无锡无动柴油发电机组维修保养.doc

无锡无动柴油发电机组维修保养柴油发动机修理技术要求1范围1.1本标准规定了装卸机械柴油发动机修理的技术要求、检查与考核。1.2本标准适用于港装卸机械柴油发动机的修理工作。2规范性引用文件下列文件中的条款通过本标准的引用而成为本标准的条款。凡是注日期的引用文件，其随后所有的修改单（不包括勘误的内容）或修订版均不适用于本标准，然而，鼓励根据本标准达成协议的各方研究是否可使用这些文件的最新版本。凡是不注日期的引用文件，其最新版本适用于本标准。港口装卸机械内燃机械修理技术要求。3术语3.1原厂规定：指内燃机生产厂对零部件及其配合的规定。3.2大修允许：指内燃机大修时，各零部件的尺寸偏差，配合公差，形位公差所允许的范围。3.3使用限度：指零件是否可以继续使用的极限。4气缸件与气缸盖4.1清除气缸体及气缸盖上的油污、积炭；清除水道内的水垢；清除油孔、油道内的污物。4.2缸体与缸盖减薄量最大允许值为1.00mm ，减薄后的缸体与缸盖应增加相应厚度的铜垫片。4.3气缸体及气缸盖应无裂纹，有0.30.4MPa 的压力下作5min 水压试验不得有渗漏现象，修补过的气缸体及气缸盖，应以0.40.45MPa的水压进行试验。4.4缸头螺丝、喷油器固定螺丝的螺纹损坏不得多于2牙。4.5气缸磨损至最大分级修理尺寸时，应予换镶气缸套，必要时允许个别更换。4.6气门导管磨损或损坏后，必须用一个合适的专用冲头将其卸下，压装时亦用专用冲头压入并注意控制导管高出气门弹簧座的距离。4.7气门座圈缺裂，烧损，应予换镶，拆卸时应使用专用工具。安装后，应用专用铰刀修铰，与气门互研，保证接触带宽度与位置有合适范围。（说明书要求的范围内）。4.8气门弹簧的拆卸与安装应使用专用工具，以防锁片弹出伤人。4.8.1检视气门工作面，察看有无磨损起槽，变宽或烧蚀出现班点，凹陷等情况，如有其中之一损伤时，就应进行光磨。4.8.2气门杆与导管配合的检验。气门杆与导管磨损后，其配合间隙增大，一般在发动机分体清洗后，应进行配合间隙的检验。气门杆与导管的配合间隙，一般进气门超过0.20毫米，排气门超过0.25毫米，应更换新气门或导管。4.8.3气门座的检修。气门座的工作面磨损后宽度超过2毫米，或工作面烧蚀出现严重斑点，凹陷；或气门座圈松动，裂纹等现象时，应通过铰削，光磨或重镶座圈、气门与气门座的研磨修复。4.9摇臂尾部的调节钉球头应落在顶杆碗形座面内。气门间隙应定期检查调整。4.10喷油器与气缸盖之间用铜垫圈密封，两个固定喷油器螺栓的螺丝应交替均匀拧紧。5曲轴和飞轮5.1曲轴表面不得有拉伤沟槽。5.2更换主轴瓦时应根据轴径的磨损程度选配，并注意瓦口方向，按规定扭力拧紧螺丝。5.3飞轮齿圈牙齿磨损后，沿齿长方向磨损达四分之一，齿形变锥应更换，可将齿圈打翻使用。6连杆、活塞与活塞销、活塞连杆组的拆卸：6.1打开边盖，拆下边杆螺丝，注意用手托住连接杆盖，以防止坠入油底壳内，并防止碰伤轴瓦。6.2从连杆下端将活塞连杆往上推，自气缸盖套上口沿气缸中心线取出活塞连杆，取出时严防碰伤气缸套内壁。6.3对活塞顶，活塞裙及活塞环槽内的积炭应清除干净，并进行检视，确定是否需换新。6.4拆装活塞销时，应放在机油内加热至100120。装活塞时必须注意活塞顶部燃烧室开口方向与连杆大头切口的相对位置，最后用尖头钳装好活塞销锁簧。6.5安装活塞环时，先装最下层的环，不宜扩张过大，以免活塞环折断。同时注意活塞环的内、外倒角方向。安装螺旋弹簧油环时，先将弹簧套入环槽，再装油环圈，使弹簧全部嵌入油环圈内圆凹槽内，并将弹簧接口置于油环圈开口的对面位置。装好后各环开口应依次错开120度，在环槽内无卡滞现象，且活塞环间隙和侧边隙应符合规定。6.6在活塞连杆、气缸套，曲轴等配合面处涂上足够的清洁机油，然后在气缸套上放置活装塞的专用工具，用木柄轻轻地将活塞打入气缸套内，这时用手在下端引导，使连杆大端轴瓦内圆与连杆轴颈贴合。注意燃烧室开口方向或连杆大头切口面的方向切不可错。装上配对的连杆盖，用扭力扳手分数次均匀交替拧紧连杆螺丝直至规定的值，各缸活塞连杆组装好后，转动曲轴应灵活无阻滞现象。7润滑系统7.1发动机润滑系统各部件应彻底清洁，按规定装复，调整油道，保证管路畅通。7.2机油粗、细滤清器应彻底清洗干净。大修时应更换滤芯。7.3机油冷却器应定期清洗，重装时应封油圈保持平整和位置正确，老化或发粘的封油圈应换新，冬季停车后应放掉其中的冷却水，以防冻裂。8冷却系统8.1水泵壳体完好，不得有裂缝，水泵叶轮完好，不得有裂纹，水泵的安装配合间隙及使用限度应符合规定。8.2风扇叶表面不得有裂纹，叶片不允许变形，铆钉不允许有松动现象。8.3散热器必须清除外部灰尘油垢，散热应理直、平行、排列整齐。9柴油机燃油系统9.1输油泵9.1.1输油泵体，手泵体均应无裂损。活塞弹簧，止回阀弹簧和滚轮弹簧的性能应符合原厂规定。9.1.2柱塞式输油泵泵体孔与柱塞配合间隙不应于0.015mm。9.2喷油泵在发动机大修时，应送主专业的校泵单位进行检测。9.3喷油器装合后必须进行调试，用手将油压压到规定压力后，以每分钟约10次的速度压油，此时喷应明显同一内燃机喷油压力偏差应不大于0.5Mpa，在每分钟喷油4080次进行雾化试验时，油雾应匀细，雾未油粒应均匀，不得有肉眼看见的油滴飞溅现象，燃油切断应及时，并有清脆的音响，喷油开始前和终了后，在喷油口不允许有渗油现象，喷油结束后允许针阀体端面或头部轻微湿润。10内燃机的装配、磨合。10.1装配10.1.1对装配的零部件应再次清洗，保证全部油道、水道和气道清洁畅通。10.1.2各轴颈与滑动轴承的结合面、活塞与气缸的配合面及其他磨擦面均应涂上机油安装。10.1.3活塞环应按原厂规定的次序与角度安装，活塞环与活塞环槽的间隙应符合规定。10.1.4曲轴轴承盖、连杆轴承盖、气缸盖及飞轮的螺栓、螺母应按规定的力矩分次按顺序拧紧。10.1.5各种锁止装置必须齐全、完整，贴合可靠。10.1.6正时齿轮应正确啮合，啮合间隙应符合规定。10.1.7应检查调整配气及喷油的相位，并符合规定10.2磨合10.2.1试车时应使用稀薄机油，转速应逐渐增加，热试转速可采用6001400r/min ，允许短时转速达到原发动机额定转速的80%，热试时间应1.5h 以上。10.2.2热试后应更换润滑油及机油滤芯。10.2.3试车过程中应进行必要的调整，使内燃机运转正常，无异常响声，水温不应超过95度，机油温度不得超过95度，机油压力应在0.150.54M 范围内。10.2.4一般大修后的内燃机功率允许比额定功率降低10%。The Wuxi non-moving diesel generator set maintenanceDiesel engine repair technical requirements1 Scope1.1 standard specifies the technical requirements for loading and unloading machinery diesel engine repair, inspection and evaluation.1.2 This standard applies to the port loading and unloading machinery diesel engine repair work.2 Normative referencesThe terms of the following documents become the standard reference in the provisions of this standard. For dated reference documents, all subsequent amendments (excluding corrigenda) or revisions do not apply to this standard, however, encourage the parties to agreements based on this standard using the latest version of these files . All dated reference documents, the latest versions apply to this standard.Port handling machinery internal combustion machinery repair technical requirements.3 Terms3.1 The vehicle shall contain: refers to the provisions of the internal combustion engine manufacturing plant parts and their complexes.3.2 overhaul to allow: refers to the internal combustion engine overhaul, the deviation