Tightening the head bolts on the KAMAZ. Transport: history and modernity

Filters for cleaning

Page 1

A) joint with a sleeve and a cylinder block

B) joint with combined seal

B) - with a ring of gasketless gas joint on a cylinder liner of a gas construction.

49. Install the cylinder head with valves assembly on the cylinder block and tighten the bolts with fasteners with washers. Before we wrap the threads of the cylinder head bolts, grease with a thin layer of graphite grease. Before installing the head of the block, it is necessary to unscrew the adjusting screws of the rocker arm several turns. Fig. 1.5.

Tightening sequence for cylinder mounting bolts

Cylinder Head Bolt Tightening Scheme

The value of the tightening torque of the bolts is 40-50N.m (4-5 kgf.m) (19 mm interchangeable head, wrench with connecting square, handle torque model 131M, graphite grease (USSA) 3333-80, brush)

50. Repeat steps 47-49 for each cylinder in the cylinder block.

51. Tighten finally the cylinder head bolts in two steps. The value of the tightening torque of the mounting bolts for receiving 120-150 N.m (12-15 kgf.m); for receiving 160-180 N.m (16-18 kgf.m) (19 mm interchangeable head, torque wrench PIM-1754)

52. Turn the crankshaft so that the flywheel retainer rod fits into the flywheel groove and the camshaft gear mark “0” is in the upper position. (lever arm)

53. Install the driven gear of the injection pump assembly with the shaft on the engine. Set the driven gear so that the “0” mark of the driven gear coincides with the same mark of the camshaft gear.

54. Install the gasket, rear bearing housing assembly with a sleeve and tighten the mounting bolts with spring washers. The value of the bolt tightening torque is 45-50 N.m (4.5-5.0 kgf.m) (Interchangeable head 17mm, wrench with connecting square, handle torque model 131M, hammer)

55.Pull the lock out of the flywheel groove and rotate the crankshaft 60 degrees in the direction of rotation, thereby setting it to the position according to table 1.4. The rotation of the flywheel by the angular distance between two adjacent holes on the protrusions corresponds to a rotation of the crankshaft by 30 degrees.

Table 1.4.

Adjustment of valves

56. Strain in valve mechanisms of the first and fifth cylinders. Clearance: for the inlet valve 0.25-0.30 mm, for the exhaust valve 0.35-0.40 mm. The tightening value of the nuts of the adjustment screws is 34-42 N.m (3.4-4.2 kgf.m)

Adjust the thermal clearances in the following order:

Check the tightening torque of the nuts of the struts of the arms of the adjustable cylinders must be tightened;

Legal environment of business
Creating your own business in Russia is carried out in accordance with applicable civil law, federal laws on individual legal forms of companies and various regulations governing the entire process of formation and functioning of private firms. For pre ...

The main measures to improve the organization of traffic on the street. Soviet
The analysis of traffic conditions on the considered section of the street. Sovetskaya showed that the roadway is in good condition, road signs are installed at all available intersections. The main activities are: 1. Update markup throughout the street. Soviet. Except t ...

Container classification
Table 1 Classification of containers Name Appearance Length, m Width, m Height, m \u200b\u200bVolume, m cube Weight, kg 20 ft Standard 6.06 2.44 2.59 33.3 21 700 Refrigerator 6.06 2.44 2 , 6 26.5 24 000 Isolated 6.06 2.44 2.44 26.3 17 760 Open Top 6.06 2.44 2.59 32.6 21 500 Tank ...

TO category:

Device operation KAMAZ 4310

Fixed parts of the crank mechanism KamAZ 4310

The cylinder block is the body (skeleton) of the engine, in which moving parts of all engine mechanisms and systems are located and work. Almost all mounted units and devices are also attached to it.

The elements of the block perceive the gas pressure forces and unbalanced inertial loads acting in the engine during the working process. It is subject to significant and uneven heating. Under the influence of mechanical loads and thermal stresses, the block can be deformed, and therefore the shape and dimensions given to it during manufacture are distorted. The latter violates the normal interaction of the elements of the mechanism, it becomes possible to skew and pinch the moving parts, leading to increased friction and intensification of wear.

It should also be borne in mind that the distortion of macrogeometry can occur due to mounting voltages, if during assembly of the engine the established procedure and the tightening torques of the threaded joints are not observed. Inadmissible deformations of the block occur when refueling a preheated engine with cold coolant, as well as when water freezes in the cooling jacket. In this regard, the elements of the block must be interconnected into a common rigid system in order to avoid unacceptable deformations of individual links.

The block is a hard casting of gray cast iron with a small amount of alloying additives (chrome, nickel).

To increase the strength, it is subjected to artificial aging, which allows to minimize deformation of the unit in operation.

The cylinder block has a V-shaped design with a camber angle of 90 °. The left row of cylinders is displaced relative to the right by 29.5 mm. This is because two connecting rods are installed on one crank pin of the crankshaft.

The cylinder block is integral with the upper part of the crankcase. The block is divided by transverse partitions, which in the lower part end with thick-walled arches forming the main bearings of the crankshaft. On the treated sites of the transverse partitions, the covers of the main supports are installed, after which they are bored. Therefore, they are not interchangeable and it is necessary to install them during assembly into their sockets and by a certain side. To do this, the numbers (1, 2, 3, 4, 5) corresponding to the number of the main bearing (numbering from the front of the engine) are knocked out on the covers and block, and mating marks are knocked out to determine whether the cover belongs to this block.

