柴油機的維修保養(yǎng)方法與節(jié)油技巧

柴油機維修保養(yǎng)的技巧與方法Dieselenginerepairandmaintenancemethodsandtechniquesof一、保養(yǎng)技巧One,maintenanceskills1、柴油發(fā)動機的“飛車”現(xiàn)象及應急措施“飛車”或超速是發(fā)動機特有的一種現(xiàn)象?！帮w車”時柴油機轉(zhuǎn)速失去控制，而且越來越快，以至超過允許的最高轉(zhuǎn)速并伴隨有巨大聲響，嚴重時導致機件損壞報廢。引起“飛車”主要原因有兩方面：一是噴油泵調(diào)速器本身的故障，使其喪失了正常的調(diào)整特性；另一方面是柴油機調(diào)速特性的改變，其特征是噴油泵調(diào)速器本身沒有故障，而柴油機在運轉(zhuǎn)過程中有額外柴油或機油進入燃燒室燃燒。發(fā)生“飛車”現(xiàn)象應采取緊急措施，發(fā)動機轉(zhuǎn)速高到一定程度時會發(fā)生故障。制止超速的緊急措施有：In1,dieselengine"flyingcar"phenomenonanditsemergencymeasures"coaster"orspeedingisapeculiarphenomenonofengine."Runaway"dieselenginespeedisoutofcontrol,butalsomoreandmorequickly,andexceedthemaximumallowedspeedandwithagreatnoise,leadingtoseveredamagetopartsscrapped."Runaway"duetotwomainreasons:oneisthefaultoffuelinjectionpumpgovernoritself,thatthelossofthenormaladjustmentcharacteristics;ontheotherhand,isadieselenginespeedregulationcharacteristicchanges,itscharacteristicistheinjectionpumpgovernoritselfhasnofault,andthedieselengineduringtheoperationprocesswithadditionaldieseloilorengineoilfromenteringthecombustionchambercombustion."Runaway"phenomenonshouldtakeemergencymeasures,athighenginespeedstoacertainextentwillmalfunction.Tostopspeedingemergencymeasures:（1）迅速將加速踏板收回到停車位置。(1)rapidlyacceleratingpedalbackintheparkingposition.（2）有減速裝置的，迅速將減壓手柄拉到停油位置（或減壓位置）。(2)adecelerationdevice,rapiddecompressionhandleispulledtostopoilposition(orreducingposition).（3）及時掛入高速擋，踏下制動踏板，緩抬離合器，使發(fā)動機熄火。(3)tohangintohighgear,depressthebrakepedal,slowlyreleasetheclutch,theengineflameout.（4）迅速斷開高壓油管，停止供油。(4)quicklydisconnectthehighpressureoilpipe,oilsupplystop.（5）迅速用衣服包緊空氣濾清器，使發(fā)動機斷氣熄火。(5)quicklywithaclothesbagairfilter,sothattheengineexpirationblowout.以上五步簡稱“減速、減壓、制動、斷氣”。Thefivestepsabovereferredtoasthe"reduction,decompression,brake,die".2、柴油機各缸工作情況檢查方法In2,thecylindersofdieselengineworkingconditioninspectionmethod（1）聽音法：用聽診器或借助金屬棒，靠近噴油器體的部位，傾聽各缸爆發(fā)的聲音，正常的聲音類似金屬敲擊“當當”的聲響。若只有“嗬嗬”連續(xù)不干脆的響聲時，則該缸供油太少或是沒有及時著火，如敲擊聲很大，說明該缸供油量太大或噴油時間過早。(1)listenandact:stethoscopeorwiththeaidofametalbar,neartheinjectorbodyparts,listentoeachcylinderexplosionsound,normalmetalpercussionsoundssimilarto"should".Ifonlythe"Ho"continuousnotjustnoise,thenthecylinderoilsupplytoolittleornotimelyignition,suchaspercussionsoundisverybig,thecylinderoilsupplyamountistoolargeorinjectiontimeofpremature.