of the size of various parts, tolerances, shape and position tolerances allowed.3.3 Limit: refers to the parts can continue to use the limit.4 cylinder with the cylinder head4.1 to clear the cylinder block and cylinder head, oil, coke; clear the waterways within the scale; clear the hole in the dirt in the oil passages.4.2 The cylinder block and cylinder head thinning maximum allowable value of 1.00mm, the cylinder block and cylinder head after the thinning should increase the corresponding thickness of the copper gasket.4.3 the cylinder block and cylinder head should be no cracks, 0.3-0.4MPa pressure mainly as 5min hydrostatic test shall not be leakage, the cylinder block and cylinder head repaired, test the water pressure 0.4-0.45MPa.4.4 cylinder head screws, injector screws thread damage is not more than 2 teeth.Repair size, 4.5 cylinder wear and tear to the maximum classification should change the insert cylinder liner to allow individual replacement when necessary.4.6 valve guides wear or damage, with a special punch will remove it with a special punch pressed into the press-fit and pay attention to controlling the conduit above the valve spring retainers distance.The lack of crack, 4.7 valve seat burning should be to change the set, demolition should be used for special tools. After installation, the application of special reamers repair hinge research, interaction with the valve to ensure that the contact width and location of the appropriate range. (Within the scope of the instructions).4.8 valve spring removal and installation of special tools should be used to prevent the lock piece pop-up hurt.4.8.1 View the valve face, look for wear from the slot, wider or ablation Ban point, depression, etc., if the injury of one of them, it should be light grinding.4.8.2 of the valve rod and the catheter with the test. The wear of the valve rod and the catheter with the gap increase, and general cleaning of the engine split, with the clearance of test. With the gap of the valve rod and the catheter, usually the intake valve of more than 0.20 mm, exhaust valve over 0.25 mm, and should be replaced with a new valve or catheter.4.8.3 maintenance of the valve seat. Face wear of the valve seat width more than two millimeters, or face ablation serious spots, dents; or loose valve seat ring, cracks and other phenomena, reaming, light grinding or re-set seat, valve and valve seat grinding Repair.4.9 Rocker regulation at the end of the nail ball head should fall within the ejector bowl seat. The valve clearance should be checked regularly to adjust.4.10 injector and cylinder head copper gasket seal between the two fixed injector bolts, screws should be alternating evenly tightened.5 crankshaft and the flywheel5.1 crankshaft surface without strain groove.5.2 to replace the main bearing wear matching should be based on shaft diameter, and note the direction of tile mouth, the torque required to tighten the screws.5.3 flywheel ring gear tooth wear, along the direction of tooth wear up to a quarter of the tooth change cone should be replaced and the ring gear can be knocked over use.6 connecting rod, piston and piston pin, piston connecting rod set demolition:6.1 Open the side cover, remove the side rod screw, pay attention to hand lift up the connecting rod cap to prevent the fall in oil pan, and to prevent bumps bearing.6.2 from the connecting rod lower end of the piston rod to push up, take strict precautions against the cylinder head to put on the rim cylinder centerline to remove the piston rod, remove the bumps cylinder liner inside wall.6.3 on the piston top and piston skirt and piston ring slot coke should be cleaned and to view, determine whether to be renewed.6.4 removable piston pin should be placed in oil heated to 100 120 . Loaded piston must pay attention to the direction