Zichai 12V190 Electric Ignition Gensets Engines Overhaul for Repairing Generator Sets

Generator set internal combustion engine overhaul
Internal combustion engine overhaul is a restoration of the repair. Mainly to restore the power performance of the internal combustion engine, economic performance and fastening performance of the parts to ensure the integrity of the internal combustion engine, along the long-term use period.
The basic content of the diesel generator set is: repair or replace the crankshaft, connecting rod, cylinder liner, valve seat, valve guide; repair eccentric bearings; replace the plunger vice, oil valve vice and needle valve vice three precision coupling; repair welding oil pipe and joints; repair and replace the water pump, governor, clear the water jacket scale; check, repair, adjust the power supply system in the line, instrumentation, charging generator and starter motor, etc.; installation, monitoring, testing, adjusting the systems, and load, test, adjust the systems, and load test.
Internal combustion engine overhaul, generally should be based on the number of hours of work and technical condition to decide. Different models of internal combustion engine overhaul hours of work are different, the time is not static, such as improper use and maintenance or poor working conditions of internal combustion engine (dusty, often work under overload, etc.), may not reach the number of hours of work before, can not continue to use. Therefore, in determining the overhaul of the internal combustion engine, in addition to the number of hours of work, but also according to the following overhaul determination conditions:
(1) the internal combustion engine work powerless (after adding load to the speed of a large drop, the sound of sudden changes), black smoke from the exhaust.
(2) the internal combustion engine at room temperature start difficulty, go hot crankshaft bearings, connecting rod bearings and piston pins have knocking sound.
(3) internal combustion engine at normal temperature, the cylinder pressure does not reach 70% of the standard pressure.
(4) The fuel and oil consumption rate of the internal combustion engine increases significantly.
(5) The cylinder out-of-roundness and taper, the clearance between the piston and the cylinder, the crankshaft journal and the connecting rod journal out-of-roundness exceed the specified limit.
Internal combustion engine overhaul, its main parts should be repaired, the whole machine will be broken down into assemblies, combinations, parts and parts, and inspection and classification, more repair technical conditions, a thorough inspection, repair and assembly test.

What circumstances require diesel generator set overhaul?
1 the cylinder liner bore wear serious
Diesel generator set cylinder liner bore wear serious its roundness or cylindrical reach or exceed the use limit. Conventional roundness to 0.05-0.063 mm, cylindricity to 0.175-0.250 mm, multi-cylinder diesel engine to wear heavier cylinders as the basis.
2 the crankshaft journal, connecting rod journal serious wear
Crankshaft journal, connecting rod journal serious wear, its roundness or cylindricity to reach or exceed the specified limit.
3 the cylinder pressure dropped significantly
Diesel generator set cylinder pressure dropped significantly, less than 75% of the rated pressure, the cylinder has an abnormal sound, and the sound does not disappear after the machine heats up.
Diesel generator sets require overhaul of 7 kinds of situations - have to drive
4 the amount of oil consumption seriously exceeds the standard
Fuel, lubricant oil consumption seriously exceeds the standard, oil pressure drop, exhaust smoke.
5 start abnormal difficulties
Difficult to start, even stop in operation, still can't start smoothly when the water temperature is 60ºC.
6 the power dropped significantly
Power dropped significantly, when the throttle is large, the power issued by the diesel generator set is less than 75% of the rated power.
7 the crankcase temperature increased significantly
Diesel generator set crankcase temperature is significantly higher, diesel engine vents and oil filling port foggy smoke, the exhaust gas with oil.

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