（2）觀色法：柴油機工作正常時，排出的廢氣顏色為淡灰色，負荷大時略深。如排黑氣，說明可燃氣體燃燒不完全。排藍煙，表明潤滑油進入氣缸內(nèi)燃燒。排白煙，則說明柴油機中有水，可燃氣體未燃燒也排白煙。排氣管連續(xù)排出不正常的煙色，說明個別缸工作不正常。(2)viewcolormethod:dieselengineworkingnormally,exhaustgascolourispalegray,whentheloadislargeslightlydeep.Iftherowofblackgas,illustratethecombustiblegasincompletecombustion.Rowsofbluesmoke,showthatthelubricatingoilintothecylindercombustion.Rowsofwhitesmoke,thedieselenginewithwater,combustiblegascombustionexhaustwhitesmokeornot.Exhaustpipecontinuousdischargeabnormalcolor,descriptionofindividualcylindernotworkingproperly.（3）感溫法：在柴油機啟動后的最初階段（工作一段時間后排氣管溫度很高，用手觸摸會燙傷）用手摸各缸排氣管的溫度，可鑒別各缸工作情況。如果各缸排氣管的溫度比其他缸高，說明該缸供油量偏高；若溫度低，則該缸供油量少、或不噴油、或噴油后沒完全燃燒或不燃燒。(3):temperaturesensingmethodindieselenginestartingaftertheinitialphase(afteraperiodoftimeworkingwiththeexhaustpipetemperatureisveryhigh,Jie:partsbeforeassemblymustbeclean,topreventtheincorporationofimpurities.Astheoiloutletvalveandvalveseatcontactzoneandenterthesmalldebris,notonlywillspill,alsodirectlyaffecttheenginework.抹：在石棉墊、紙墊、各種螺塞和漏油處涂抹石棉油。抹石棉油時要薄而均勻，不要太厚，也不要把墊的整個面都抹上，只需涂抹漏油的局部。With:inasbestospad,padofpaper,allkindsofplugsandoilpaintstone.Stonecottontowipethinanduniform,nottoothick,nottopadthewholefacewith,onlyapplythelocaloilspill.磨：研磨或銑削零件的結合面，其作用是恢復表面的光潔度和精度，使油管接頭或墊片研磨后能保持密封，不漏油。Grinding:grindingorcuttingpartsofthesurface,itsroleistorestorethesurfacesmoothnessandprecision,sothatthepipejointorgasketaftergrindingcanremainsealed,nooilleakage.緊：密封裝置的緊度要適宜，不能過緊或過松。如柴油機的各種接觸面和密封螺母等，必須保持適宜的緊度。Tight:sealtightnesstofit,nottootightortooloose.Suchasdieselvariouscontactsurfacesandthesealingnut,mustmaintainpropertightness.2、氣缸壓力關。為了保證有足夠的氣缸壓力，活塞與缸套的配合間隙，活塞環(huán)的端、邊間隙必須符合要求，氣門與氣門座的密封性、噴油器前端的密封性要好，氣缸墊要好，且厚度符合要求。In2,thecylinderpressure.Inordertoensurethereisenoughpressureinthecylinder,pistonandcylinderclearance,pistonringendgap,edgemustconformtotherequirements,thevalveandvalveseatsealing,thefrontendoftheinjectorcylindergasketsealingbetter,better,andthicknesstomeettherequirements.3、燃燒室容積關。柴油機修理后往往會使燃燒室容積發(fā)生變化，改變原有的壓縮比，直接影響柴油機的正常工作。燃燒室容積改變的因素有：活塞位置裝反，氣缸墊厚度不當，曲柄連桿機械磨損或彎曲，渦流室鑲塊錯位，氣門下陷量過大等。在修理時，應對這些情況加以注意。In3,thevolumeofthecombustionchamber.Dieselenginerepairafteroftencausesthevolumeofthecombustionchamberischanged,changetheoriginalcompressionratio,directlyaffectsthenormaloperationofdieselengine.Combustionchambervolumechangefactorsare:thepositionofthepistonisreversed,thethicknessofcylinderheadgasketproperly,acrankconnectingrodmechanicalwearorbending,swirlchamberinsertmismatch,thelargevalvesinkage.Duringrepairs,torespondtothesesituationsofattention.4、正時關。