Installation Requirements of Yuchai D Series Diesel Engine
by Starlight Generator dieselgeneratortechThe followings are the main installation requirements for Yuchai YC4108D and YC4208ZD series diesel engines. Do read the requirements and instructions carefully to avoid mistaken operation.
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:
First,
tighten t0 60 ~ 80N. m;
Then,
tighten t0 160 ~ 180N. m;
Finally,
tighten t0 220 ~ 260N. 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. 27mm.
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 tum as shown in Figure 2, 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:
First, tighten to 50 ~ 70N. m;
Then,
tighten t0 100 ~ 120N. m;
Finally, tighten t0 160 ~ 200N. m.
3 Installation of the camshaft
Position
the camshaft into the cylinder body with caution to make sure not scratch the
surface of the journals, cams, and liners. And then install the circlip, cam
thrust plate, cam gear, and cam retainer. Finally, tighten fastening bolt with
more than 300N. m tightening torque. The
camshaft should he 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 450. The valves and valve seat inserts should be grinded in
pair, and checked through kerosene. It must he guaranteed that kerosene don’t
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±0.1 mm 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
cannot 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, don’t finish that in once time and
following the sequence shown in Figure 6 in three steps:
First, tighten t0 60 ~ 80N. m ; .
Then,
tif;hten t0 120 ~140N. m;
Finally, tighten t0 210 ~ 250N. 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 try gear meshing clearance is between 0. 07 ~ 0. 25mm.
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 he accordance with the requirement offered
in the main fit clearance ( or interference).
We supply multiple brand of diesel generator sets such as Cummins, Perkins, Volvo, Deutz, Ricardo, Doosan Daewoo, Yuchai, Shanchai, Weichai, Wuxi, etc.
The genset style is varied, such as silent type, trailer type, portable type and so on.
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Created on Jan 4th 2018 00:35. Viewed 607 times.