Fig. 10. The cylinder block

To prevent turning of the liners in the bed connector, recesses are made in which the tabs of the liners enter. The covers of the main bearings are fastened with two bolts that are tightened with a torque of 210 ... 235 Nm (21 ... 23.5 kgf-m).

In order to increase the rigidity of the lower part of the block, its side walls are pulled together with the covers of the main supports with bolts-ties. Tightening torque 82 ... 92 Nm (8.2 ... 9.2 kgf-m).

In the fifth root support (rear), annular grooves are made on both sides, designed to install two pairs of half rings. From turning the half rings in the cover, recesses are provided.

On the surfaces of the cylinder part of the block, which serve as attachment planes for the cylinder heads, there are openings for supplying coolant, for the passage of the pusher rods, a steam outlet and pins are pressed in to fix the cylinder heads. In one of the pins, a channel is made for supplying oil to the cylinder head to the rack of the rocker axles.

The front and rear ends of the block are processed perpendicular to the axis of the bores under the main bearings. For precise installation of the front cover and the flywheel housing, two mounting pins are pressed in.

At the front end of the block there is a socket for installing a water pump and channels for supplying coolant to the left and right rows of cylinders.

On the right in the front crankcase, the platform for attaching the oil filter was machined and channels were made for supplying oil to the oil filter and diverting it to the main oil line.

Below the right side of the connector there is a platform for attaching the oil pump and channels for supplying oil from the discharge and radiator sections of the oil pump.

In the collapse of the block, platforms for fastening the high pressure fuel pump are made.

Bores for camshaft bearings are made in the upper part of the crankcase partitions.

In the crankcase partitions, channels were drilled for supplying oil from the main oil line to the crankshaft and camshaft bearings, a high pressure fuel pump, a full-flow oil filter, a fan drive fluid coupling, a compressor, as well as a channel for supplying lubricant to the centrifugal oil filter.

The cylinder part of the block is at the same time the wall of the cooling jacket, forming a protective belt around the cylinder seats. Each cylinder seat has two precise coaxial cylindrical holes made in the upper and lower parts of the block.

Cylinder liners are inserted into the cylinder jacks of the block. The inner part of the liner, limited on one side by the cylinder head, and on the other by the piston bottom, forms the volume where the engine runs. The walls of the cylinder liners serve as guides for the piston during its reciprocating motion. Describing the operating conditions of the liner, it should first be noted that the movement of the piston relative to its working surface (the so-called cylinder mirror) is accompanied by friction and causes wear. If the diametrical wear and geometric distortions of the liner mirror exceed the limit values, then the sealing of the working cavity is violated, the starting properties of the engine deteriorate, the oil consumption is significantly increased and the engine power is reduced.

The KAMAZ-740 engine has wet sleeves (the outer surface of the liner is washed with coolant), easily removable, cast from special cast iron. The working surface is quenched by high-frequency currents and processed to obtain a special surface that looks like a grid. The depth of the troughs is 2.5 ... 2.7 microns. Such a surface contributes to running-in and reduces the likelihood of scuffing, as the oil absorption of the working surface increases.

A shoulder is made in the upper part of the liner, the lower plane of which the liner is mounted on the corresponding thrust end face of the cylinder block. At the end of the shoulder there is a protrusion that protects the cylinder head gasket from direct exposure to hot gases, and a special groove is made for better compression of the cylinder head gasket. The centering of the sleeve in the hole of the block is carried out by the upper and lower cylindrical belts. The lower part of the sleeve is made on a cone, which prevents the capture of o-rings when installing it in the unit. In the middle part of the cylinder, a space (cooling jacket) is formed between the liner and the block, through which the coolant circulates.

To prevent leakage of coolant, the lower shell belt is sealed with two silicone rubber rings installed in the grooves of the block, and the upper one with a rubber ring placed under the shoulder.

Fig. 11. Cylinder head with valves assembly:
1 - cylinder head; 2 - head cover gasket: 3 - cover fastening bolt; 4 - cylinder head cover; 5 - a bolt of fastening of a head; 6 - sleeve; 7 - exhaust valve; 8 - valve seat; 9 - a directing plug of the valve; 10 - a washer of valve springs; 11 - external and internal valve springs; 12 - a plate of valve springs; 13 - plate bushing; 14 - valve cracker; 15 - sealing cuff; 16 - inlet valve

The tops of the cylinders (Fig. 11) are cast from aluminum alloy. Each cylinder has a separate head. The head is attached to the cylinder block with four bolts. The bottom surface of the head is ground. The head is centered on the mating surface of the cylinder block with two fixing pins, pressed into the block. The inlet and outlet channels are made in the cylinder head. The inlet channel has a tangential shape, which ensures a swirl of the incoming air, and therefore, better mixing. The inlet and outlet channels are led to the opposite side walls of the head and through gaskets are connected to the corresponding pipelines. In the attachment plane, sockets for the inlet and outlet valves are made, into which the valve seats are pressed in. Valve guides are pressed into the head body. The working chamfers of the valve seats are finally machined after pressing and unrolling the guide valves.

