康明斯柴油发动机维修保养注意事项.doc

康明斯柴油发动机维修保养注意事项202020年4月19日文档仅供参考康明斯柴油发动机维修保养注意事项Cummings diesel engine repair and maintenance matters needing attention中国客车制造商近期采用康明斯系列柴油机型越来越多，如常州长江双层城市客车装配B2230CN G 发动机；EQ 5061 XXYK 厢式客货两用车装用4BT 319AA 发动机；EQ 6890L K 豪华客车选用6BTA 发动机；EQ 6590 ( 款)、EQ 6690 ( 款) 客车也选用4BT 319AA 增压发动机。实践表明，康明斯发动机在客车上动力强劲，经济省油，使用可靠，排放污染低。为延长康明斯柴油机的使用寿命，以6BT 系列机型为例，介绍几点维修注意事项及故障诊断方法，供修理时参考。Chinese bus manufacturers recently using Cummings series diesel engine is more and more, such as the Yangtze River in Changzhou city bus assembly B2230CN double G engine; EQ 5061XXYK van vans fitted with the 4BT319AA EQ6890L K luxury passenger car engine; engine using6BTA; EQ 6590( ), EQ 6690( ) bus also use4BT319AA supercharged engine. Practice shows that, Cummins engine in bus driving power, fuel economy, reliable use, low emission pollution. As an extension of Cummings the service life of diesel engines, the6BT series model as an example, introduces several repair points for attention and the methods of fault diagnosis for passenger cars are repaired, reference.、维修注意事项1, repair the matters needing attention（）6BT118 机型镶装缸套(1)6BT118type inserting cylinder制造商未在该机上镶装缸套，但允许在气缸磨损量超过使用极限后镶装专用缸套。我公司对专用缸套和牟平102 系列缸套都进行了镶装试验。镶专用缸套时，先将缸套承孔镗至104. 94 mm ，并保证承孔与缸套的过盈量为0.05 0. 07 mm。注意在承孔下部留7 8 mm 高的止口，再将已在- 20C 条件下冷却1 h 以上的缸套涂胶并压入承孔，最后切除缸套上端高出缸体上平面的部分，将缸套内孔镗至101. 97 mm (留0102 0. 03 mm 的珩磨量) ，使珩磨表面粗糙度为Ra0. 4 Lm，保证缸套与活塞之间的间隙符合规定。镶牟平102 系列缸套时，先将缸套承孔上部加工出112. 05mm、深10 mm 的台阶(俗称上止口) ，再将缸套承孔镗至约107.95 mm (留0.02 0. 03 mm 的珩磨量)，然后珩磨，使承孔表面粗糙度为Ra0.4Lm，并保证承孔与缸套的过盈量为0.02 0. 03mm。最后将缸套外圆表面涂少量机油，压入承孔。The manufacturer is not in the machine insert liner, but allows the cylinder wear exceeds the limit after inserting special cylinder. I company for cylinder liner and the Muping 102 series cylinder have been embedded test. Insert special cylinder, the cylinder bearing hole boring to 104.94 mm, and ensure the bearing bore and cylinder interference amount was 0.05 0.07 mm. Attention in the bearing hole of lower part of7 8 mm high port, and then in - 20 C under the conditions of cooling over 1 h cylinder gluing and press into the bearing hole, finally resected cylinder upper high cylinder part, the cylinder sleeve inner hole boring to 101.97 mm (with0102 0.03mm ), quantity of the honing honing surface roughness is Ra0.4 Lm, ensure that the clearance between the cylinder liner and piston in accordance with the provisions. With Muping102 series cylinder, the cylinder bearing hole of upper processing of 11205mm,10mm level ( commonly known as the upper stop ), then the cylinder bearing hole boring to 107.95mm (with0.02 0.03 mm honing volume ), and then make the bearing hole honing, surface roughness of Ra0.4Lm, and to ensure the bearing bore and cylinder interference amount was 0.02 0 03mm. The liner outer surface apply a small amount of oil, pressed into a bearing hole.经过这两种缸套镶装试验，总结如下：The two cylinder is inlaid with the test, summarized as follows:、使用牟平102 系列缸套装机能够大大缩短修理时间。