宁波柴油发电机组维修保养.doc

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1、宁波柴油发电机组维修保养宁波柴油发电机组维修保养宁波柴油发电机组维修保养发动机维修技术分析与总结发动机的修理技术是通过维修人员凭着丰富的时间经验和理论知识,依靠发动机的规定和技术要求进行分解和修复,现对维修中所存在的技术问题进行分析、总结。现通过对发动机维修时常遇见的问题做简要的分析,以供有关人员在今后的工作中参考:1发动机的分解为使分解能顺利进行,一般由外向内的分解程序进行分解,拆卸下来的螺栓和零部件要按要求存放好,防止丢失和变形,如曲轴、缸盖,凸轮轴等要按要求放置平衡,防止受力不均而产生变形,造成不必要的损失。对有要求按照规定程序进行分解的零部件,一定要按规定的分解程序进行分解。例如:气缸

2、盖和曲轴主轴泵螺栓,如果没有严格按照规定的拆卸程序进行拆卸,一旦程序错乱,便会造成缸盖和曲轴的变形,甚至报废。2零部件选择目前,由于市场上出售的零件良莠不齐,有些配件由于库存时间过长,其性能以无法达到原厂设计的标准和技术要求,特别是假冒伪劣配件,其性能达不到原厂设计的技术要求,严重影响机械安全和技术性能,所以在安装配件前,必须严格对新配件做出详细的技术检查。而有些维修人员在安装新配件时,没有对新配件做技术检查就直接安装在发动机上,这种做法是很不合理的。例如:一辆日本三菱FV413货车在正常行驶时水温高,经检查是发动机水泵进水口胶管在水循环时被吸扁,原来胶管是劣质产品,由于胶管长度较长,而胶管内

3、并无防变形弹簧,由于发动机工作时,水温升高,使胶管变软,被水泵吸扁,冷却水无法正常循环,造成发动机水温过高,更换正厂的水进水管后,发动机工作时水温正常,因此在维修发动机时,应使用正厂的配件,不可用其它型号的配件代用,更不能错用。3零部件的清洗在维修发动机时,正确的清洗方法是提高修理质量和延长其使用寿命的关键。有些维修人员在清洗过程中不注重零部件的清洗,没有合理的选择清洗剂和清洗方法,导致零部件腐蚀损坏和早期磨损。因此,在清洗发动机各个部位的零部件时,必须认真彻底地清除其表面的油污和杂质。而在选用清洗剂时,为了不使零部件表面受到破坏,影响配件的技术性能,对不同材质的零部件的选用的清洗剂也不同,特

4、别是精密零部件和橡胶类零件都不允许有任何程度的腐蚀。例如:铝合金类,铜制品类和橡胶类零部件不宜放在碱性或酸性清洗剂中清洗,避免对其产生不同程度破坏和腐蚀,影响其技术性能。4零部件的安装装配时,要由内向外的装配程序进行安装,并严格按照工作原理和规定要求进行安装。特别是对外部特征比较相似,容易发生装反的零部件。更应注意:例如发动机的汽缸垫、活塞、正推垫片、油封、活塞环等。这些零部件如果在安装时不了解其工作原理和结构,最易装反,导致装配后不能正常工作,发生机械事故。所以在装配零部件时,一定要了解零部件的结构和工作原理,掌握正确方向和安装要求。5零部件的配合间隙发动机装配时,零部件的安装有严格的技术要

5、求,各项配合间隙必须严格测量,对不符合要求的零部件要进行调整或更换,特别是活塞间隙、活塞与缸套的配合减息、气门间隙、主轴瓦与主轴颈配合间隙、连杆瓦羽联赣州颈间隙、活塞肖与肖套配合间隙、曲轴的轴向间隙等。各部位都有严格的尺寸和配合公差要求。在实际维修中,有些维修人员根本没有按技术要求进行检测后再进行装配,而是有目地将零配件直接安装导致间隙过大时轴承磨损加剧,而过大时将引起轴承抱死和烧熔等现象,使发动机根本无法正常工作,甚至会因零部件的配合间隙不当导致严重的机械事故的发生。6螺栓的选用由于发动机工作时温度变化和变载荷作用比较大,因此,装配发动机时,正确选用专用的螺栓对保证发动机维修后能否正常工作至