Fig. 12. Seal gas joint:
a - with gasket; b - uncoated; 1 - steel cylinder head gasket; 2 - a basic ring; 3 - cylinder head; 4 - a sealing ring of a gas joint; 5, 8, 12 - sealing rings; 6, 11 - cylinder block; 7, 10 - sealing gasket of the cylinder head; 9, 13 - cylinder liner

To increase the durability of the head and the reliability of the gas joint seal, a steel ring is pressed into the mounting plane. The free inner space of the head forms a liquid jacket for cooling the head during engine operation. Coolant enters the cylinder head from the unit through two openings, and is discharged from the head through a rectangular channel from the intake pipe side. At this point, flanges and threaded holes for securing the outlet pipe are provided on the lateral plane of the head.

A cavity for installing the nozzle is made in the cylinder head, the thrust pin of the bracket for attaching the nozzle is pressed in, and the pin is screwed. In the upper part of the head with the help of two studs, a rack with the axles of the rocker arm is attached. To fix the rack, two pins are pressed into the cylinder head.

On top of the cylinder head is closed by a lid made of aluminum alloy. The seal of the junction of the head and cover is provided by a rubber-cork gasket.

The gas joint is sealed between the end of the cylinder liner and the head by a gasket made of sheet steel, which is pressed into the shaped groove of the liner (Fig. 12, a) with a steel ring pressed into the head.

The mounting planes of the block and cylinder head are sealed with a rubber gasket.

Since October 1984, a gasket-free gas joint seal has been introduced (Fig. 12.6). The tightness of the gas joint is ensured by high precision machining of the surfaces of the ring and cylinder liner. To compensate for microroughness of the mates, a lead coating is applied to the mating surface of the ring. The seal of the bypass channels for the coolant is carried out by rubber o-rings installed in the openings of the cylinder head.

Fig. 13. Flywheel housing:
1 - flywheel housing; 2 - hole for installing the crankshaft oil seal; 3 - supporting platform for mounting the bracket; 4 - hole for installing the shaft of the drive of the high pressure fuel pump with gear assembly; 5 - hole for mounting the support of the gearbox control drive; 6 - flywheel lock; 7 - a cover of a support of a drive of management of a transmission; 8 - a cover of a bearing of a shaft of a drive of TNVD; 9 - a crankshaft oil seal

The main malfunction of the head of the block during car operation is a violation of the tightness of the joint between the cylinder liner and the head of the block due to weak or uneven tightening of the head nuts, damage to the gasket, prolonged engine operation with overload or engine overheating.

An external sign of these malfunctions, as a rule, will be a decrease in engine power.

The flywheel housing is made of aluminum alloy and bolted to the rear end of the cylinder block through a gasket made of paronite. The exact fixing of the mating parts is carried out by two pins, pressed into the cylinder block. Tightening torque of the flywheel housing bolts 90 ... 100 Nm (9 ... 11 kgf-m).

A hole is provided on the left side of the flywheel housing for installing the starter. In the middle of the lower part of the crankcase (Fig. 13) there is an opening for the crankshaft oil seal. In the flywheel housing, some drive units of the engine assemblies are located. So, in the upper part there is a shaft with a gear for driving a high-pressure fuel pump (TNVD), a gear for driving a compressor and a power steering pump, two bores are made: in the center - under the cover of the bearing of the pump shaft of the injection pump, on the left - under the drive shaft of the gearbox gearbox. At the top, on the lower part of the flywheel housing, on the right, there are a breather, a flywheel lock and an oil filler neck.

The front cover of the unit is cast from aluminum alloy. It is bolted to the front end of the crankcase through a paronite gasket. Precise installation is provided by two centering pins, pressed into the unit. The cover also houses the drive units of the units. In front of the cover there is a bore for the passage of the driven shaft of the fluid coupling, the drive shaft of the generator and the water pump. An oil filter for centrifugal oil cleaning is attached to the right side of the cover. The brackets of the front engine mount are attached to the right and left.

TO Category: - Device operation KAMAZ 4310

31. The designation of the inserts of the corresponding neck, the diameter of the bed in the connecting rod is plotted on the back side of the insert (replaceable head 19mm, key with connecting square)

32. Lubricate the connecting rod bearing shells and install them in the connecting rod caps and in the lower connecting rod heads. Lubricate with oil M10G2K. The protrusions on the liners should coincide with the recesses on the lid and connecting rod (oil container, brush)

33. Turn the crankshaft to set the first crank pin to the lower position (lever).

34. Separate the locks of the piston rings of the piston with the connecting rod and rings assembly of the first cylinder 180 degrees relative to each other and install the piston with the connecting rod and rings assembly in the corresponding cylinder using the mandrel. The piston index must be the same as the liner index. Pistons with an index of 10, can be installed in any sleeves. When installing the pistons, tuck under the valves on the piston bottom to shift towards the collapse of the cylinder block. (sending for installation of the piston, wooden hammer)

35. Install the connecting rod cover on the corresponding connecting rod and pre-secure with bolts and nuts. With a tightening torque of 29-31 Nm (2.9-3.1 kgf.m.), the mating marks of the numbers on the connecting rod and its cover should be the same. The groove on the connecting rod must coincide when installed with the locking mustache on the connecting rod cover (replaceable head 19mm., Key with connecting square, extension cord, handle torque model 131M).

36. Repeat work 33, 34 for sequential installation of pistons with connecting rods and rings assembly in 8.2,7,3,4,5 and 6 cylinders.

36. Turn the crankshaft so that the first connecting rod journal is in the lower position. The numbering report shall be kept from the front of the cylinder block.