因为该缸套的内孔面为成品面，不需镗、磨及在镗缸机上装夹缸体、定中心而费力费时；其次缸套在压入承孔前不需冷处理。但用专用缸套装机，每次修理时需镗旧缸套次、珩磨1 次、缸体装夹2次和定中心次，还要冷处理缸套。A, using the Muping102 series cylinder set machine can greatly shorten the repair time. Because the cylinder bore surface of finished surface, need not be boring, milling and in the cylinder boring machine with the clamping cylinder, centering and laborious and time-consuming; the second cylinder in press in the bearing hole of no need of cold processing. But with a special cylinder set machine repair, every time when boring old cylinder jacket2 times,1 times, honing cylinder clamping2 and center2, and cold treatment of cylinder liner.、使用牟平102 系列缸套装机，维修质量容易保证。因为缸体在珩磨机上经过多次装夹和定中心后，会因定位误差积累而超差，增加了维修质量难度，特别是用移动式镗缸机产生的误差更大。而使用牟平102 系列缸套，只要第1 次承孔镗磨质量符合技术要求，以后能够像五十铃载货车发动机一样直接压入、压出缸套，而且组装上活塞连杆后工作时不会产生偏缸。B, using the Muping102 series cylinder set machine repair, easy quality assurance. Because of in cylinder honing machine after repeated clamping and centering, due to positioning error accumulation and tolerance, increased the difficulty of repair quality, especially the mobile cylinder boring machine error is greater. While the use of Muping 102 series cylinder, as long as the first bearing hole boring mill quality can meet the technical requirements, can later be like Isuzu truck engine directly pressed into the cylinder, press, and assembly piston rod after work will be generated when the partial cylinder.（）6BT519 机型的止推轴瓦(2)6BT519type thrust bearing安装在6BT 519 型柴油机第6 道主轴承座的国产固定式翻边止推轴瓦，其上的止推片与主轴瓦为刚性连接。这种连接的面积比较小，且连接处的应力比较集中，因此止推片在曲轴的频繁冲击下可能会断裂而掉落。而进口的组合式翻边止推轴瓦，其上的止推片与主轴瓦采用燕尾槽连接，允许止推片作微量的摆动，以弥补曲轴及主轴承座止推面对曲轴轴线的垂直度误差，保证止推片对曲轴止推面良好配合。因此，在柴油机大修时将固定翻边止推轴瓦更换为组合式翻边止推轴瓦，且控制轴向间隙在标准范围内，不会再出现该座孔严重磨损、止推片掉到油底壳的现象。对该座孔已严重磨损的两个侧面能够采用氧乙炔火焰喷涂法修复。Installed in the 6BT type 519diesel engine main bearing seat sixth domestic fixed flanged thrust bushing, the thrust plate and the main bearing as rigid connection. The connecting area is relatively small, and the connecting position of stress concentration, so the thrust plate on the crankshaft the frequent shock may rupture. While imports combined flanging thrust bearing, the thrust plate and the main bearing adopts dovetail groove connection, allowing the thrust plate for micro swing, to compensate for the crankshaft and the main bearing crankshaft thrust face verticality error, ensure the thrust plate on the crankshaft thrust surface with good. Therefore, in the diesel engine overhaul fixed flanged thrust bearing replacement for combined flanging thrust bearing, and the control of axial gap in the standard range, will not appear again the seat hole serious wear, thrust plate fall into the oil sump phenomenon. The seat hole has severe wear of the two sides can be used oxygen - acetylene flame spray repair method.（）机油冷却器的装配(3) the oil cooler assembly机油冷却器在润滑系统中工作环境较差，易出现故障，从而使机油冷却不良，机油粘度下降，润滑条件恶化，易造成零件早期磨损，甚至产生烧瓦等事故。另外，机油温度过高而蒸发，易使密封性较差处漏油。