康明斯柴油發(fā)動機(jī)維修保養(yǎng)注意事項

康明斯柴油發(fā)動機(jī)維修保養(yǎng)注意事項Cummingsdieselenginerepairandmaintenancemattersneedingattention我國客車制造商近期采用康明斯系列柴油機(jī)型越來越多，如常州長江雙層城市客車裝配B2230CNG發(fā)動機(jī)；EQ5061XXYK廂式客貨兩用車裝用4BT319AA發(fā)動機(jī)；EQ6890LK豪華客車選用6BTA發(fā)動機(jī)；EQ6590(2000款)、EQ6690(2000款)客車也選用4BT319AA增壓發(fā)動機(jī)。實踐表明，康明斯發(fā)動機(jī)在客車上動力強(qiáng)勁，經(jīng)濟(jì)省油，使用可靠，排放污染低。為延長康明斯柴油機(jī)的使用壽命，以6BT系列機(jī)型為例，介紹幾點維修注意事項及故障診斷方法，供修理時參考。ChinesebusmanufacturersrecentlyusingCummingsseriesdieselengineismoreandmore,suchastheYangtzeRiverinChangzhoucitybusassemblyB2230CNdoubleGengine;EQ5061XXYKvanvansfittedwiththe4BT319AAEQ6890LKluxurypassengercarengine;engineusing6BTA;EQ6590(2000),EQ6690(2000)busalsouse4BT319AAsuperchargedengine.Practiceshowsthat,Cumminsengineinbusdrivingpower,fueleconomy,reliableuse,lowemissionpollution.AsanextensionofCummingstheservicelifeofdieselengines,the6BTseriesmodelasanexample,introducesseveralrepairpointsforattentionandthemethodsoffaultdiagnosisforpassengercarsarerepaired,reference.１、維修注意事項1,repairthemattersneedingattention（１）6BT118機(jī)型鑲裝缸套(1)6BT118typeinsertingcylinder制造商未在該機(jī)上鑲裝缸套，但允許在氣缸磨損量超過使用極限后鑲裝專用缸套。我公司對專用缸套和牟平102系列缸套都進(jìn)行了鑲裝試驗。鑲專用缸套時，先將缸套承孔鏜至φ104.94mm，并保證承孔與缸套的過盈量為0.05～0.07mm。注意在承孔下部留7～8mm高的止口，再將已在-20°C條件下冷卻1h以上的缸套涂膠并壓入承孔，最后切除缸套上端高出缸體上平面的部分，將缸套內(nèi)孔鏜至φ101.97mm(留0102～0.03mm的珩磨量)，使珩磨表面粗糙度為Ra0.4Lm，保證缸套與活塞之間的間隙符合規(guī)定。鑲牟平102系列缸套時，先將缸套承孔上部加工出φ112.05mm、深10mm的臺階(俗稱上止口)，再將缸套承孔鏜至約φ107.95mm(留0.02～0.03mm的珩磨量)，然后珩磨，使承孔表面粗糙度為Ra0.4Lm，并保證承孔與缸套的過盈量為0.02～0.03mm。最后將缸套外圓表面涂少量機(jī)油，壓入承孔。Themanufacturerisnotinthemachineinsertliner,butallowsthecylinderwearexceedsthelimitafterinsertingspecialcylinder.IcompanyforcylinderlinerandtheMuping102seriescylinderhavebeenembeddedtest.Insertspecialcylinder,thecylinderbearingholeboringtoφ104.94mm,andensurethebearingboreandcylinderinterferenceamountwas0.05~0.07mm.Attentioninthebearingholeoflowerpartof7~8mmhighport,andthenin-20°Cundertheconditionsofcoolingover1hcylindergluingandpressintothebearinghole,finallyresectedcylinderupperhighcylinderpart,thecylindersleeveinnerholeboringtoφ101.97mm(with0102～0.03mm),quantityofthehoninghoningsurfaceroughnessisRa0.4Lm,ensurethattheclearancebetweenthecylinderlinerandpistoninaccordancewiththeprovisions.WithMuping102seriescylinder,thecylinderbearingholeofupperprocessingofφ11205mm,10mmlevel(commonlyknownastheupperstop),thenthecylinderbearingholeboringtoφ107.95mm(with0.02~0.03mmhoningvolume),andthenmakethebearingholehoning,surfaceroughnessofRa0.4Lm,andtoensurethebearingboreandcylinderinterferenceamountwas0.02~003mm.Thelineroutersurfaceapplyasmallamountofoil,pressedintoabearinghole.