37. Tighten the connecting rod bolts of the first connecting rod journal. Tighten the nuts to an extension of the connecting rod bolts of 0.25-0.27 mm. The nuts of the M13X 1.25 connecting rod bolts manufactured since July 1, 1985, are tightened with a tightening torque of 120-130 Nm (12-13 kgf.m.) (19 mm interchangeable head, wrench with connecting square, extension elongation control , torque grip 131M)

38. Check the gap between the ends of the lower connecting rod head and the crankshaft cheeks, the clearance should be at least 0.15 mm (set of probes No. 2)

39. Turn the cylinder block to a horizontal position. (stand)

40. Lubricate the flywheel housing gasket, install the gasket using the flywheel housing mandrel on the cylinder block, Fig.1.3.

Mandrel for installing flywheel housing

1-mandrel

combine holes in the crankcase, gasket and block, install the bolts and fasteners with springs and flat washers and wrap them, apply TsIATIM-201 grease. The value of the tightening torque of the flywheel housing bolts is 90-110 N.m (9-11 kgf.m) (capacity, brush, dispatch, replaceable head 17 mm and 19 mm, wrench with connecting square, torque model handle 131M)

41. Install the flywheel assembly on the engine and align the holes for the flywheel mounting bolts. Install the flywheel so that the locating pin on the crankshaft fits into the hole in the flywheel. (beam crane, suspension for installing the flywheel.)

42. Install and tighten the fastening bolts with the flywheel lock fasteners and bend the edges of the plates on the verge of the bolts. The magnitude of the tightening torque of the mounting bolts 150-170N.m (15-17 kgf.m) Locking plates were installed on engines up to issue No. 75800 until February 1979. (replaceable head 19 mm, key with connecting square, torque wrench PIM-1754 model, hammer, chisel)

43. Check the runout of the flywheel end relative to the axis of the crankshaft. The amount of runout should be no more than 0.25 mm. Runout replace at maximum diameter. (devices with indicator model PRI-1P)

44. Install the fluid coupling drive shaft.

45.Lubricate the gasket of the front cover of the block, apply the lubricant TsIOTIM-201 (capacity, brush)

46. \u200b\u200bInstall the gasket and the fluid coupling of the fan drive with the front cover of the block assembly on the front end of the cylinder block and tighten the mounting bolts with spring and flat washers.

The magnitude of the tightening torque of the M10 mounting bolts is 50-60 N.m (5-6 kgf.m), and the M12 bolts 90-110 N.m (9-11 kgf.m) (beam crane, suspension, interchangeable heads 17.19 mm, key with connecting square, handle torque model 130M)

47. Install the pusher rods assembly of the first cylinder in the rod pusher.

48. Install the cylinder head gasket and rubber gasket Fig.1.4.

Cylinder head installation

A) joint with a sleeve and a cylinder block

B) joint with combined seal

B) - with a ring of gasketless gas joint on the cylinder liner of a gas construction.

Tightening sequence for cylinder mounting bolts

Cylinder Head Bolt Tightening Scheme

The value of the tightening torque of the bolts is 40-50N.m (4-5 kgf.m) (19 mm interchangeable head, wrench with connecting square, handle torque model 131M, graphite grease (USSA) 3333-80, brush)

50. Repeat steps 47-49 for each cylinder in the cylinder block.

52. Turn the crankshaft so that the flywheel retainer rod fits into the flywheel groove and the “0” mark of the camshaft gear is in the upper position. (lever arm)

53. Install the driven gear of the injection pump assembly with the shaft on the engine. Set the driven gear so that the “0” mark of the driven gear coincides with the similar gear mark

camshaft.

Table 1.4.

Adjustment of valves

Parameter

The value of the parameters at the position of the crankshaft

Angle of rotation

crankshaft 600 2400 4200 6000

Cylinders

Regulated

valves 1-5 4-2 6-3 7-8

Adjust the thermal clearances in the following order:

Check the tightening torque of the nuts of the struts of the arms of the adjustable cylinders must be tightened;

Check with a feeler gauge the gap between the toes of the rocker arm (Fig. 1.6.) And the valve stems of the 1st and 5th cylinders. The probe 0.3 mm thick for the inlet and 0.4 mm for the exhaust valves must enter with force (the front valves of the first row of cylinders are inlet, the left row are exhaust);

Valve Clearance Check

To install the device for adjusting the gaps, if necessary, loosen the screw nut, install the dipstick into the gap and turn the screw with a screwdriver, set the required gap. While holding the screw with a screwdriver, tighten the nut with a wrench and rotate the clearances. (A device for adjusting thermal gaps, a set of probes, a replaceable head 13 mm, a handle dynamometer model 131M)

57. Rotate the crankshaft 180 degrees in the direction of rotation. (Lever)

58. Adjust the clearance in the valve 0.25-0.30 mm, for the inlet valve 0.35-0.40 mm. The value of the tightening torque of the nuts of the adjusting screws 34-42 N.M (3.4-4.2 kgf.m) (A set of probes, a 13 mm replaceable head, a torque model handle 131M, a device for adjusting clearances)

59. Repeat work 57-58 for valve mechanisms of the sixth and third cylinders and the seventh and eighth cylinders, respectively.