机油蒸气还会与燃烧不完全的水蒸气、空气及进入柴油机的灰尘混合，改变机油的性质，破坏正常的润滑，影响柴油机正常工作。可见，机油冷却器的检修是柴油机润滑系统检修的重要部件。笔者认为，机油冷却器除清洗外，装配时应注意以下事项：Oil cooler in lubricating system of poor working conditions, failure, so that the oil cooling bad, oil viscosity decrease, lubrication conditions worsened, causing parts of early wear, even bearing burning accident. In addition, the oil temperature is too high and evaporation, easy to make the poor sealing oil leakage at. Oil vapor will and incomplete combustion of water vapor, air and dust mixed in the diesel engine, changing the oil properties, disrupt the normal lubrication, affect the normal operation of diesel engines. Visible, oil cooler repair is diesel engine lubrication system maintenance is the most important part of. The author thinks, oil cooler in addition to cleaning, assembly should pay attention to the following matters:、 将冷却器芯装入冷却器体，然后将冷却器体放在平台上，使其后端朝上。 A, the cooler core into the cooler body, and then the cooler body is placed on the platform, so that the rear end face.、注意装配记号。将冷却器芯的装配记号与冷却器壳体上的装配记号对准，如图所示。另外，有些冷却器具有两个标示记号，在管束端板有一个“V ”记号，在孔缘内径上切有缺口“ ”，如图所示。装配时用缺口“ ”记号将冷却器芯与壳体记号对准。 B, note assembly mark. The cooler core assembly mark and the cooler housing assembly mark alignment, as shown in figure 1. In addition, some cooler has two mark mark, in tube end plate having a V mark, in diameter hole edge cutting notch , as shown in figure 2. When the assembly notch mark will be cooler core and shell alignment mark.图：管筒式机油冷却器芯的装配记号图：冷却器芯的标示记号Figure 1: tube type oil cooler core assembly mark figure 2: cooler core mark mark、 一定要用植物油润滑“O ”形密封圈。新型“O ”形密封圈有两条红带，其材料接触机油后会迅速胀大，难以顺利装入。然后将其推入冷却器与冷却器体之间，注意勿使“O ”形密封圈卷嵌在芯与体之间。该密封圈为一次性用品。C, must use vegetable oil lubricant O shaped sealing ring. Model O shaped seal ring has two red belt, the material of the contact after the oil could quickly swell, difficult to successfully mount. Then push into the cooler and the cooler body, pay attention not to make O shaped sealing ring is embedded in the core and the body volume. The sealing ring is a disposable items.、 装上档圈，应使零件号朝上。D, put the ring, should make the part number is up.、将支盖、新垫片支架和新垫片装到冷却器体上，将螺钉拧紧至41 47 Nm ，然后装好所有螺钉。E, the supporting cover, new gasket bracket and a new gasket fitted into the cooler body, the screws are tightened to41 47 N.m, and then install all bolts.（）柴油机冷却通道(4) diesel engine cooling channel在柴油机大修时，有的班组忽视对冷却通道的彻底清洗，具体表现在，散热器和缸盖拆下后扔到一旁，到总装时再将其表面擦拭干净。这是造成冷却系产生故障较多的原因之一。如装6BT 系列柴油机，常常发生散热器上水室顶部和气缸盖出水管一端的两根除气管都不通。这样，在加注冷却液时，积聚在气缸体内套的空气和气、水混合物就无法排出，冷却液也无法充满水套。柴油机在工作过程中，当积滞的气体达到一定程度时，还会造成水泵流量下降，结果是在气缸体水套内部产生局部高温，最终造成气缸体局部热应力猛增而使缸体局部破裂。因此，在柴油机大修或其产生高温故障时，应认真清洗冷却系，切不可马虎了事。