How to Install Diesel Engine Parts Correctly

This article will show you the detailed information of diesel engine installation requirements.

1. Installation of the crankshaft

During crankshaft installation, the main bearing bolts should be tightened from thrust gear(the third gear) to both ends in order, and in three steps:

① tighten to 60－80 N.m

② tighten to 160－180 N.m

③ tighten to 220－260 N.m

During every time, the crankshaft should be rotated to check the mobility. It should be able to rotate freely after the final tightening.The axial clearance should be between 0.1 and 0.27 mm.

2. Installations of the piston and the connecting rod

When installing the piston rings, put the surfaces marked upward( the second positive twist ring inner fillet upward). During positioning the piston-connecting rod assembly into the cylinder bore, stagger the joints in turn. And put the arrow marked on the top surface of piston towards the front end of the engine. Remember spreading some clean oil before tightening connecting-rod bolts. The tightening torque should be between 160-200N.m, and completed in three steps:

① tighten to 50－70 N.m

② tighten to 100－120 N.m

③ tighten to 160－200 N.m

3. Installation of the camshaft

Position the camshaft into the cylinder body with caution to make sure not scratch the surfaces of the journals, cams, and liners. And then install the cir clip, cam thrust plate, cam gear, and cam retainer, Finally,tighten fastening bolt with more than 300N.m tightening torque. The camshaft should be able to rotate freely, and its axial clearance is between 0.1-0.2mm.

4. Installation of the valves and valve guides

The valve guides should be pressed in at normal state with 20±0.3mm distances between their top surfaces and the surfaces of the cylinder head spring seats. Both the valve face angles of intake and exhaust valves are 45º. the valves and valve seat inserts should be grind in pair, and checked through kerosene. It must be guaranteed that kerosene do not leak within three minutes. The valve recession heights of the valves should be between 1±0.2mm.

5. Installation of the injectors

Before mounting the cylinder head, the injectors should be installed in the cylinder head first. The nozzles should protrude 3.4±0.1mm from the bottom surface of the cylinder head, which can be ensured by adjusting the width of the injector washer. And then remove the injectors to prepare for following installation. As long as adjusted, the injectors and washers can not be exchanged during installation.

6. Installation of the cylinder head

During cylinder head installation, the cylinder head bolts should be tightened to a tightening torque of between 210-250 N.m, do not finish that in once time and following the sequence shown in the following figure by three steps:

① tighten to 60－80 N.m

② tighten to 120－140 N.m

③ tighten to 210－250 N.m

7. Installation of the gear train

The crankshaft timing gear, injection pump gear, and camshaft gear should all be accordance with the timing requirement, so there are timing marks, which should be aligned during installing the gears, on them and timing idle gear. Oil the tooth surface after installing. The range of the gear meshing clearance is between 0.07-0.25mm.

Caution

1. every component should be cleaned before being installed, especially the oil passages, no dirt is permitted in them.

2. No corrosion, burr, or scratch is permitted on the fit surfaces of every component.

3. Friction surfaces and important fit surfaces should be oiled before installing.

4. Fit clearance( or interference) should be accordance with the requirement offered in the main fit clearance(or interference).

Interested in diesel generator price and tech?

Diesel Generator Power Ratings: Standby vs Prime vs Continuous

Diesel generator sets are commonly used in a variety of sectors due to their dependable performance and high efficiency. They can be used for emergency power supply in the event of a power cut or used in places without connection to a power grid. When selecting a diesel generator for your home or business, you need to consider many factors, such as generator’s ratings. In this article, we’ll explain the three basic rating types - standby, prime, and continuous in diesel generators. ISO-8528-1:2018 defines basic generator set rating categories based on four operational categories: Emergency Standby Power (ESP), Prime Power (PRP), Continuous Power (COP) and Limited-Time Running Prime (LTP). Read on and learn the application of power ratings for engines used in generating sets. Standby Power Rating Standby Power(ESP) is used to supply emergency power when the external power supply is interrupted, such as power outages. Standby power rated generators can supply reliable electricity as t...

Main Structural Features of Natural Gas Engine - Weichai WP13NG Gas Generator

1.1 Main structural features of natural gas engine ● A cover per cylinder, dependable operation, easy disassembly. ● Frame-type main bearing structure and high complete machine rigidity which benefits the reliability and service life of complete machine. ● Electronic throttle is adopted to control engine revolving speed. ● Mixture supply system uses mixer to regulate air-fuel ratio and adopts proportional mix and supercharged inter-cooling method to stabilize gas supply. ● Water-cooling middle case turbocharger applicable to gas engine features is selected and circulating water shall be used to cool down turbocharger lubrication cooling oil so as to effectively prevent pressure bearing lubricating oil from coking and to improve turbocharger’s reliability. ● Designed gas mixing system satisfies gas fuel features to effectively support stable lean burn and enhance thermal efficiency. ● Two pairs of friction couples of inlet, outl...

What Should You Pay Attention to in Routine Maintenance of Diesel Generator Sets

In modern society, the stability of power supply is directly related to the operation efficiency of enterprises and people's quality of life. Diesel generators have become an indispensable backup power supply or main power source in various industries due to their high efficiency, durability and reliability. However, to ensure the smooth operation and optimal performance of the generator sets, regular maintenance is essential. Here is what you need to pay attention to in the routine maintenance of diesel generators. Keep your generator clean It’s important to keep the generator’s exterior and the generator room clean. Regularly remove any dirt, dust, or debris that may accumulate to on the generator’s surface. This is not only for the sake of beauty, but also for the smooth operation of the unit. Cleaning the generator’s exterior, air intake vents, exhaust outlets and generator room can effectively reduce the risk of generator overheating. In addition, check if the connection bol...

Diesel Generator Tech

Search This Blog