斯堪尼亚柴油发电机组发动机维修

卡特彼勒柴油发动机3406C 操作与保养

正确的操作和保养是发动机获得最长使用寿命和最大经济效益的关键因素。

 按照操作和保养手册中的说明去做，可以使发动机的使用费用最低，且发动机的使用寿命最长。

发动机起动前

进行每日和其它的定期保养。

检查发动机室，这样可以防止以后的重大故障。

围绕发动机的检查

围绕发动机的检查

       为使您的发动机得到最长的使用寿命，在起发动机以前，进行一次彻底检查。

  察看润滑油或冷却液有无泄漏、有无松动的              螺栓和脏物堆积，清除任何脏物。

      护罩必须正确就位，修理损坏的护罩、更换           丢失的护罩。

      确保转动零件周围无障碍物。

进排气系统

      确保进气管道和空气滤清器安装就位。

      确保所有的管夹箍和接头拧紧。

      察看空气滤清器保养指示器。当黄色膜片进    入红色区域或红色柱塞定在可见位置内时，    应保养空气滤清器。

冷却系统

检查冷却系统有无泄漏或接头是否松动。

检查冷却系统软管有无绽裂，及管夹箍是否松驰。

检查水泵有无泄漏的迹象。

检查风扇驱动皮带是否松驰及有无损坏。

检查冷却液液位。如有必要，添加冷却液。

被驱动设备

进行被驱动设备所需的任何保养。

如果需要，检查被驱动设备的润滑油油位。

如果发动机与被驱动设备之间有离合器，确保离合器已脱开。

如果发动机驱动的发电机，确保发电机输出端的主断路器已断开。

电气系统

检查线路的下列状况：

连接有无松动

线路有无磨损或损坏

检查交流发电机皮带有无绽裂和损坏。

确保接地是牢靠的。

燃油系统

在发动机运转前或运转中，燃油回油管路中的所有阀门都必须是打开的，以防止高的燃油压力。

检查燃油管路的接头是否松动和有无泄漏。

确保向发动机供给燃油。

如果已有几个星期没有起动发动机，燃油可能已从燃油系统中泄出，所以在起动前首先用手动注油泵给发动机注油。

润滑系统

检查发动机曲轴箱机油油位，保持机油油位在机油油尺“发动机停车”侧上的“加”和“满”的标记之间 。

检查下列零部件处有无泄漏：曲轴密封、曲轴箱、机油滤清器、机油油道堵头、传感器和气门室盖。

检查曲轴箱呼吸器上的管子、T形管和管夹箍。

起动系统

拆开那些对起动马达啮合时产生的大电流没有防护作用的电池充电器。

检查蓄电池电缆的连接是否良好和有无腐蚀。

检查仪表和控制面板状态是否良好。

将停机装置和报警器复位。

自动起动

       要实现自动起动，发动机控制开关必须在“自动 ” 位置。当远程的起动/停车触点闭合时，发动机自动地起动。

  警告：当发动机处于“自动 ” 模式时，发动机可能在任何时刻起动。为避免人身伤害，当发动机处于“自动 ” 模式时，人员必须远离发动机。

手动起动

       警告： 如果有“不准操作”（DO NOT OPERATE）的警告标签或类似标签挂在起动开关或操纵机构上时，不要起动发动机或扳动任何操纵机构。

       1.    执行“发动机起动前”部分所叙述的步骤。

       2.    如果发动机与被驱动设备之间有离合器，确保       离合器已脱开。

       3.    将发动机控制开关转到“手动起动”　　　　       （MAN.START）位置，手动起动发动机。

空气起动马达

把压缩空气压力调到最大。

       注意：压缩空气压力最大不能超过 1030 kPa (150 psi)

额外的压缩空气量。

电起动马达

维持蓄电池中正确的电解液液位。

保持蓄电池中充满电。

加热蓄电池室或把蓄电池存放在较温暖的地方。

用跨接电缆起动发动机,斯堪尼亚发电机组,斯堪尼亚发电机组维修,斯堪尼亚柴油发电机组维修,宁波斯堪尼亚柴油发电机组维修,浙江斯堪尼亚柴油发电机组维修,斯堪尼亚柴油发电机组维修保养,斯堪尼亚柴油发电机组维修报价,当使用外部电源起动发动机时，只能使用电压与起动马达的额定电压相同的电源。