In the diesel engine overhaul, some teams neglecting cooling passages in the performance of specific, thorough cleaning, radiator and cylinder head removed aside, to the assembly when the surface is wiped clean. This is caused by the cooling system has more faults reasons. As of6BT series diesel engine, radiator water chamber top and often occurred in cylinder head outlet end of the two air out. Thus, in filling in coolant, accumulate in the cylinder sleeve, air and water mixture is unable to discharge, cooling liquid can filled with water jacket. Diesel engine in the course of work, when the accumulated gas to a certain extent, can also cause water pump flow decreased, the result is in a cylinder water jacket internally generated local high temperature, resulting in local thermal stress of cylinder body and the cylinder explosion partial rupture. Therefore, the diesel engine or the high temperature failure, should be carefully cleaning cooling system, must not be sloppy.、故障诊断2, fault diagnosis（）断油电磁阀故障(1) oil cut-off electromagnetic valve fault6BT 柴油机在波许高压分配泵右上角处装有一个断油电磁阀。当钥匙开关处于熄火断电档时，阀芯在弹簧作用下回位切断油路，使柴油机熄火；当钥匙开关位于起动档时，电磁阀通电产生磁力吸取阀芯，油路接通，柴油机正常工作。一些新技工由于对这种装置的原理和作用不太了解，导致不能诊断出柴油机不能起动或熄火的故障原因。The 6BT diesel distribution pump Pausch high right corner is provided with a fuel cut solenoid valve. When the key switch is power cutoff gear, valve spring return to cut off oil, diesel engine flameout; when the key switch located in the starting position, the electromagnetic valve is energized to produce magnetic suction valve, oil circuit is switched on, the normal operation of diesel engines. Some new craft due to this principle and effect of do not know, can lead to diagnosis of diesel engine can not start or flameout fault reason.若柴油机起动时起动机工作正常，柴油箱及滤清器无阻塞，供油管无漏气现象，但多次不能起动，一般是断油电磁阀处出现故障。首先检查电磁阀线路中左起第3 个熔断器是否烧坏。若烧坏应立即更换。若未烧坏，再拆电磁阀上的接线，用示灯检查是否通电。若通电，一般是电磁阀烧坏或阀芯卡住，可改制一个专用扳手将电磁阀拆下。在无条件更换时，可将阀芯抽出后，再装回电磁阀体，即可起动柴油机。此时，可用挂档方法熄火。If the starting of the diesel engine starter when normal work, a diesel tank and filter without obstruction, the oil pipe without leakage, but many can not start, is generally broken oil solenoid valve failure. First check electromagnetic valve circuit third left a fuse is burned. If the burn should be replaced immediately. If not burn, and then split on the solenoid valve wiring, with indication lamp check whether electricity. If electricity, general electromagnetic valve is burned or valve stuck, can make a special spanner, the solenoid valve is removed. In unconditional replacement, valve core can be extracted, and then loaded back electromagnetic valve, then starting diesel engine. At this time, the gear method available.（）机油压力低(2) the oil pressure low6BT 系列柴油机采用机油冷却器芯，对冷却机油、加强润滑起了积极作用。但冷却器芯片焊点有破裂时，机油会大量进入水道，润滑油道的机油大量减少。机油警告灯亮时，从冷却系膨胀箱有机油溢出，应及时排除此故障。否则，将烧坏轴承甚至柴油机。6BT series diesel engine using engine oil cooler core, on the cooling oil, has played a positive role in strengthening lubrication. But cooler chip solder joint rupture, oil will enter the water, lubricating oil passage oil can reduce the number of. Oil warning light, from the cooling system expansion tank with the oil spill, should be ruled out this fault. Otherwise, will burn even diesel engine bearing.