6、关重要。例如:气缸盖螺栓、连杆螺栓、曲轴主轴承螺栓、喷油器固定螺栓等,都是采用特殊材质的螺栓,其强度高,抗剪切力强。如果发现螺栓损坏或丢失时,一定要按要求选用同等规格和技术要求的螺栓。在选用时,一些重要螺栓的头部都标有记号,以便识别。如果随意选用其它螺栓代用或自行加工代替,这些螺栓因材质差或加工工艺不合格,导致在工作中发生拉卡,滑丝等损伤,严重时产生断裂,造成敲坏气缸体的严重事故,因此,在选用螺栓时,质量一定要符合规格和技术要求,切忌乱代乱用。7螺栓拧紧程序和力矩发动机各部位螺栓拧紧时,一定要按照规定的拧紧程序和力矩进行拧紧,各部位螺栓在拧紧时都规定了严格的拧紧程序和力矩。而一些维修人员在拧紧

7、螺栓时不按规定程序和力矩进行拧紧,不使用扭力扳手,随意使用加力杆,导致拧紧力矩不足或过大。而当力矩不足时,易产生螺栓松脱,力矩过大时螺栓易拉伸变形,断裂,例如:扭紧气缸盖螺栓时,如果不按规定程序和力矩拧紧,将导致发动机气缸体和气缸盖变形,并冲坏气缸垫片,因此在维修发动机时,一定要按规定程序和力矩扭紧螺栓,防止因螺栓拧紧力矩过大,过小或不按程序而导致故障的发生。8垫片的使用发动机各部位的垫片种类很多,常用的有平垫、弹簧垫、石棉垫、纸板垫、铜垫、铝垫等。不同种类的垫片有着不同的作用。有些起着防松、防脱的作用,有些起作密封的作用。如果在使用垫片时不按规定和要求进行选择,导致机械事故的发生。例如:发动

8、机气缸垫过薄时,容易产生漏油或漏气,甚至冲坏气缸垫,过厚时使气缸压缩比降低,严重影响发动机的正常工作和机械性能,因此在选用垫片时一定要按要求选用符合技术要求的垫片,防止事故的发生。9附件的检查发动机的附件总类很多,有柴油滤清器、机油滤清器、空气滤清器、风扇罩、水温表、水箱盖、油压表、感应等。如果缺乏对附件检查和维护保养,将严重影响发动机的正常工作,减少发动机的使用寿命,因此对附件的检查和保养是必不可少的,对延长发动机的使用寿命至关重要。结束语:本文论述了在装配发动机时经常被忽视的问题和应对措施。在装配时必须了解其工作原理,按照规定的技术要求和程序进行装配,进一步提高了维修质量,减少了故障的发生

9、,使修复的发动机能处于最佳的性能状态。NingbodieselgeneratorsetmaintenanceEnginemaintenancetechnicalanalysisandsummaryEnginerepairtechnicalmaintenancepersonnelwithawealthoftimeexperienceandtheoreticalknowledge,relyontheprovisionsoftheengineandtechnicalrequirementsdecompositionandrepairarenowonthemaintenanceofthetechnic

10、alproblemstoanalyze,summarize.Nowdoabriefanalysisofenginemaintenanceisoftenmet,fortherelevantpersonnelinthefutureworkofreference:AnengineofdecompositionSothatdecompositionofasmooth,generallyfromoutsidetoinsidethedecompositionprocessdecomposed,removedboltsandpartsaccordingtotherequirementsofstorageto

11、preventlossanddistortion,suchascrankshaft,cylinderhead,camshaft,accordingtotherequirementsplacedonbalance,topreventunevenforcedeformation,resultinginunnecessarylosses.Decomposedpartsdecompositionisrequiredinaccordancewithprescribedprocedures,mustaccordingtotheprovisionsofthedecompositionprocess.Fore