正時關包括供油正時和配氣正時，若供油不正時，S195、X195型柴油機可借助噴油泵與齒輪室蓋之間的墊片調(diào)整，每增減0.1mm厚的墊片，相當于飛輪弧長6.3mm。若配氣不足時，應先檢查與糾正正時齒輪安裝上的誤差，然后調(diào)整氣門間隙，氣門間隙每變動0.1mm，曲軸轉(zhuǎn)角變化3°，相當于飛輪弧長11.1mm，調(diào)整時應注意活塞壓縮到上止點時，進、排氣門間隙（冷車狀態(tài)）不能小于0.2mm，以防機件受熱膨脹，氣門關閉不嚴，或氣門頭撞擊活塞。In4,itclosedwhen.Timingclosingincludingfuelinjectiontimingandvalvetiming,iftheoilsupplyisnotpositive,S195,X195dieselenginewithfuelinjectionpumpandthegearchambercoverbetweentheshimadjustment,eachchange0.1mmthickshim,equivalenttotheflywheelarclength6.3mm.Ifthegasisinsufficient,shouldfirstcheckandcorrecttiminggearinstalledontheerror,andthenadjustthevalveclearance,clearanceofvalvechangeseach0.1mm,variationofcrankangle3°,equivalenttotheflywheelarclength11.1mM,adjustmentshouldbepaidattentiontowhenpistoncompressiontotheTDC,inlet,exhaustvalveclearance(coldstate)cannotbelessthan0.2mm,topreventmechanicalthermalexpansionvalveclosed,lax,orthevalveheadimpactpiston.5、“三濾”關?？諝鉃V清器技術狀態(tài)不好，會使灰塵進入氣缸，加速活塞環(huán)、氣缸、氣門與氣門座早期磨損，造成啟動困難，功率下降。柴油、機油濾清器技術狀態(tài)不好，會使雜質(zhì)進入有關零部件之間，造成三大精密偶件早期磨損，加速曲軸與軸瓦磨損，嚴重者會造成柴油機早期報廢。5,"filter".Airfiltertechnicalstatusisnotgood,leaddustintothecylinder,pistonrings,cylinderspeed,valveandvalveseatofearlywear,startupdifficultiescausedbythedeclineofpower.Diesel,oilfiltertechnicalstatusisnotgood,willmaketheimpuritiesintotherelevantparts,resultinginthreeprecisioncouplingofearlywearandtear,accelerationofthecrankshaftandbearingwear,seriouspersoncancauseearlyrejectiondieselengine.6、柴油霧化關。柱塞副、出油閥副及噴油器針閥副的技術狀態(tài)不好，會造成噴油霧化不良，柴油機啟動困難，燃燒不完全，積炭增多，以致發(fā)動機功率下降，油耗增加，因此，對燃油系，特別是精密偶件要認真進行檢查。In6,dieselfuelsprayoff.Plungervice,anoiloutletvalvesideandinjectorneedleDeputytechnicalstatusisnotgood,willcausetheatomizationofthefuelinjectorofdieselenginestartingisdifficult,bad,incompletecombustion,cokeincreased,resultinginreductionofenginepower,fuelconsumptionincrease,therefore,thefuelsystem,especiallytheprecisioncouplingofcarefulcheck.7、通孔與小孔關。（1）通孔關：現(xiàn)以S195型柴油機為例，軸承、襯套的5處通孔在安裝時要對正。In7,thethroughholeandtheholeclearance.(1)thethroughholeclearance:nowtakeS195dieselengineasanexample,bearing,bushing5throughholesinthemountingtoit.A、主軸承。