使用更高的电源电压或电焊机的输出电压会损坏发动机的电气系统。 电源冲击会导致发动机电子控制模块的损坏。

最好是使用一组备用的蓄电池，不推荐使用外部电源来起动发动机 。

发动机起动后

暖机

       1.　在提高发动机转速到额定转速前， 让发动机在      低怠速下运转2到3分钟，以使缸套水温开始上升。

       2. 　在暖机期间，检查所有仪表上的读数。

       3. 　再一次围绕发动机进行检查 ，检查发动机有无液体和空气泄漏。

       注意：当发动机在额定转速和小负荷下运转时，将较快地达到正常工作温度。

接合被驱动设备

1. 确保各种仪表都处于相应发动机转速的正常范围内。

2. 增加发动机转速到额定转速。在加负荷以前，必须将发动机转速增加到额定转速。

3.    接合离合器以给发动机加负荷。

4. 继续检查所有仪表的读数和被驱动设备。

仪表

当发动机在运转时，要频繁地观察仪表。

定期地将仪表上的数据记录下来 。

将记录下来的数据与标准数据相比较，以确保发动机在正常运转。 比较这些数据有助于知道发动机性能的变化。

确定并纠正仪表上任何明显的读数变化。

部分负荷运转

延长在低怠速或较少负荷下的运转时间会引起机油消耗量的增加和气缸中积炭。

积炭会造成功率损失和性能变坏。

如有可能，至少每小时加满负荷运转一次，这样能烧掉气缸中过多的积炭。

警报器和停机装置

为防止发动机损坏，警报器和停机装置都设定在临界工作温度、压力或转速下。

当出现不正常的工作状况时，警报器报警，以警告操作者。

当出现更危急的不正常工作状况时，停机装置起作用，停止发动机的运转。

停机装置有助于防止设备的损坏。

       如果一种发动机保护装置使发动机停机，则必须确定停机的原因。在再次起动发动机之前，进行必要的修理。

       应熟悉下列项目：

警报器和停机装置的类型

警报器和停机装置的位置

使各种保护装置起作用的各种工作状态

起动发动机之前所需的复位步骤

手动停机

在发动机停机前，应使其逐渐冷却。

发动机已在负荷下运转后，立即使发动机停机会造成过热和发动机零部件的加速磨损。

涡轮增压器中心壳体中的过高温度会造成机油焦化问题。

使用以下的步骤作为发动机的一般停机程序：

1.  脱开发动机与被驱动设备之间的离合器

2.  在使发动机停机前，让发动机有一段时间冷却：

a. 如果启用了发动机的冷机功能，则把发动机控制开关转到“冷机/停机”（COOLDOWN/STOP） 位置。

b.如果没有启用发动机的冷机功能， 则让发动机运转在高怠速大约五分钟，然后再让发动机停机。

3.  把发动机控制开关转到“关机/复位” （OFF/RESET）位置。

自动停机

当发动机运转在自动模式而远程起动/停机触点断开时，将出现自动停机。

如果发动机启用冷机功能，那么发动机在停机前将按设定的时间冷机，然后停机。否则，发动机会立即停机。

紧急停机

       紧急停机装置仅用于 紧急情况。 正常停机不要使用紧急停机装置。

发动机正常运转时，紧急停机按钮在“突起”位置。

当需要紧急停机时，按下紧急停机按钮。这会切断发动机的燃油供应。 这同时也会启动进气切断装置 (如果装备)。

       在确定和纠正迫使出现紧急停机的问题之前，不要起动发动机。

       在发动机再次起动之前，紧急停机按钮和进气切断装置都必须复位。

顺时针旋转紧急停机按钮使按钮复位，紧急停机按钮会回到“突出”位置。

转动进气切断装置的复位旋钮到 “开”（OPEN）位置。

       确保发动机两侧的进气切断装置都已复位。如果只复位了发动机一侧的进气切断装置，则会导致发动机的损坏。

3406C 发动机保养时间表

需要时的保养

发动机空气滤清器滤芯（双滤芯）－清洗/更换

发动机空气滤清器滤芯（单滤芯）－检查/更换

燃油系统 - 注油

压缩空气起动马达润滑器油位－检查