of the piston at the top of the combustion chamber opening and the relative position of the connecting rod cut, the last tip clamp installed piston pin lock spring.6.5 installation piston ring, fitted to the lowest ring, not expansion is too large to avoid broken piston ring. Also note that the piston rings inside and outside chamfer direction. The coil spring oil ring is installed, the first spring set into the ring groove, oil loading ring, spring all embedded in the oil ring circle within the circular groove and spring interface into the oil ring opening of the opposite position. Installed after the ring opening in order to stagger 120 degrees in the ring slot card hysteresis phenomenon, and the piston ring gap and side clearance should be required.6.6 coated with clean engine oil with the surface of the piston rod, cylinder liner, crankshaft, special tools to place live loaded plug and then put in the cylinder, the piston into the cylinder comprising a wooden handle gently, then hand to guide in the bottom of the inner circle connecting rod big end bearing and connecting rod journal to fit. Note the direction of the incision surface of the combustion chamber opening direction or the connecting rod must not be wrong. Fitted with matching rod cap torque wrench scores alternately tighten the connecting rod screws until the values specified in the piston rod assembly, rotate the crankshaft should be flexible and no block.7 lubrication systemThe 7.1 engine lubrication system components should be thoroughly cleaned and refitted as required, adjust the oil duct to ensure patency.7.2 crude oil, and fine filter should be thoroughly cleaned. Overhaul should replace the filter.7.3 oil cooler should be cleaned regularly, reload when oil sealing ring formation and in the correct position, aging or tacky oil sealing ring should be renewed, the winter parking should be let go after one of the cooling water to prevent the cracking.8 cooling system8.1 pump casing is intact, no cracks, the water pump impeller in good condition, no cracks, water pump installation with the gap and the use of limits should be specified.8.2 fan leaf surface shall not crack, the blade does not allow deformation, the rivet does not allow loosening.8.3 Radiator must remove external dust, grease, heat straighten parallel, arranged in neat rows.9 diesel engine fuel system9.1 fuel pump9.1.1 The oil pump, hand pump should be no dehiscence. Piston spring, check valve springs and roller spring performance in line with the original provisions.9.1.2 plunger pump pump hole and the plunger with the gap should not be 0.015mm.9.2 fuel injection pump in the engine overhaul should be sent to the main professional school pump units for testing.9.3 Injector must be installed together commissioning, hand hydraulic pressure to the required pressure, oil pressure speed of about 10 times per minute, the spray should be obvious the same internal combustion engine fuel injection pressure deviation should not exceed 0.5Mpa , 40-80 times per minute injector atomization experiment, the oil mist should be uniform fine mist not oil particles should be uniform, shall not be visible to the naked eye droplets splashing fuel cut off should be timely, and crisp sound. injection before the start and the end in the injector port does not allow oil leakage phenomenon after the end of the injector allows the face or head of the needle valve body is slightly moist.10 internal combustion engine assembly, adjustments.10.1 assembly10.1.1 assembly parts should again be cleaned to ensure all the oil road, waterway and airway clean smooth.10.1.2 journal and binding surface, with the surface of the piston and cylinder sliding bearings and other friction surface should be coated with oil installation.10.1.3 piston rings should be the original prov