每對主軸承油槽上都鉆有油孔，分別與氣缸體、主軸頸上的油孔相通，安裝時，只要主軸承的凸緣缺口對準定位銷，就能防止主軸承轉(zhuǎn)動，保證油孔對準，使?jié)櫥吐窌惩o阻，避免燒壞。A,mainbearing.Eachofthemainbearingoilgrooveondrilloilhole,respectively,andthecylinderbody,theshaftneckholecommunicatedwiththeoil,wheninstalled,aslongasthemainbearingflangenotchonthequasi-steadypin,canpreventthemainbearingrotation,ensuringtheoilholealignment,sothatthelubricatingoilpathsmoothoperator,toavoiddamage.B、搖臂襯套。向搖臂內(nèi)壓入襯套時，如孔不對準，搖臂軸及襯套就會因缺乏潤滑干摩擦而燒損，使氣門間隙變大，產(chǎn)生嚴重的敲擊聲。B,rockerarmbushing.TotherockerarmispressedintotheBush,suchasholesarenotaligned,rockershaftandbushingcanbeduetolackoflubricationfrictionandloss,sothatthevalvegapbecomeslarge,resultinginseriouspercussionsound.C、連桿襯套。連桿小頭鉆有集油孔，和連桿襯套的油孔相通，向連桿小頭內(nèi)套銅套時，若兩個油孔不對準，銅套和活塞銷發(fā)生“當當”的敲擊聲，甚至咬死。C,connectingrodbushing.Connectingroddrillsetoilhole,andtheconnectingrodbushingholecommunicatedwiththeoiltotheconnectingrodsleeve,coppersets,iftwooilholesarenotaligned,acoppersleeveandapistonpin"should"percussionsound,andevenkilled.D、起動軸襯套。安裝起動軸襯套時，兩襯套油孔要分別與機體和齒輪蓋上相對應的集油凹槽相通，否則起動軸與襯套就會加快磨損，引起供油角度和配氣相位變化，導致柴油機功率下降。D,startingshaftbushing.Installationandstartingshaftbushing,twobushingoilholerespectively,andthebodyandthegearcovercorrespondingtotheoilcollectinggrooveiscommunicated,orstartingshaftandbushingwillacceleratewear,causingthefeedangleandgasdistributionphasechanges,causingdieselenginepowerdecrease.（2）小孔關：主要有以下4個小孔。(2)holeclearance:mainlyhasthefollowing4holes.A、油箱蓋通氣孔。該孔堵塞后，油箱不再與大氣相通，油箱上部因油面下降會出現(xiàn)負壓，造成供油中斷，燃油受熱后蒸發(fā)，使油箱內(nèi)壓力升高，會引起油箱開關處漏油，因此，此孔不能堵。A,thetankcoverhole.Theholeplug,thetankisnolongerwiththeatmosphere,theupperpartofthetankforoildropwillappearnegative,resultingininterruptionoffuelsupply,heatofevaporation,pressureoftheoiltankisincreased,willcausethefueltankswitchtoleaktheoil,therefore,theholecannotbeblocked.B、曲軸箱換氣孔。換氣孔堵塞后，曲軸箱內(nèi)廢氣越積越多，曲軸箱內(nèi)氣壓升高，會使機油滲漏，高溫廢氣混入機油，還會加快機油變質(zhì)，加速機件磨損，因此，在維修時一定要疏通此孔。B,crankshaftboxforholes.Airclogging,thecrankshaftinsidethegasaccumulatesmoremore,thecrankshaftinsidethepressuretorise,willmakeoilleakage,hightemperatureexhaustgasmixedwithoil,butalsoacceleratestheoildeterioration,acceleratedwearofmachineparts,therefore,therepairmustbeclearthathole.C、輸油泵泄油孔。輸油泵上的泄油孔堵塞，會導致推桿和導管間少量柴油滲漏進入噴油泵，沖淡殼體內(nèi)的潤滑油，加速零件磨損，因此，此孔也不能堵。C,oilpumpoildrainhole.Oilpumpoftheoildrainholeplugging,causesthepushrodandtheconduitleakageintothelittledieselfuelinjectionpump,dilu