Wear Patterns and Repair of Diesel Generator Cylinders

All mechanical equipment in operation is prone to wear and tear, and the cylinder, a crucial component of diesel generators, is no exception. Understanding the wear patterns of cylinders and mastering corresponding repair methods is essential for maintaining the performance and extending the service life of diesel generators. Below, Dingbo Generator Manufacturer will provide a detailed introduction to these key aspects.

Wear is the main failure mode of cylinders. Therefore, studying the causes of cylinder wear and mastering its wear patterns is of great significance not only for detecting the degree of cylinder wear but also for taking effective measures in the maintenance, management and use of diesel generator sets to reduce cylinder wear and extend the service life of the engine.

1.Taper wear along the length direction: The wear is relatively large in the area where the piston ring moves. This uneven wear, which is more severe at the top and milder at the bottom, causes the cylinder to form a "taper" along its length.

2.Out-of-round wear along the circumferential direction: From the cross-section of the cylinder, the wear along the circumferential direction is also uneven, with more wear in some directions and less in others, resulting in an out-of-round cross-section of the cylinder.

3. Step formation above the first piston ring: In the area where the piston ring does not make contact, there is no wear. However, after long-term operation of the internal combustion engine, a noticeable step forms above the first piston ring.

The above cylinder wear patterns seriously affect the working performance of the internal combustion engine. When the wear exceeds a certain range, it will damage the normal fit between the piston, piston ring and cylinder, preventing the piston ring from tightly pressing against the cylinder wall, which leads to gas leakage and oil blow-by. In severe cases, it will cause "knocking" phenomenon, increase fuel consumption and reduce power of the internal combustion engine, making it unable to work normally and even causing accidents.

Repair of Corroded Water Channel Openings

The water channel openings of cylinder heads are prone to corrosion, which can lead to leakage in severe cases, especially for aluminum alloy cylinder heads. Epoxy resin can be used for repair, or the openings can be re-drilled after surfacing. Additionally, the patch plate repair method can be adopted.

The specific steps of the patch plate repair method are as follows:

① Process the corroded water channel opening into a stepped circular or elliptical hole with a depth of about 3mm. Then, make a patch plate with the same shape as the water channel opening using a 4mm thick aluminum plate, leaving an appropriate amount of interference.

② Use a hammer and a flat head tool to drive the repair plate into the hole, then trim it and re-drill the water outlet. In addition to the interference pressure of the patch, adhesive can also be used for bonding.

Guangxi Dingbo Generator Set Manufacturing Co.,Ltd. was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. If you want get more information, please feel free to send email to [email protected] we will pay highly attention on your question.