60. Install the gasket, the cover of the head of the first cylinder and tighten the bolt of fastening with flat washers. The bolt tightening torque is 17-22 N.m (1.7-2.2 kgf.m) (Interchangeable head 13 mm, wrench with connecting square, handle torque model 131 M)

61. Repeat 60 for the remaining seven cylinder head covers.

62. Put adjusting washers on the front eyebolt and screw the eyebolt into the cylinder block. There should be no more than four shims. Screw the bolt relative to the longitudinal axis of the engine by 15 degrees. (Special insert)

63. Install the gasket of the front flange of the valve of the lubrication system, the oil pump assembly with tubes, tighten the bolts with the lock washers of the oil pump and the bolt of the bracket of the suction tube to the cylinder block and bend the mustache of the lock washers on the verge of the bolts. The tightening torque of the mounting bolts is 50-60 N.m (5.0-6.0 kgf.m). On engines No. 163856, the lock washers were replaced with spring washers (oil pump mounts) and flat (mount bracket mounts). (Replaceable head 17mm, key with connecting square, handle torque model 131M, hammer, chisel)

64.Tighten the bolts with lock washers of the front flange of the inlet pipe of the valve of the lubrication system to the cylinder block and bend the mustache of the lock washers on the verge of the bolts. The tightening torque of the mounting bolts is 50-60N.m (5-6 kgf.m). On engines with issue No. 163851 from February 15, 1980, lock washers were replaced with spring washers. (13 mm interchangeable head, key with connecting square, torque handle model 131M, hammer, chisel)

65. Glue the gasket on the cylinder block, lubricating its surface with a thin layer of grease or sealant paste. Apply Litol-24 or “Sealant” lubricant TU 6-10-1796-71 or UN-25 TU MHP 3336-52. Gasket material: rubber. (Capacity, wooden spatula)

66.Check thoroughly the cleanliness of the internal surfaces of the engine, install the pan and tighten the bolts securing the nut with spring washers. (Pneumatic impact wrench model IP-3113, replaceable head 13 mm)

67. Turn the engine on the bench with the cylinder heads up. (Stand)

2. ENGINE TEST

2.1. Equipment, instruments, tools.

Crane beam, suspension for transportation and installation of the engine on a stand model 130.219.00.000.000; test bench for engines model 470.004 - 470.006; a set of probes, a handle dynamometer model 131M, a lever for turning the crankshaft of the engine model 7829-4087 or 7829-4063, a device for adjusting valves I-801.14.000; interchangeable heads 13.14, 17, 19, 22 mm, wrench with connecting square, open-end wrenches 8, 10, 13, 14, 17, 19, 22, 24 mm, ring wrenches 17, 19, mm, screwdriver fitter and assembly 8.0 mm, electric forklift series 02.

1. Install the engine on a stand, fix it and prepare the engine for running-in and testing, for which the following work should be done:

Unscrew drain plugs from engine oil sump,

Connect the exhaust pipes of the gas pipeline with the flanges of the exhaust manifolds of the engine,

Connect the balancing electric brake of the stand to the flywheel of the engine with a propeller shaft,

Connect the fuel drain pipe from the nozzles to the fuel system of the stand,

Install the water pump drive belts and tighten them,

Close and secure the guard cover on the fan side,

Connect the rod to the fuel supply lever from the high-pressure fuel pump,

Connect the rod to the stop lever of the injection pump,

Connect water inlet and outlet hoses to the engine,

Connect the oil supply hoses to the centrifugal oil filter and to the full-flow oil filter

Remove the 8th section high pressure fuel pipe

Fuel pump (first cylinder of the engine) and connect to the sensor fitting,

Connect the fuel supply hose (drain) from the fuel filter,

Connect a flexible metal hose for air supply from the air filter to the engine,

Install technological plugs in the hole for supplying water and oil to the compressor and power steering pump,

turn on the supply of water, oil and fuel to the engine. (beam crane, suspension, engine test stand, interchangeable heads 13,14,17,19 and 22 mm, a wrench with a connecting square, open spanners 8,10,13,14,17,19 22 and 27 mm, keys ring nuts 17.19 mm)

) separate for each cylindermade of aluminum alloy. Cylinder head has a cooling cavity in communication with the cooling cavity of the unit.

To strengthen the bottom of the head, its thickness was increased in the area of \u200b\u200bthe exhaust channel and an additional rib was made in comparison with the cylinder head 740 engine.10.

Each cylinder head is mounted on two locating pins, pressed into the cylinder block, and fastened with four alloy steel bolts. One of the locating pins simultaneously serves as a hub for oil supply to lubricate the rocker arms. The sleeve is sealed with rubber rings. In the head compared to the head 740 engine.10, enlarged engine oil drain hole from under the valve cover into the rod cavity. The windows of the inlet and outlet channels are located on opposite sides of the cylinder head. The inlet channel has a tangential profile to ensure optimal rotational movement of the air charge, which determines the parameters of the working process and environmental performance of the engine, therefore replacing the cylinder heads with a mod. 740.10 is not allowed.

Cast iron seats and ceramic-metal valve guides are pressed into the head. Valve seats have an increased interference fit compared to mod engine seats. 740.10, and are fixed with a sharp edge. The outlet seat and valve are profiled to provide less resistance to exhaust emissions.

Application of exhaust valve mod. 740.10 is not recommended.

