模式而遠程起動/停機觸點斷開時，將出現自動停機。

如果發動機啟用冷機功能，那么發動機在停機前將按設定的時間冷機，然后停機。否則，發動機會立即停機。

緊急停機

       緊急停機裝置僅用于 緊急情況。 正常停機不要使用緊急停機裝置。

發動機正常運轉時，緊急停機按鈕在“突起”位置。

當需要緊急停機時，按下緊急停機按鈕。這會切斷發動機的燃油供應。 這同時也會啟動進氣切斷裝置 (如果裝備)。

       在確定和糾正迫使出現緊急停機的問題之前，不要起動發動機。

       在發動機再次起動之前，緊急停機按鈕和進氣切斷裝置都必須復位。

順時針旋轉緊急停機按鈕使按鈕復位，緊急停機按鈕會回到“突出”位置。

轉動進氣切斷裝置的復位旋鈕到 “開”（OPEN）位置。

       確保發動機兩側的進氣切斷裝置都已復位。如果只復位了發動機一側的進氣切斷裝置，則會導致發動機的損壞。

3406C 發動機保養時間表

需要時的保養

發動機空氣濾清器濾芯（雙濾芯）－清洗/更換

發動機空氣濾清器濾芯（單濾芯）－檢查/更換

燃油系統 - 注油

壓縮空氣起動馬達潤滑器油位－檢查

壓縮空氣罐中的水和沉淀物 －排放

冷卻系統液位－檢查

被驅動設備－檢查/更換/潤滑

發動機空氣濾清器保養指示器－檢查

發動機空氣預濾器－清潔

發動機機油油位－檢查

燃油箱中的水和沉淀物 － 排放

儀表板 － 檢查

圍繞發動機的檢查

首次 250工作小時

發動機氣門間隙－檢查/調整

轉速傳感器 －清潔/檢查

發動機機油油樣（SOS） －獲取

發動機機油和機油濾清器－更換

曲軸箱呼吸器－清洗

燃油細濾清器－清洗粗濾清器/更換細濾清器

冷卻液中的添加劑－測試/添加

交流發電機和風扇皮帶－檢查/調整/更換

蓄電池電解液液位－檢查

散熱器－清潔/檢查

風扇驅動軸承－潤滑

軟管和管夾箍－檢查/更換

燃油箱 —放出水和沉淀物

每 1000工作小時

發動機保護裝置－檢查

燃油控制連桿 － 潤滑

每 3000工作小時或 2年

普通冷卻液－更換

長效冷卻液－添加添加劑

氣門間隙－檢查/調整

曲軸減振器－檢查

發動機支座－檢查

渦輪增壓器－檢查

冷卻系統節溫器 －更換

每 5000工作小時

噴油嘴 － 測試/更換

交流發動機，空氣壓縮機，水泵，起動馬達和渦輪增壓器 － 檢查/大修或更換

發動機轉速傳感器 － 檢查/更換

每 6000工作小時或 4年

冷卻系統中長效冷卻液－, 更換

CAT.C15. 柴油發電機組

性能參數：

     直列型六缸水冷四沖程直接噴射渦輪增壓后冷卻。

     缸徑 x 行程：137.20mm x 171.40mm

     排氣量     ：15. 20升

     額定功率   ：400 千瓦 (主用)

     額定轉速   ：1500rpm

     轉向面向飛端逆時針

     耗油量(100%)負載帶風扇： 101.3公升/小時

     重量             ：4160 kg不包括柴油。

C15發電機組配置

控制系統EMCP

    電子模塊式控制面扳

    標準向后裝置              電壓微調

   自起動/停機控制開關

   緊急停機按鈕    面板照明燈

     數字式顯示 -     三相交流電壓運行小時計  

  機油壓力                      水套水溫度

  直流電壓                           轉速

   系統診斷故障代碼         備用故障報警

一、環保

C15發電機組采用世界上最 先進的ACERT技術，發電機組排放滿足歐三Tier 3，Stage IIIA排放標準

二、運行可靠，使用壽命長

所有配件都是卡特彼勒原廠設計、制造和檢測，做過扭力分析測試，并以整機交付用戶；

 發電機與發動機的性能匹配，負荷調整模塊可使發動機免受負荷沖擊和改善負荷接受能力

三、適合新疆的氣候特點

A 、耐受環境溫度－40℃～+50℃時：

C15發電機組配有水套水加熱器零下溫度時迅速啟動并加載

具有可在+50℃環境溫度下使用的散熱器

B、適合于沙漠地區：

C15發電機組配有沙漠重載空濾器

四、產品質量有保證

在新疆烏魯木齊和庫爾勒設有CAT零件銷售中心及售后服務中心；

C15發電機組能在營房連續使用一年，不受1000小時限制。

底座燃油箱 (最小可持續運行10 小時.)