12、xample:thecylinderheadandcrankshaftmainpumpbolts,ifnotinstrictaccordancewiththeprovisionsofthedemolitionprocesstobedemolished,oncetheprogramisconfusionwillresultindeformationofthecylinderheadandcrankshaft,orevenscrapped.TwopartsselectionAtpresent,thesaleofpartsonthemarketvariesgreatly,someaccessorie

13、sinventoryfortoolong,itsperformancecannotmeettheoriginaldesignstandardsandtechnicalrequirements,inparticularcounterfeitparts,itsperformanceuptolessthantheoriginaldesignofthetechnicalrequirements,seriouslyaffectthemechanicalsafetyandtechnicalperformance,beforeinstallingtheaccessories,mustbestrictlyma

14、keadetailedtechnicalexaminationofnewaccessories.Somemaintenancepersonnelintheinstallationofnewaccessories,thereisnotechnicalinspectionofnewaccessoriesdirectlymountedontheengine,thisapproachisveryunreasonable.Forexample:aJapaneseMitsubishiFV413goodsvehiclesinnormaldriving,highwatertemperature,checken

15、ginewaterpumpinlethoseinthewatercyclebeingsuckedflat,theoriginalhoseinferiorproductsduetoalongerhoselength,hosedidnotanti-deformationofthespring,duetoenginework,thewatertemperature,softenedhose,waterpumpsuctionflat,thenormalcycleofcoolingwater,causingtheenginewatertemperatureistoohigh,thereplacement

16、istheplantswaterinletpipewatertemperature,engineworknormalmaintenanceoftheengine,youshoulduseGenuineaccessories,notsubstituteothertypesofaccessories,nottomisuse.3partscleaningInthemaintenanceoftheengine,thecorrectcleaningmethodistoimproverepairqualityandextenditslifethekey.Somemaintenancepersonnelin

17、thecleaningprocessdoesnotpayattentiontothecleaningofparts,thereisnoreasonablechoiceofcleaningagentsandcleaningmethodscausepartstocorrosiondamageandearlywear.Therefore,thecleaningofvariouspartsoftheengineparts,mustbecarefullyandthoroughlytoremovethesurfaceoilandimpurities.Selectionofcleaningagents,in

18、ordernottomakethecomponentsurfaceisdestroyed,affectingthetechnicalperformanceoftheaccessories,theselectionofthedifferentmaterialcomponentsofthecleaningagent,especiallyprecisionpartsandrubberpartsarenotallowedtohaveanyThedegreeofcorrosion.Forexample:classaluminumalloy,copperproductsclass,andrubberpar

19、tsshouldnotbeonthealkalineoracidiccleaningagents,cleaning,andavoidtheirvaryingdegreesofdamageandcorrosiontoaffectitstechnicalperformance.FourpartsoftheinstallationAssembly,theassemblyprocessfromtheinsideoutinstallation,andrequirementsforinstallationinstrictaccordancewiththeprinciplesandprovisions.In

20、particular,externalcharacteristics,pronetoholdanti-parts.Shouldpayattentionto:suchastheenginecylinderheadgasket,piston,pushinggaskets,oilseals,pistonringsandother.Ifthesepartsduringinstallationdonotunderstanditsworkingprincipleandstructureofthemostanti-transvestite,leadingtonotworkproperlyafterassem

21、bly,mechanicalaccidents.Partsintheassembly,besuretounderstandthestructureandworkingprincipleoftheparts,tomasterthecorrectdirectionandinstallationrequirements.5partswiththegapEngineassembly,theinstallationofthepartsstringenttechnicalrequirements,allwiththegapmustbestrictlymeasurementdoesnotmeetthereq

22、uirementsofpartstobeadjustedorreplaced,especiallythepistonclearance,pistonandcylinderwiththecutininterestrates,valveclearance,themainbearingandmainjournal,withthegap,connectingrodbearingBWFGanzhouneckgaptoliveSaixiaoandtheShawsetwiththegap,theaxialclearanceofthecrankshaft.Eachsitehasastrictsizeandfi

23、ttolerancerequirements.Inactualmaintenance,somemaintenancepersonneldidnotaccordingtothetechnicalrequirementsfortestingafterassembly,butthepurposeofsparepartsinstalleddirectlyleadtobearingwearincreasedgapistoolarge,toolargewillcausethebearinglockingandShaorongsuchphenomena,sothattheenginesimplydoesno