The joint "cylinder head - liner" (gas joint) - without laying ( fig. Gas joint ) A steel sealing ring 3 is pressed into the bored groove on the lower plane of the head. Through this ring, the cylinder head is mounted on the sleeve collar. The tightness of the seal is ensured by high precision machining of the mating surfaces of the sealing ring and cylinder liner 5. The sealing ring additionally has a lead coating to compensate for microroughnesses of the sealing surfaces.

Gas joint: 1 - cylinder head; 2 - a ring sealing bypass of a cooling liquid; 3 - gas joint ring; 4 - filler gasket; 5 - cylinder liner; 6 - a sealing ring; 7 - sealing gasket; 8 - cylinder block; 9 - screen.

To reduce harmful volumes in the gas joint, a fluoroplastic gasket - filler 4 is installed. The gasket - filler is fixed on the protruding belt of the gas joint ring due to the inverse cone with an interference fit. The use of aggregate gaskets reduces specific fuel consumption and exhaust smoke. One-time placeholder.

To seal the bypass channels of the coolant, sealing rings 2 made of silicone rubber are installed in the holes in the bottom of the head.

The space between the head and the block, the engine oil drain holes and the rod passage holes are sealed with a gasket 7 of the cylinder head made of heat-resistant rubber.

When assembling the engine, the cylinder head bolts should be tightened in three steps in ascending order of numbers indicated on fig. Tightening Torque Sequence must be:

1 dose - up to 39-49 N.m (4-5 kgf.m);
2 reception - up to 98-127 N.m (10-13 kgf.m);
3 reception - up to 186-206 N.m (19-21 kgf.m).

Before screwing, grease the threads of the bolts with a layer of graphite grease.

After tightening the bolts, it is necessary to adjust the gaps between the valves and the rocker arms. The valve mechanism is closed by an aluminum cover 15 (see. Fig. The gas distribution mechanism). For noise insulation and sealing the joint of the cap - cylinder head, a vibration isolation washer 14 and a rubber gasket 19 were used.

Tightening Torque Sequence

Tighten the cylinder head cover bolts with a torque of 12.7-17.6 N.m (1.3-1.8 kgf.m).

The valve stems are graphitized before assembly, the working surfaces of the valve guides and valve stems are lubricated with clean diesel oil. Valve seating must be airtight. The tightness test is carried out with dry air at a pressure of 0.15 MPa. Permissible air leakage must not exceed 3.6 cm3 / min. Valves must be securely fixed with crackers.

Before installation, the cylinder head is carefully blown with compressed air from the compressor. Joints of cylinder head and liner, head and block are sealed with gaskets, b. The rings of the gas seal joint after installation in the head are crimped by a force of 4500 N. The output (protrusion) of the plane of the ring from the head after crimping should not exceed 0.08 mm. Nicks and burrs on the ledges are not allowed. Before installing the cylinder heads on the cylinder block, the plane of their mates, as well as the gaskets are blown with compressed air. The rubber o-rings of the cylinder heads are mounted flat side to the cylinder block. Each cylinder head should be free to install on pins without impacts. The threads of the cylinder head bolts are lubricated with a thin layer of graphite grease. The 6th tightening is performed evenly, in 3 steps, to exclude possible misalignment of the heads. Tightening torques should be at the 1st intake of 40-50 N * m; with the 2nd intake of 120-150 N * m, with the 3rd intake - 190-210 N * m (Fig. 13). The high-pressure fuel pump (TNVD) is installed in the collapse of the cylinder block on special surfaces.

Fig. 3. The output of the piston bottom above the thrust shoulder of the cylinder liner and the installation of liner and head seals in the block:

a - the magnitude of the output of the piston bottom above the thrust shoulder of the cylinder liner; b - seals of the liner and cylinder head in the block; I is the piston; 2 - supporting shoulder of the cylinder liner; 3 - a sealing ring of a head of cylinders; 4 - a sealing ring of a cylinder liner; 5 - cylinder head; 6 - cylinder head gasket; 7 - cylinder block; 8 - a sealing ring of the lower part of the supporting shoulder of the cylinder liner; 9 - cylinder liner

Fig. 4. Tightening the bolts of the block head:

^ 1-2-3-4 - tightening sequence

The bolts are evenly tightened in 2 steps in the sequence shown in fig. 4 a. The bolt tightening torque when installing the high-pressure fuel pump is 40-80 N * m.

To install the high-pressure fuel pump, the crankshaft is rotated to a position where the lock located on the flywheel housing will fit into the groove on the flywheel. In this case, the mark on the rear flange of the driving coupling half must be on top, which ensures the position of the piston of the first cylinder at the end of the compression stroke. After that, the injection pump is installed. To do this, the marks on the pump housing and the injection advance coupling are combined, and the pump housing is fixed.

The shaft of the driven gear of the fuel pump drive is assembled with a bearing and gear. A cracker of the drive of the sensor of the electrotachometer to a depth of (7 ± 0.2) mm is pressed into the rear end of the shaft. When pressing gears and bearings onto the shaft, the transmission of forces through the balls is not allowed. When the assembled shaft is mounted on the engine, the mark on the driven gear of the fuel pump drive is aligned with the mark on the camshaft gear, as shown in Fig. 5, after which the bearing is pressed into the front support and the rear bearing housing is installed.