通過這兩種缸套鑲裝試驗，總結(jié)如下：Thetwocylinderisinlaidwiththetest,summarizedasfollows:ａ、使用牟平102系列缸套裝機(jī)可以大大縮短修理時間。因為該缸套的內(nèi)孔面為成品面，不需鏜、磨及在鏜缸機(jī)上裝夾缸體、定中心而費力費時；其次缸套在壓入承孔前不需冷處理。但用專用缸套裝機(jī)，每次修理時需鏜舊缸套２次、珩磨1次、缸體裝夾2次和定中心２次，還要冷處理缸套。A,usingtheMuping102seriescylindersetmachinecangreatlyshortentherepairtime.Becausethecylinderboresurfaceoffinishedsurface,neednotbeboring,millingandinthecylinderboringmachinewiththeclampingcylinder,centeringandlaboriousandtime-consuming;thesecondcylinderinpressinthebearingholeofnoneedofcoldprocessing.Butwithaspecialcylindersetmachinerepair,everytimewhenboringoldcylinderjacket2times,1times,honingcylinderclamping2andcenter2,andcoldtreatmentofcylinderliner.ｂ、使用牟平102系列缸套裝機(jī)，維修質(zhì)量容易保證。因為缸體在珩磨機(jī)上經(jīng)過多次裝夾和定中心后，會因定位誤差積累而超差，增加了維修質(zhì)量難度，尤其是用移動式鏜缸機(jī)產(chǎn)生的誤差更大。而使用牟平102系列缸套，只要第1次承孔鏜磨質(zhì)量符合技術(shù)要求，以后可以像五十鈴載貨車發(fā)動機(jī)一樣直接壓入、壓出缸套，而且組裝上活塞連桿后工作時不會產(chǎn)生偏缸。B,usingtheMuping102seriescylindersetmachinerepair,easyqualityassurance.Becauseofincylinderhoningmachineafterrepeatedclampingandcentering,duetopositioningerroraccumulationandtolerance,increasedthedifficultyofrepairquality,especiallythemobilecylinderboringmachineerrorisgreater.WhiletheuseofMuping102seriescylinder,aslongastheD,putthering,shouldmakethepartnumberisup.ｅ、將支蓋、新墊片支架和新墊片裝到冷卻器體上，將螺釘擰緊至41～47N．m，然后裝好所有螺釘。E,thesupportingcover,newgasketbracketandanewgasketfittedintothecoolerbody,thescrewsaretightenedto41～47N.m,andtheninstallallbolts.（４）柴油機(jī)冷卻通道(4)dieselenginecoolingchannel在柴油機(jī)大修時，有的班組忽視對冷卻通道的徹底清洗，具體表現(xiàn)在，散熱器和缸蓋拆下后扔到一旁，到總裝時再將其表面擦拭干凈。這是造成冷卻系產(chǎn)生故障較多的原因之一。如裝6BT系列柴油機(jī)，常常發(fā)生散熱器上水室頂部和氣缸蓋出水管一端的兩根除氣管都不通。這樣，在加注冷卻液時，積聚在氣缸體內(nèi)套的空氣和氣、水混合物就無法排出，冷卻液也無法充滿水套。柴油機(jī)在工作過程中，當(dāng)積滯的氣體達(dá)到一定程度時，還會造成水泵流量下降，結(jié)果是在氣缸體水套內(nèi)部產(chǎn)生局部高溫，最終造成氣缸體局部熱應(yīng)力猛增而使缸體局部破裂。因此，在柴油機(jī)大修或其產(chǎn)生高溫故障時，應(yīng)認(rèn)真清洗冷卻系，切不可馬虎了事。Inthedieselengineoverhaul,someteamsneglectingcoolingpassagesintheperformanceofspecific,thoroughcleaning,radiatorandcylinderheadremovedaside,totheassemblywhenthesurfaceiswipedclean.Thisiscausedbythecoolingsystemhasmorefaultsreasons.Asof6BTseriesdieselengine,radiatorwaterchambertopandoftenoccurredincylinderheadoutletendofthetwoairout.Thus,infillingincoolant,accumulateinthecylindersleeve,airandwatermixtureisunabletodischarge,coolingliquidcanfilledwithwaterjacket.Dieselengineinthecourseofwork,whentheaccumulatedgastoacertainextent,canalsocausewaterpumpflowdecreased,theresultisinacylinderwaterjacketinternallygeneratedlocalhightemperature,resultinginlocalthermalstressofcylinderbodyandthecylinderexplosionpartialrupture.Therefore,thedieselengineorthehightemperaturefailure,shouldbecarefullycleaningcoolingsystem,mustnotbesloppy.