机油泵垫片损坏也会导致机油从机油泵处泄漏，从而主油道压力降低，机油警告灯亮，曲轴齿轮处发生异响。拆检更换机油泵垫片并认真装合后，故障即可排除。Oil pump gasket damage can also cause the oil from the oil pump leakage, thereby the main oil pressure is reduced, the oil warning lights, crankshaft gear is abnormal sound. Dismantling the replacement of oil pump gasket and serious combination, fault can be ruled out.（）柴油机异响(3) abnormal noise of diesel engine异响声发生在气门机构的现象比较普遍，表现为气门室盖处响声较大，声音清脆。油门加大转速升高响声加剧，是气门间隙过大所致。在准确判断出响声的缸号后，校准间隙并锁紧调整机构即可。其次，水泵处会发生连续的“嗡嗡”声，加速时响声加剧，一般为轴承因缺乏润滑而已被损坏。更换轴承时用榔头敲打不顶用，需用压床压出。Abnormal noise occurs in the valve mechanism of the phenomenon is commonner, performance for the valve chamber cover larger sound crisp sound. Accelerator enlarges speed increased noise aggravate, is the valve clearance is too large. The judge noise cylinder number, calibration intervals and locking and adjusting mechanism. Secondly, the water pump will happen continuous buzz sound, acceleration noise increased, usually due to lack of lubrication for bearings only damaged. Replacement of bearings in the hammer is not available, use press press.（）增压器漏机油(4) the turbocharger oil leakage、增压器空气压缩机漏机油。压缩机漏机油表现为: 柴油机工作时烧机油，排蓝烟。如果打开压缩机出气口或柴油机进气软管时有油，需更换压缩机挡油环前端的甩油环和密封环并清洁或更换空气格；如果机油沿空气压缩机叶轮轴漏油，需拆检回油管并清洗。A, turbocharger air compressor lubricating oil leakage. Compressor oil leakage performance: the diesel engine burning oil, exhaust smoke. If you open the compressor outlet or diesel engine air inlet hose is needed to replace oil, compressor oil ring oil ring and the front end of the sealing ring and clean or replace the air grid; if the oil along the air compressor impeller shaft oil leakage, dismantling and cleaning for oil return pipe.、增压器排气口漏机油。排气口漏机油将导致柴油机工作时烧机油。拆下排气口连接管，如排气口附近有机油漏的痕迹，应更换涡轮轴上的密封环。B, turbocharger exhaust outlet of oil leakage. Outlet drain oil will cause the diesel engine burning oil. Remove the air outlet connecting pipe, such as an exhaust mouth nearby organic oil leakage traces, should replace the turbine shaft seal ring.（）增压器轴承损坏(5) the supercharger bearing damage增压器涡轮转子轴承损坏，涡轮轴转速下降，涡轮转子总成的径向或轴向摆差大，需要拆检增压器，必要时更换转子轴承、转子总成。组装增压器时，对组成涡轮转子总成的涡轮轴、叶轮、机油甩油环、止推套等高速旋转零件，在进行动平衡时打上的安装位置标记必须一一对应。另外，还应检查并保证静态时，涡轮转子总成的轴向间隙(0.03 0. 07 mm ) 和径向间隙(0.30 0. 46 mm )。Turbocharger rotor bearing damage, the turbine shaft speed decreases, the turbine rotor assembly of radial or axial swing big, need dismantling the supercharger, necessary when replacing the rotor bearing, a rotor assembly. Assembly for turbocharger, on the composition of turbine rotor assembly of the turbine shaft, impeller, oil oil slinger, thrust sleeve of high-speed rotating parts, in dynamic balancing type installation position marking must be one one corresponding. In addition, also should check and ensure that the static, turbine rotor assembly of axial clearance (0.03 0.07 mm ) and radial clearance (0.30 0.46 mm ).值得引起注意的是，若柴油机是新的或长期停用的，在修理中和起动前，应对增压器轴进行人工添加机油润滑。否则，会发生轴承抱轴，导致转子、轴承严重弯曲变形，整个涡轮增压器报废。It is worth notic