Fig. 5. Placement and installation of gears of drive units:

a - placement of timing gears in the rear of the engine; b is a diagram of the installation of timing gears on labels; 1 - bolt M12X1 mounting the roller bearing; 2, 21 - intermediate gears; 3 - a bolt; 4, 17 - washers; 5 - cuff; 6 - rear bearing housing; 7 - laying; 8 - cracker; 9 - a shaft of a gear wheel of a drive of the fuel pump of a high pressure; 10 - key; 11, 15 - ball bearings; 12 - a gear wheel of a drive of the fuel pump of a high pressure; 13 - camshaft assembly with gear; 14 - persistent washer; 16 - axis; 18 - bolt M10X1; 19 - tapered double row roller bearing; 20 - key; 22 - a persistent ring; 23 - a lock ring; 24 - a leading gear wheel of a cranked shaft

After installing the fuel pump, tighten the bolts of the front flange of the fuel injection pump coupling half, connect the oil pipelines, install the nozzles, then connect the low and high pressure fuel lines, final adjustment of the fuel injection, the lock knob is installed in a small groove on the lock housing to fix the coupling on the shaft.

The valve mechanism is assembled and adjusted after lapping and checking the valves in the valve seats. The valves are adjusted at four positions of the crankshaft. The first position of the crankshaft is determined relative to the start of fuel injection in the first cylinder. The subsequent position of the crankshaft is determined by its rotation by the angle indicated in the table. 3. At each position, valve clearances of two cylinders are simultaneously adjusted in the order of operation: 1-5-4-2-6-3-7-8.

The thermal clearance is adjusted in the following order:

cylinder head covers are removed;
the cylinder head bolts are tightened in the sequence indicated;
the flywheel lock is set to the lower position; the manhole cover is removed at the bottom of the clutch housing;
a crowbar is inserted into the holes on the flywheel and the crankshaft is rotated until the latch engages with the flywheel;
the flywheel lock is installed in the upper position;
the crankshaft rotates 60 ° counterclockwise when viewed from the flywheel; the rotation of the flywheel by the angular distance between two adjacent holes corresponds to the rotation of the crankshaft by 30 °, i.e., to the first position. In this case, the valves of the 1st and 5th cylinders are closed, the valve rods are easily rotated by hand;
checked the tightening torque of the nuts of the struts of the rocker arms of the adjustable cylinders; if necessary, the nuts are tightened;
the probe checks the gap between the toes of the rocker arm with the ends of the valve rods of the 1st and 5th cylinders, as shown in Fig. 5; the probe with a thickness of 0.3 mm for the inlet and 0.4 mm for the exhaust valves must enter with force; the front valves of the right row of inlet cylinders, the left row of exhaust.

Fig. 6. Installation of a high pressure fuel pump (TNVD) on the engine:

a - the order of an inhaling of bolts of fastening of TNVD; b - installation of the injection pump clutch for fuel injection into the first cylinder of the engine; I, III, IV, II - the sequence of tightening bolts for fastening the injection pump when installing it on the engine; 1 - fuel pump housing; 2 - fuel injection timing clutch; 3 - a disk of a shaft of an injection pump drive with a comb; 4 - a shaft of a drive of the coupling of advance of injection of fuel; 5 - cover; 6 - marks dies on the disk drive shaft of the injection pump; 7 - mark on the housing of the injection advance clutch; 8 - mark on the fuel pump housing; 9, 12, 13, 15 - bolts of fastening of TNVD; 10 - section for supplying fuel to nozzles; 11 - direction of the order of tightening bolts for fastening the injection pump; 14 - a torque wrench for tightening bolts

Angles of rotation of the crankshaft relative to the position corresponding to the beginning of fuel injection in the first cylinder (to regulate the thermal clearances of the valves of the remaining cylinders), the bolts of the fuel injection pump mounting bolts are checked for tightness, and, and the position of the marks on the end of the housing of the fuel injection advance coupling, the high pressure fuel pump housing and the drive flange pump coupling halves, as shown in fig. 6b; if the risks do not coincide, the crankshaft is turned with a special key through the hole in the lower part of the flywheel housing by the flywheel by one turn until there are scratches on the disk comb of the injection pump drive shaft, while the risks must be combined;

The adjustment of the thermal gap is facilitated by the use of the I-801.14.000 device, shown in Fig. 7. At the same time, the nut of the adjustment screw loosens and is inserted into the gap of the probe. Turn the adjusting screw with a screwdriver to set the required clearance. Holding the screw with a screwdriver, the nut is tightened and the clearance is checked. Further adjustment of the clearances in the valve mechanism is made in pairs in the cylinders of the 4th and 2nd (position II), 6th and 3rd (position III), 7th and 8th (position IV), turning the crankshaft 180 ° rotation each time. The control of the correctness of the adjustment is checked on a running engine. With correctly adjusted clearances, there should be no knocking in the valve mechanism. The hatch covers of the clutch housing and cylinder heads are installed after adjustment for the intended purpose. The clearance should be: for intake valves - 0.15-0.20 mm; for exhaust valves - 0.30-0.35 mm.

3. The angles of rotation of the crankshaft relative to the position corresponding to the beginning of fuel injection in the first cylinder (to regulate the thermal clearances of the valves of the remaining cylinders)

Fig. 7. Assembling the valve actuator and adjusting the thermal gap between the valve and the pusher using a feeler gauge, key and screwdriver:

1 - adjusting screw; 2 - a lock-nut

Fig. 8. Adjustment of the thermal gap in the valve mechanism using the I-801.14.000 device:

1 - ring wrench with a wrench; 2 - screwdriver with a screwdriver; 3 - rocker adjusting screw; 4 - a lock-nut; 5 - rocker toe; 6 - plate probe; 7 - valve spring

Before adjusting, tighten the locknuts of the adjusting screws and check the clearances.