24、twork,becauseeventhepartsoftheco-ordinationbetweenThegapduetoimproperseriousmachineryaccidents.Choiceof6boltsBecauseoftherelativelylargetemperaturechangesandvariableloadsintheenginework,assemblingtheengine,thecorrectselectionofspecialboltsrightcanworktoensuretheenginemaintenanceisessential.Forexampl

25、e:thecylinderheadbolts,rodbolts,crankshaftmainbearingbolts,fuelinjectormountingboltsarespecialmaterialbolts,itshighstrength,shearandstrong.Iftheboltisdamagedormissing,accordingtocertainrequirementsofthebolttousethesamespecificationsandtechnicalrequirements.Intheselectionoftheboltheadismarkedmarkedto

26、facilitateidentification.Iftherandomselectionoftheotherboltsalternativeorself-processinginsteadofboltsduetopoormaterialorprocessfailure,leadingtoLahappenedatwork,slipthewiredamage,seriousfracture,resultinginseriousincidentsknockthebadcylinder,sowhenintheselectionofbolts,thequalitymustmeetthespecific

27、ationsandtechnicalrequirementstoavoidchaosgenerationofindiscriminateuse.7bolttighteningproceduresandtorqueTightentheboltsoftheengineparts,inaccordancewiththeprescribedtighteningproceduresandtorquetightenallpartsbolttightenprovidethestricttighteningproceduresandtorque.Anumberofmaintenancepersonneltig

28、htentheboltsaccordingtoprescribedproceduresandtorquetighten,donotuseatorquewrenchisfreetousetheafterburnerrod,resultingininadequateorexcessivetighteningtorque.Whenthetorqueisinsufficient,easytoproducetheboltsloose,thetorqueistoolargeboltseasytotensiledeformation,fracture,suchas:tighteningcylinderhea

29、dbolts,ifnotaccordingtoprescribedproceduresandtorquetighten,willresultintheenginecylinderblockandcylindercoverdeformation,andwashedouttheheadgasket,sothemaintenanceoftheengine,certainlyaccordingtotheprovisionsoftheproceduresandtorquetighteningbolttopreventthebolttighteningtorqueistoolarge,toosmallor

30、notaccordingtotheprocedurewhichledtothefailureoccurred.8padsofuseEngineparts,gasketsaremanykindsofcommonflatwasher,springwasher,asbestosmats,cardboardmat,coppermats,aluminummats,etc.Differenttypesofpadshavedifferentroles.Someplaysalocking,anti-offrole,andsomeforsealing.Theuseofshimsaccordingtothepro

31、visionsandrequirementsofselect,resultinginamechanicalaccident.Forexample:whentheenginecylinderheadgasketistoothin,pronetospillsorleak,orevenwashedoutthecylinderheadgasketistoothicktomakethecylindercompressionratiolower,seriouslyaffectingthenormalworkingoftheengineandmechanicalproperties,sowe,followi

32、ngintheselectionofgasketshallbeselectedtomeetthetechnicalrequirementsofthegaskettopreventaccidents.9AnnexinspectionThegeneralcategoryoftheannextotheenginealot,dieselfilter,oilfilter,airfilter,fancover,watertemperature,radiatorcaps,oilpressuregauge,sensorandsoon.TheabsenceofthenormalworkoftheAnnexins

33、pectionandmaintenance,willseriouslyaffecttheengine,reduceenginelife,theannexinspectionandmaintenanceisessentialforextendingthelifeoftheengineiscritical.Conclusion:ThispaperdiscussestheoftenneglectedissuesintheassemblyoftheengineAndresponsemeasures.Mustunderstandhowitworksintheassembly,inaccordancewiththeprovisionsofthetechnicalTechniquerequirementsandproceduresforassembly,tofurtherimprovethequalityofmaintenance,reduced,thereforeTheoccurrenceofimpairedrepairtheengineinthebestperformancestatus.扩展阅读:第 12 页 共 12 页

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