压缩空气罐中的水和沉淀物 －排放

冷却系统液位－检查

被驱动设备－检查/更换/润滑

发动机空气滤清器保养指示器－检查

发动机空气预滤器－清洁

发动机机油油位－检查

燃油箱中的水和沉淀物 － 排放

仪表板 － 检查

围绕发动机的检查

首次 250工作小时

发动机气门间隙－检查/调整

转速传感器 －清洁/检查

发动机机油油样（SOS） －获取

发动机机油和机油滤清器－更换

曲轴箱呼吸器－清洗

燃油细滤清器－清洗粗滤清器/更换细滤清器

冷却液中的添加剂－测试/添加

交流发电机和风扇皮带－检查/调整/更换

蓄电池电解液液位－检查

散热器－清洁/检查

风扇驱动轴承－润滑

软管和管夹箍－检查/更换

燃油箱 —放出水和沉淀物

每 1000工作小时

发动机保护装置－检查

燃油控制连杆 － 润滑

每 3000工作小时或 2年

普通冷却液－更换

长效冷却液－添加添加剂

气门间隙－检查/调整

曲轴减振器－检查

发动机支座－检查

涡轮增压器－检查

冷却系统节温器 －更换

每 5000工作小时

喷油嘴 － 测试/更换

交流发动机，空气压缩机，水泵，起动马达和涡轮增压器 － 检查/大修或更换

发动机转速传感器 － 检查/更换

每 6000工作小时或 4年

冷却系统中长效冷却液－, 更换

CAT.C15. 柴油发电机组

性能参数：

     直列型六缸水冷四冲程直接喷射涡轮增压后冷却。

     缸径 x 行程：137.20mm x 171.40mm

     排气量     ：15. 20升

     额定功率   ：400 千瓦 (主用)

     额定转速   ：1500rpm

     转向面向飞端逆时针

     耗油量(100%)负载带风扇： 101.3公升/小时

     重量             ：4160 kg不包括柴油。

C15发电机组配置

控制系统EMCP

    电子模块式控制面扳

    标准向后装置              电压微调

   自起动/停机控制开关

   紧急停机按钮    面板照明灯

     数字式显示 -     三相交流电压运行小时计  

  机油压力                      水套水温度

  直流电压                           转速

   系统诊断故障代码         备用故障报警

一、环保

C15发电机组采用世界上最 先进的ACERT技术，发电机组排放满足欧三Tier 3，Stage IIIA排放标准

二、运行可靠，使用寿命长

所有配件都是卡特彼勒原厂设计、制造和检测，做过扭力分析测试，并以整机交付用户；

 发电机与发动机的性能匹配，负荷调整模块可使发动机免受负荷冲击和改善负荷接受能力

三、适合新疆的气候特点

A 、耐受环境温度－40℃～+50℃时：

C15发电机组配有水套水加热器零下温度时迅速启动并加载

具有可在+50℃环境温度下使用的散热器

B、适合于沙漠地区：

C15发电机组配有沙漠重载空滤器

四、产品质量有保证

在新疆乌鲁木齐和库尔勒设有CAT零件销售中心及售后服务中心；

C15发电机组能在营房连续使用一年，不受1000小时限制。

底座燃油箱 (最小可持续运行10 小时.)

燃油软管 和油水分离器

工业等级消音器带波纹管

在底座和散热水箱、发动机、发电机间安装

   线性隔离减振器

3 级具有跳闸电路断路器---国际电器协会认可

45 安培充电机

卡特电池组、电池支架和连线

卡特长寿命冷却液

降低噪音

周围环境温度在50°C

窗式控制面板

Plated /  SS hardware

Powder baked paint

内部安装消音器

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.