Repair Procedures for 700kW Diesel Generators 1

Repairing a 700kW diesel generator follows certain procedures. How can you quickly and accurately locate the generator's faults? You need professional and systematic knowledge of generator repair. Today, the author will popularize relevant content for you.

Cylinder Block

1.Damage to the Cylinder Block

Common damages to the cylinder block include bearing burnout, deformation of the main bearing holes, cracks, breakage, corrosion of the water port, and wear of the mating surfaces.

During visual inspection, there should be no cracks or damages. If any damage that causes water leakage, oil leakage, or air leakage is found, it must be repaired or replaced. Special attention should be paid to checking for cavitation and corrosion at the sealing ring area where the cylinder block contacts the cylinder liner.

2.Main Bearing Holes

For cylinder blocks with bearing burnout, the diameter of the main bearing holes must be measured, and non - standard main bearing holes must be corrected.

3.Camshaft Holes

When the exposed copper area on the surface of the camshaft bushing exceeds 120 degrees, the camshaft bushing must be replaced. If the camshaft bushing is excessively worn, it must also be replaced; otherwise, it will cause low oil pressure. If the bushing rotates in the seat hole, the size of the seat hole must be checked. If it exceeds the standard, repair the seat hole and replace the bushing.

4.Cylinder Liner Seat Holes

Check the out - of - roundness of the cylinder liner seat holes, which should not exceed 0.025mm. Check for cracks on the shoulder of the cylinder liner seat hole. The protrusion of the cylinder liner should be between 0.15 - 0.20mm. After the new cylinder liner is installed in the cylinder block, it should not swing from side to side.

Piston, Piston Ring, and Piston Pin Assembly

The damage phenomena of the piston include:

1.Ablation of the piston top surface;

2.Wear of the side walls of the piston ring grooves and breakage of the ring lands;

3.Increase in the diameter and out - of - roundness of the piston pin hole;

4.Cracks in the pin boss area;

5.Scratching at the piston skirt;

6.Wear and ovality at the piston skirt;

7.Presence of ridges inside the piston ring grooves;

8.Excessive piston wear.

Connecting Rod Assembly

The main damages to the connecting rod assembly include:

1.Wear of the small - end bushing;

2.Wear and deformation of the small - end bushing seat hole and the big - end bearing seat hole;

3.Bending and twisting of the connecting rod;

4.Cracks, elongation, thread wear, or thread stripping of the connecting rod screws or bolts;

5.Scratching on the connecting rod body;

6.Bearing burnout and deformation of the connecting rod.

When installing the connecting rod assembly, it must be operated according to the correct torque parameters and correct steps, and the bolts and screws must be re - checked.

Warning: The installation of the connecting rod assembly must be carried out personally by the engineering director. Damaged connecting rod assemblies must be scrapped; otherwise, it will cause the danger of the connecting rod breaking, punching through the cylinder block, and breaking the crankshaft.

Dingbo Power 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.