Replacement and Repair of Wet Cylinder Liner of Diesel Generator Set

When removing the old cylinder liner from the diesel generator set, you can tap the bottom of the cylinder liner and use a special puller to remove it. If there are no special tools available, place the cylinder block on its side and pad the lower end of the cylinder liner of the diesel generator set with hardwood. Then, use a round wood or iron pipe to support the hardwood, and use a hammer to knock out the round wood to knock out the cylinder liner. After removing the old cylinder liner of the diesel generator set, scrape away the metal rust, dirt, and other debris from the bearing hole in the cylinder body of the diesel generator set, and sand the joint between the cylinder block and the cylinder liner with an abrasive cloth to expose the metal luster, preventing deformation of the cylinder liner due to compression. In particular, the cylinder bore wall where the sealing ring contacts must be smooth to prevent water leakage due to uneven rubber sealing ring damage. If there are hard deposits on the lower shoulder of the cylinder liner, due to unevenness around it, the installation of the cylinder liner is inclined, resulting in gaps at the upper shoulder. After pressing the cylinder head tightly, a return torque occurs, causing deformation of the cylinder liner of the diesel generator set, which is prone to early wear, piston ring breakage, piston eccentric wear, oil channeling, and other failures.

The surface roughness of the joint surface between the wet cylinder liner support shoulder and the cylinder block bearing hole of the diesel generator set shall not exceed 1.60tm and there shall be no spots or grooves. The cylindricity tolerance of the upper and lower bearing holes on the cylinder block of a diesel generator set cannot exceed 0.015 mm. The fit clearance between the bearing holes and the cylinder is 0.05 to - 0.15 mm. Before installation, the cylinder liner without sealing ring should be placed into the bearing hole. When pressing the cylinder liner of the diesel generator set tightly, the end face of the cylinder liner of the diesel generator set should be 0.03-0.24mm higher than the plane of the cylinder body, and the height difference of each cylinder should not be greater than 0.03mmn. If it is too high, use a scraper to repair the bottom surface of the upper groove of the cylinder block or file the upper surface of the cylinder sleeve; If it is too low, it can be adjusted by pressing a copper wire under the cylinder liner flange.

Before pressing the wet cylinder liner of a new cylinder liner of a diesel generator set, a new rubber sealing ring coated with white paint should be installed to prevent water leakage. The pressing method is the same as the installation of dry cylinder liners.

The wet cylinder liner of diesel generator sets is usually not polished due to the small force applied during pressing and the unaffected inner diameter of the cylinder liner. If the roundness or cylindricity error of the cylinder is too large after measurement, the cylinder liner of the diesel generator set should be pulled out, and the rust part of the bearing hole should be inspected and repaired. Rotate the cylinder liner of the diesel generator set by 90 ° and press it in, but the sealing ring needs to be replaced. After the cylinder liner of the diesel generator set is pressed in, the sealing ring shall not be deformed and shall be well sealed. If necessary, a hydraulic test shall be conducted to ensure no leakage.

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