Diesel Generator Flywheel and Ring Gear Troubleshooting

A diesel generator set is composed of various components, each playing a critical role in ensuring the unit’s normal operation. Therefore, understanding potential faults is essential for effective maintenance and repair. Today, Dingbo Power Generator Factory shares key insights into common faults and solutions related to generator flywheels and ring gears.

The most frequent faults of flywheels include ring gear wear and tooth damage. During a diesel engine overhaul, repairs should be based on the ring gear’s wear condition. The following repair methods are recommended:

1. Ring Gear Wear or Damage

If the ring gear is unilaterally worn, it can be flipped for reuse, but the tooth edges must be chamfered and corrected.

If both sides of the ring gear are severely worn, or teeth are broken/cracked, the ring gear must be replaced. Use the heating method for replacement: Heat the new ring gear in oil to 300°C to expand it, then quickly press it onto the flywheel with the chamfered side facing the flywheel while still hot.

2. Flywheel Working Surface Wear

If the flywheel’s working surface is worn into grooves or wavy patterns, grinding is required. The total grinding depth should not exceed 1.2mm.

3. Insufficient Interference Fit Between Ring Gear and Flywheel

If the interference fit between the ring gear inner diameter and the flywheel is too small or nonexistent, welding can be used for positioning. Weld sparingly, with evenly spaced welding points around the ring gear circumference. Ensure smooth welds and uniform bead size.

4. Inspection and Adjustment of Flywheel Runout

Mount a dial indicator on a magnetic base, then rotate the flywheel one full turn. Measure the axial runout at 4 equidistant points (as shown in the diagram).

Calculate the maximum allowable axial runout by multiplying the distance from the crankshaft center to the dial indicator probe by 0.025mm.

Installation Notes:

Clean the flywheel and crankshaft flange before installation.

lign the flywheel and crankshaft to their correct relative positions using alignment marks.

Tighten the mounting bolts in the sequence and torque specified in the technical manual.

Secure lock washers to prevent flywheel loosening during operation.

Guangxi Dingbo Power Equipment Manufacturing Co.,Ltd was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. The company has a registered capital of 218.88 million yuan. The company covers an area of 86,000 square meters and a building area of 55,000 square meters. There are more than 660 employees, including 456 professional technicians and 106 senior technicians. It has 46 sales and service outlets nationwide. The main products are diesel engines, generator sets, and diesel generators, providing users with a one-stop service of design, supply, debugging and maintenance at any time. Dingbo has always insisted on using first-class talents, building first-class enterprises, manufacturing first-class products, creating first-class services, and making every effort to build a first-class domestic enterprise. If any question please feel free to visit our website https://www.dieselgeneratortech.com/ or send email to [email protected].