5.2 ^ Assembly and installation of gas distribution parts
Assembly and installation of the camshaft, gas distribution mechanism in the bushings, pressed into the cylinder block. Before installing in the cylinder block, the camshaft is assembled with the rear bearing housing and the camshaft. Before assembly with the bearing housing, the shaft journal and the housing sleeve are wiped with a cloth and lubricated with clean diesel oil. After preheating to a temperature of (100 + -10) ° С, the gear wheel is pressed onto the shaft journal as far as it will go. The clearance between the gear and the bearing housing should be 0.25-0.30 mm.

The camshaft assembly is shown in fig. 9.

Before installing the camshaft in the cylinder block, the inner surface of the support sleeves and the camshaft support necks are lubricated with clean diesel oil. The camshaft is installed neatly without damaging the working surfaces of the bushings.

Installation of parts of the timing mechanism, transmitting forces from the camshaft to the rocker arms. Pusher guides complete with pushers are mounted on the pins of the cylinder block and bolted to the block. The bolts are tightened with a tightening torque of 70-90 N * m.

The rods are wiped before installation in the cylinder block, and the tips are lubricated with clean diesel oil. The rack with rocker arms assembly should easily enter the mounting pins and studs without impact. The rocker arms are set so that the scope of the adjusting screw is aligned with the tip of the rod. The adjusting screws must be screwed into the rocker arm as far as it will go.

Fig. 9. Camshaft assembly:

^ 1 - camshaft; 2 - bearing housing; 3 - distribution gear; 4 - key; 5 - bearing

Tightening the nuts and fastening the strut with the rocker arms assembly is carried out with a tightening torque of 40-60 N * m, after which the gap between the toe of the rocker arm and the end of the valve is adjusted.

5.3 ^ Assembly and installation of the oil pump and oil pan
The oil pump, before being installed on the engine, is assembled with the driven gear of the oil pump drive, with a suction tube and a valve tube of the lubrication system. The bolts of the flanges of the tubes of the oil pump and the bolts of the oil pump are tightened in two steps (tightening torque 50-60 N * m).

After installing the oil pump, the lower part of the crankcase is closed by a sump.

Installing the front cover of the cylinder block, manifolds and pipelines.

The front cover of the cylinder block is mounted on the block assembly with the fluid coupling of the fan drive and the alternator drive pulley. Before that, a power coupling half and a crankshaft washer are put on the crankshaft. The hydraulic coupling drive shaft is introduced into the power take-off coupling. The cover bolts are tightened with a tightening torque of 50-60 N * m.

The intake and exhaust manifolds and water pipes of the cooling system are thoroughly blown with compressed air before installation on the engine. Tightening the bolts of their fastening is carried out sequentially in 2 stages (preliminary and final).

5.4 ^ Assembling the crankshaft and installing it in the cylinder block
The crankshaft is blown with compressed air before assembly.

The crankshaft is assembled in the following sequence. In the cavity of the oil channels of the necks are installed centrifugal oil treatment bushings. From above the channels are pressed with plugs. After that, gears and balances are pressed onto the crankshaft. The gear of the oil pump drive and the front remote counterweight are installed on the toe of the crankshaft, on the shank - the distribution gear assembly with the oil deflector and the rear remote counterweight. Gears and balances on the crankshaft are pressed during assembly. Before pressing, they are heated to a temperature of 105 ° C. The pinion is pressed into the shaft shoulder until it stops. The assembled crankshaft is shown in fig. 10.

Before installing the crankshaft in the cylinder block, it is balanced dynamically relative to the axis of the extreme root journals on the balancing machine. Before balancing, a load weighing (8525 ± 1) is installed on each neck. The centers of gravity of the loads must coincide with the axles of the connecting rod necks. Permissible imbalance should not exceed 80 g. The imbalance is eliminated by removing metal by drilling in counterweights made in one piece with the shaft.

Immediately before installing the crankshaft in the block, the working surface of the main bearing shells and the main shaft journals are lubricated with clean diesel oil. The dimensions of the main bearing shells must correspond to the dimensions of the crankshaft necks and the seats in the cylinder block. Thrust half rings of the shaft are installed in the undercut of the last main bearing so that the sides with grooves are adjacent to the thrust ends of the shaft. The bolts of the main bearing caps are pre-tightened from the right and then from the left rows of cylinders with a tightening torque of 90-120 N * m, and then finally with a tightening torque of 210-235 N * m.

The tightening of the connecting rod bolts is controlled by their elongation. The extension of the connecting rod bolts after tightening the bearings should be 0.25-0.27 mm.

Fig. 10. Crankshaft assembly:

1 - front end of the crankshaft; 2 - key; 3.6 - counterweights; 4 - gear wheel drive oil pump; 5 - a stub; 7 - distribution gear; 8 - oil deflector; 9 - an adjusting pin; 10 - key

When the bearings are assembled correctly, the crankshaft must rotate freely from the effort of the hand applied to the flywheel mounting pins. The axial clearance in the thrust bearing should be 0.05-0.20 mm.

Tightening the head bolts on the KAMAZ. Transport: history and modernity

Popular articles

Latest Articles

Sections

Pages

Special Projects

Contacts