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XII Cylinder Block and PistonСодержание книги
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Preparatory data 12.1 Fault diagnosis 12.2 Cylinder block 12.3 Piston 12.4 Preparatory Data Function of cylinder block: Cylinder block provides the space for gas compression, combustion and expansion and guides piston movement. It also transfers part of heat in the cylinder to surrounding coolant. Function of piston: 1. Piston can bear the pressure generated by combustion of mixed combustible gas in the cylinder and transmit the pressure to connecting rod to drive crankshaft to rotate. 2. It forms a combustion chamber with cylinder head. Precautions on Operation All the components shall be cleaned before inspection and test, and purged with high-pressure air. Table of standard values of baseline projects and allowable limit
Fault Diagnosis Low compression pressure White smoke from exhaust pipe Worn, burnt or broken piston Worn or damaged piston ring Work or damaged cylinder and piston Worn or damaged cylinder and piston Broken washer, air leakage between crankcase and gas Higher compression pressure Noisy piston Too much carbon deposited in the combustion chamber Damaged cylinder, piston and piston ring Worn piston pin hole and piston pin 12.3 Cylinder Head Removal Remove cylinder block Inspection Inspect wear of cylinder inner wall. If it is seriously worn, replace it.
Remove washer and location pin.
Piston Removal Remove piston pin retainer. Attention: Please do not drop the retainer into crankcase during removal. Take out piston pin and remove piston. Remove piston ring. Inspect piston, piston pin and piston ring. Attention: Please do not break or hurt piston ring. Remove deposited carbon inside the piston ring.
Install the piston ring. Measure the clearance between piston ring and piston ring groove. Allowable limit: First ring: 0.12 mm Second ring: 0.12 mm
Remove piston ring and install all the piston rings onto bottom of cylinder. Attention: Compress piston rings into the cylinder with piston head. Measure the joint clearance between piston rings. Allowable limit: First ring: 0.4 mm Second ring: 0.5 mm
Measure piston pin hole ID. Allowable limit: ¦µ15.04 mm
Measure piston pin OD. Allowable limit: §¶14.976mm Measure the clearance between piston pin hole and piston pin. Allowable limit: 0.064mm
Measure piston OD
Attention: Measuring position forms a 90Ўг angle with piston pin, about 11mm below piston skirt.
Allowable limit: ¦µ59.93mm Inspect wear and scratch on inner wall of cylinder.
Attention: Measure cylinder ID at three positions, i.e. upper, intermediate and lower positions. The position forms a 90Ўг angle with piston pin. Allowable limit: ¦µ60.063mm Measure the clearance between cylinder and piston. Take the maximum clearance as standard. Allowable limit: 0.07mm
Measure the roundness of cylinder inner wall (internal diameter difference between X direction and Y direction). Allowable limit: 0.01mm Measure the cylindricity of inner wall of cylinder (internal diameter difference of three positions (upper, intermediate and lower) along X direction or Y direction).
Allowable limit: 0.01mm
Check flatness of cylinder surface. Allowable limit: 0.05mm
Measure Connecting rod small end ID. Allowable limit: ¦µ15.068mm
Installation of piston Install location pin. Apply engine oil evenly on each piston ring and piston. Install piston to its place with bevel upward. Attention: Piston shall not be scratched and piston ring shall not be broken. When the piston ring is installed, it can rotate freely in the piston ring groove.
Scrape the washer attached to the crankcase. Attention: No foreign matters can be dropped into the crankcase. Install piston, piston pin and piston pin retainer. Attention: The larger side of the groove at the piston head should be installed towards the intake valve.
Install Cylinder Install washer and location pin onto the crankcase. Apply evenly engine oil on inner wall of cylinder, piston and piston ring. Install carefully the piston ring into the cylinder. Attention: Do not hurt piston ring. XIII Crankcase Preparatory data 13.1 Fault diagnosis 13.2 Crankcase 13.3 Clutch 13.4 Gearshift mechanism 13.5 Bent axle connecting rod assembly 13.6 Variable speed chamber 13.7 Preparatory Data Function of crankcase: Crankcase is the force bearing part of engine. It is mainly used to support crankshaft, clutch, transmission, cylinder block and cylinder head. It bears impact from combustion and inertia force from movement of crankshaft connecting rod; and forms a partial enclosed space (for air and oil). Suspension hole is set on the crankcase, which can be connected with the suspension hole in the vehicle block so that the engine can be linked together with frame and other parts.
Precautions on Operation: Crankcase is a thin-wall casting part. Avoid impact on it during operation in case it may be distorted or broken. Clean carefully all the components before inspection and test and purge them with high-pressure gas. Drain the lubricating oil from crankcase before working on it. Table of standard values of baseline projects and allowable limit Unit: mm
Fault Diagnosis Low compression pressure Crankcase air leakage Engine overheat Clutch clipping Poor lubrication Failure in gear Gear shift fork broken or deformation Shifting fork guide pin broken Wheel gear convex claw worn Auto-off gear The joint claw is worn with the edge into a fillet. Force of return spring of the speed shifting mechanism is weakened. The spline tooth of spline shaft and the spline groove of sliding gear are worn, resulting a greater axial force in the gear while working. Gearshift hub and shifting fork are worn.
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