２、故障診斷2,faultdiagnosis（１）斷油電磁閥故障(1)oilcut-offelectromagneticvalvefault6BT柴油機(jī)在波許高壓分配泵右上角處裝有一個斷油電磁閥。當(dāng)鑰匙開關(guān)處于熄火斷電檔時，閥芯在彈簧作用下回位切斷油路，使柴油機(jī)熄火；當(dāng)鑰匙開關(guān)位于起動檔時，電磁閥通電產(chǎn)生磁力吸取閥芯，油路接通，柴油機(jī)正常工作。一些新技工由于對這種裝置的原理和作用不太了解，導(dǎo)致不能診斷出柴油機(jī)不能起動或熄火的故障原因。The6BTdieseldistributionpumpPauschhighrightcornerisprovidedwithafuelcutsolenoidvalve.Whenthekeyswitchispowercutoffgear,valvespringreturntocutoffoil,dieselengineflameout;whenthekeyswitchlocatedinthestartingposition,theelectromagneticvalveisenergizedtoproducemagneticsuctionvalve,oilcircuitisswitchedon,thenormaloperationofdieselengines.Somenewcraftduetothisprincipleandeffectofdonotknow,canleadtodiagnosisofdieselenginecannotstartorflameoutfaultreason.若柴油機(jī)起動時起動機(jī)工作正常，柴油箱及濾清器無阻塞，供油管無漏氣現(xiàn)象，但多次不能起動，一般是斷油電磁閥處出現(xiàn)故障。首先檢查電磁閥線路中左起第3個熔斷器是否燒壞。若燒壞應(yīng)立即更換。若未燒壞，再拆電磁閥上的接線，用示燈檢查是否通電。若通電，一般是電磁閥燒壞或閥芯卡住，可改制一個專用扳手將電磁閥拆下。在無條件更換時，可將閥芯抽出后，再裝回電磁閥體，即可起動柴油機(jī)。此時，可用掛檔方法熄火。Ifthestartingofthedieselenginestarterwhennormalwork,adieseltankandfilterwithoutobstruction,theoilpipewithoutleakage,butmanycannotstart,isgenerallybrokenoilsolenoidvalvefailure.Firstcheckelectromagneticvalvecircuitthirdleftafuseisburned.Iftheburnshouldbereplacedimmediately.Ifnotburn,andthensplitonthesolenoidvalvewiring,withindicationlampcheckwhetherelectricity.Ifelectricity,generalelectromagneticvalveisburnedorvalvestuck,canmakeaspecialspanner,thesolenoidvalveisremoved.Inunconditionalreplacement,valvecorecanbeextracted,andthenloadedbackelectromagneticvalve,thenstartingdieselengine.Atthistime,thegearmethodavailable.（２）機(jī)油壓力低(2)theoilpressurelow6BT系列柴油機(jī)采用機(jī)油冷卻器芯，對冷卻機(jī)油、加強(qiáng)潤滑起了積極作用。但冷卻器芯片焊點有破裂時，機(jī)油會大量進(jìn)入水道，潤滑油道的機(jī)油大量減少。機(jī)油警告燈亮?xí)r，從冷卻系膨脹箱有機(jī)油溢出，應(yīng)及時排除此故障。否則，將燒壞軸承甚至柴油機(jī)。6BTseriesdieselengineusingengineoilcoolercore,onthecoolingoil,hasplayedapositiveroleinstrengtheninglubrication.Butcoolerchipsolderjointrupture,oilwillenterthewater,lubricatingoilpassageoilcanreducethenumberof.Oilwarninglight,fromthecoolingsystemexpansiontankwiththeoilspill,shouldberuledoutthisfault.Otherwise,willburnevendieselenginebearing.機(jī)油泵墊片損壞也會導(dǎo)致機(jī)油從機(jī)油泵處泄漏，從而主油道壓力降低，機(jī)油警告燈亮，曲軸齒輪處發(fā)生異響。拆檢更換機(jī)油泵墊片并認(rèn)真裝合后，故障即可排除。