Diesel generator set assembly requirements and precautions


Assembly is the last stage of generator set repair work and is also a very important part of the generator set repair process. Because the assembly of the generator set is not only to assemble the various parts into the generator set assembly, but also to identify whether the processed or replaced parts and original parts can guarantee the quality. Therefore, the quality of each assembly determines the quality of the entire generator set repair. The following introduces the main requirements and precautions for assembly.

  1. Main requirements for assembly
  2. Ensure the tightness, contact area and matching clearance of each mating part
  3. Ensure that each assembly mark or matching relationship is not confused
  4. Ensure the fastening requirements of parts
  5. Ensure that parts are not damaged
  6. Ensure that there is no “three leaks” phenomenon (oil leakage, water leakage and air leakage)
  7. Ensure that each adjustment parameter is correct (accurate oil supply time, correct injection pressure and oil pressure, appropriate valve and decompression clearance, oil supply and uneven oil supply of each cylinder, fan belt resistance must meet the specified requirements, etc.)
  8. Precautions for assembly
  9. The body, parts and components to be assembled should be cleaned, especially the oil channels of the lubrication system should be cleaned and blown through.
  10. Before assembling parts or components that have relative motion and friction with each other (such as cylinder sleeve and piston connecting rod group, shaft and bearing, etc.), they should be coated with clean engine oil. When installing the oil pump and oil filter, fill the engine oil. For diesel generator sets that are started by hand, you can wait until the whole machine is installed before testing the machine without filling the oil first. When installing the oil pump and oil filter, you can wait until the whole machine is installed. When the crankshaft is shaken by hand, the place on it where air can be released can be opened. After a while, oil will come out, which means that the oil has been filled. For other models, such as those that are not easy to shake by hand, and the oil pump is not exposed in the oil pan, etc., the oil should be filled in advance.
  11. To choose the right tools, it is not allowed to knock the surface of the parts with a steel hammer. If it is necessary to knock, it should be padded with soft metal or use a wooden or rubber hammer to knock to avoid damaging the surface of the parts.
  12. Assemble the parts with directions and marks as required.
  13. All kinds of gaskets should be intact and coated with the best amount of butter.
  14. The screws of the main bearing, connecting rod bearing, cylinder head and flywheel should be tightened symmetrically and evenly in 2 to 3 times, and have the specified torque. Safety devices should be installed.
  15. After the moving parts are installed, they should be tested to observe their operation and tightness. After installation, the crankshaft should be turned to check whether the moving and rotating parts are stuck, and check for air leaks, oil leaks and water leaks. If any, eliminate them in time.