燃油軟管 和油水分離器

工業等級消音器帶波紋管

在底座和散熱水箱、發動機、發電機間安裝

   線性隔離減振器

3 級具有跳閘電路斷路器---國際電器協會認可

45 安培充電機

卡特電池組、電池支架和連線

卡特長壽命冷卻液

降低噪音

周圍環境溫度在50°C

窗式控制面板

Plated /  SS hardware

Powder baked paint

內部安裝消音器

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 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.

Diesel generator set concept and its testing methods

Diesel generator set

Diesel generator set of power station of AC power supply device of a type, is a small independent power generation equipment, driven by an internal combustion engine, driving synchronous AC generator and power generation.

Modern diesel generating set comprises a diesel engine, a three-phase AC brushless synchronous generator, a control box ( screen ), the cooling water tank, coupling, fuel tank, muffler and the common base and other components of the overall steel. Diesel engine flywheel shell and the generator front end cover of the axial convex shoulder is positioned directly connected together, and a cylindrical elastic coupling from the flywheel direct drive generators to rotate, the way of connection are fixed together by bolts, so that the two are connected into a steel body, ensure diesel engine crankshaft and the concentricity of generator rotor in the specified range.

Diesel generator set is composed of internal combustion engine and synchronous generator which is formed by the combination of an internal combustion engine, maximum power by components of the mechanical load and thermal load limit, called the rated power, AC synchronous generator rated power refers to the rated speed, long continuous operation, the rated output power, usually diesel engine rated power output with synchronous alternator output rated power, called the matching ratio.

Diesel generator

1 Overview

Diesel generator is a small power generation equipment, means the diesel fuel, diesel engine prime mover driven generator power machinery. Diesel generator diesel engine, generator, by the general control box, fuel tank, starting and control storage battery, protection device, emergency cabinet and other components. Integral can be fixed on the foundation, location, can be installed in the trailer, for mobile use.

Diesel generator is a continuous operation of power generation equipment, if the continuous running at more than 12h, the output power will be lower than the rated power of about 90%.

Although the diesel generator power is low, but because of its small size, flexible, lightweight, supporting complete, convenient operation and maintenance, and is widely used in mining, railway, field construction sites, road traffic safeguard, and factory, enterprise, hospital departments, as a backup power source or a temporary power supply. A newly developed in recent years, the unmanned automatic emergency power station, a more expanded the range of use of the generating unit.

At present, China's export production capacity of the production plant has more than 10Tianjin power equipment factory. Products are exported to Europe and the dozens of countries and regions, well received.

2classification and specifications

Diesel generator to generator power output size classification, unit energy from 10kW-750kW various specifications. Each kind of specification and consists of protecting type ( with super speed, high water temperature, low oil pressure protection device ), emergency and mobile power station type structures. The mobile station is divided again for speed and vehicle speed to match the high-speed off-road type and low speed normal mobile type.

3order matters needing attention

Diesel generating sets export inspection according to the provisions of the contract or agreement about the technical or economic indicators for inspection, users in the selection and contract, should pay attention to the following points:

(1) if environmental conditions and diesel generator calibration value between environmental conditions, should be in when signing the temperature, humidity and altitude value, to provide suitable models and ancillary equipment;

(2) to illustrate the use of the cooling means, especially the large capacity units, more attention should be paid;

(3) the order, except should describe the unit models, also shows what type;

(4) diesel generator voltage regulation rate were 1%,2%,2.5% of the rated voltage. What, should note;

(5) the normal supply, to provide a certain amount of wearing parts, otherwise need, also should note.

4 test items and methods

Diesel generating sets of complete sets of products, including diesel engine, generators, control components, protective device. The inspection of export products, including the following:

(1) product technology, test data review;

(2) product specifications, models, main dimensions;

(3) the overall product appearance quality;

(4) unit performance: the main technical parameters, operation adaptability, all kinds of automatic protection device reliability, sensitivity;

(5) the contract or agreement provisions of other projects.