Oilpumpgasketdamagecanalsocausetheoilfromtheoilpumpleakage,therebythemainoilpressureisreduced,theoilwarninglights,crankshaftgearisabnormalsound.Dismantlingthereplacementofoilpumpgasketandseriouscombination,faultcanberuledout.（３）柴油機(jī)異響(3)abnormalnoiseofdieselengine異響聲發(fā)生在氣門機(jī)構(gòu)的現(xiàn)象比較普遍，表現(xiàn)為氣門室蓋處響聲較大，聲音清脆。油門加大轉(zhuǎn)速升高響聲加劇，是氣門間隙過大所致。在準(zhǔn)確判斷出響聲的缸號后，校準(zhǔn)間隙并鎖緊調(diào)整機(jī)構(gòu)即可。其次，水泵處會發(fā)生連續(xù)的“嗡嗡”聲，加速時響聲加劇，通常為軸承因缺乏潤滑而已被損壞。更換軸承時用榔頭敲打不頂用，需用壓床壓出。Abnormalnoiseoccursinthevalvemechanismofthephenomenoniscommonner,performanceforthevalvechambercoverlargersoundcrispsound.Acceleratorenlargesspeedincreasednoiseaggravate,isthevalveclearanceistoolarge.Thejudgenoisecylindernumber,calibrationintervalsandlockingandadjustingmechanism.Secondly,thewaterpumpwillhappencontinuous"buzz"sound,accelerationnoiseincreased,usuallyduetolackoflubricationforbearingsonlydamaged.Replacementofbearingsinthehammerisnotavailable,usepresspress.（４）增壓器漏機(jī)油(4)theturbochargeroilleakageａ、增壓器空氣壓縮機(jī)漏機(jī)油。壓縮機(jī)漏機(jī)油表現(xiàn)為:柴油機(jī)工作時燒機(jī)油，排藍(lán)煙。如果打開壓縮機(jī)出氣口或柴油機(jī)進(jìn)氣軟管時有油，需更換壓縮機(jī)擋油環(huán)前端的甩油環(huán)和密封環(huán)并清潔或更換空氣格；如果機(jī)油沿空氣壓縮機(jī)葉輪軸漏油，需拆檢回油管并清洗。A,turbochargeraircompressorlubricatingoilleakage.Compressoroilleakageperformance:thedieselengineburningoil,exhaustsmoke.Ifyouopenthecompressoroutletordieselengineairinlethoseisneededtoreplaceoil,compressoroilringoilringandthefrontendofthesealingringandcleanorreplacetheairgrid;iftheoilalongtheaircompressorimpellershaftoilleakage,dismantlingandcleaningforoilreturnpipe.ｂ、增壓器排氣口漏機(jī)油。排氣口漏機(jī)油將導(dǎo)致柴油機(jī)工作時燒機(jī)油。拆下排氣口連接管，如排氣口附近有機(jī)油漏的痕跡，應(yīng)更換渦輪軸上的密封環(huán)。B,turbochargerexhaustoutletofoilleakage.Outletdrainoilwillcausethedieselengineburningoil.Removetheairoutletconnectingpipe,suchasanexhaustmouthnearbyorganicoilleakagetraces,shouldreplacetheturbineshaftsealring.（５）增壓器軸承損壞(5)thesuperchargerbearingdamage增壓器渦輪轉(zhuǎn)子軸承損壞，渦輪軸轉(zhuǎn)速下降，渦輪轉(zhuǎn)子總成的徑向或軸向擺差大，需要拆檢增壓器，必要時更換轉(zhuǎn)子軸承、轉(zhuǎn)子總成。組裝增壓器時，對組成渦輪轉(zhuǎn)子總成的渦輪軸、葉輪、機(jī)油甩油環(huán)、止推套等高速旋轉(zhuǎn)零件，在進(jìn)行動平衡時打上的安裝位置標(biāo)記必須一一對應(yīng)。此外，還應(yīng)檢查并保證靜態(tài)時，渦輪轉(zhuǎn)子總成的軸向間隙(0.03～0.07mm)和徑向間隙(0.30～0.46mm)。Turbochargerrotorbearingdamage,theturbineshaftspeeddecreases,theturbinerotorassemblyofradialoraxialswingbig,needdismantlingthesupercharger,necessarywhenreplacingtherotorbearing,arotorassembly.Assemblyforturbocharger,onthecompositionofturbinerotorassemblyoftheturbineshaft,impeller,oiloilslinger,thrustsleeveofhigh-speedrotatingparts,indynamicbalancingtypeinstallationpositionmarkingmustbeoneone