SV470-SV620 Service Manual
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Engine Components and Filters: Damage Profiles, Probable Causes and Prevention
ENGINE COMPONENTS AND FILTERS: DAMAGE PROFILES, PROBABLE CAUSES AND PREVENTION Technical Information AFTERMARKET Contents 1 Introduction 5 2 General topics 6 2.1 Engine wear caused by contamination 6 2.2 Fuel flooding 8 2.3 Hydraulic lock 10 2.4 Increased oil consumption 12 3 Top of the piston and piston ring belt 14 3.1 Hole burned through the top of the piston in gasoline and diesel engines 14 3.2 Melting at the top of the piston and the top land of a gasoline engine 16 3.3 Melting at the top of the piston and the top land of a diesel engine 18 3.4 Broken piston ring lands 20 3.5 Valve impacts at the top of the piston and piston hammering at the cylinder head 22 3.6 Cracks in the top of the piston 24 4 Piston skirt 26 4.1 Piston seizure on the thrust and opposite side (piston skirt area only) 26 4.2 Piston seizure on one side of the piston skirt 27 4.3 Diagonal piston seizure next to the pin bore 28 4.4 Asymmetrical wear pattern on the piston skirt 30 4.5 Piston seizure in the lower piston skirt area only 31 4.6 Heavy wear at the piston skirt with a rough, matte surface 32 4.7 Wear marks on one side of the piston skirt 33 5 Support – piston pin bushing 34 5.1 Seizure in the pin bore 34 5.2 Cratered piston wall in the pin boss area 35 6 Piston rings 36 6.1 Piston rings with burn marks and seizure marks on the 36 piston skirt 6.2 Damage to the ring belt due to fractured piston rings 37 6.3 Heavy wear of the piston ring grooves and piston rings 38 6.4 Heavy radial wear of the piston rings 39 7 Cylinder liners 40 7.1 Pitting on the outer -
TR3-TR3B Supercharger Installation Instructions for TR3 from TS13052E Through TR3B ("High Port" TR3’S) PART# 150-128, 150-130 440 Rutherford St
TR3-TR3B Supercharger Installation Instructions For TR3 from TS13052E through TR3B ("High port" TR3’s) PART# 150-128, 150-130 440 Rutherford St. Goleta, CA 93117 1-800-642-8295 • FAX 805-692-2525 • www.MossMiata.com Tools required: The vehicle shown in most of the illustrations is a Triumph TR3 with a steering rack conversion and an electric fan • TR3 Shop manual conversion. Although the instructional photographs may differ from your specific application, they are adequate to • Strap Wrench provide you with the information you need to complete a • Timing light successful installation of this product. Focus on the parts that are similar, rather than focus on the differences. • Thread sealer or Teflon tape • Phillips screwdrivers Note that the fuel lines will be replaced as part of the installation and that the tank will need to be filled with • Flat-blade screwdrivers at least 91-octane fuel before the car is started. For • Torque wrench up to 65 ft-lbs maximum safety drain the tank before starting the installation process. • 3/16" Allen wrench • Hack saw or cut-off wheel Warning: Never smoke or work around open flames. • Wire cutters, strippers and crimpers If your car is + (positive) ground (earth), we will be • Side cutters (dikes) converting it to – (negative) ground (earth) during this installation. You must follow the extra steps detailed • 1/4", 3/8", & 1/2" ratchets in the back of these instructions regarding the proper • 3" and 6" extensions for above ratchets procedure to convert the subject vehicle to negative ground. • Combination wrenches and sockets in the following sizes: Note: For maximum performance and to prevent • 7mm, 8mm, 10mm, 12mm, 13mm, 17mm premature failure, your engine should be in good mechanical condition and been recently tuned. -
Finite Element Analysis of a Car Rocker Arm
Proceedings of the 2015 International Conference on Operations Excellence and Service Engineering Orlando, Florida, USA, September 10-11, 2015 Finite element analysis of a car rocker arm Tawanda Mushiri D.Eng. Student; University of Johannesburg, Department of Mechanical Engineering, P. O. Box 524, Auckland Park 2006, South Africa. [email protected] Lecturer; University of Zimbabwe, Department of Mechanical Engineering, P.O Box MP167, Mt Pleasant, Harare Charles Mbohwa Professor and Supervisor; University of Johannesburg, Auckland Park Bunting Road Campus, P. O. Box 524, Auckland Park 2006, Room C Green 5, Department of Quality and Operations Management, Johannesburg, South Africa. [email protected] Abstract High Density Polyethylene (HDPE) composite rocker arm has been considered for analysis owing to its light weight, higher strength and good frictional characteristics. A 3-D finite element analysis was carried out to find out the maximum stresses developed in the rocker arms made of steel and composite. From the results it was noted that almost same stresses are developed for both the materials (steel and the composite). With this it may be concluded that the stresses developed in the composite is well within the limits without failure. Therefore the proposed composite may be considered as an alternate material for steel to be used as rocker arm. Keywords High Density Polyethylene (HDPE), Rocker arm, finite element, modelling, simulation, steel, composite 1.0: Introduction A rocker arm is an oscillating lever that conveys radial movement from the cam lobe into linear movement at the poppet valve to open it. One end is raised and lowered by a rotating lobe of the camshaft (either directly or via a tappet (lifter) and pushrod) while the other end acts on the valve stem. -
Dynamic Analysis of Crankcase and Crankshaft
International Engineering Research Journal Page No 1531-1541 Dynamic Analysis of Crankcase and Crankshaft Gouthami S. Tulasi, Post Graduate Student, Department of Mechanical Engineering, RSCOE JSPM Pune, S. M. Jadhao, Assistant Professor, Department of Mechanical Engineering, RSCOE JSPM Pune for any crank radius, connecting rod geometry, and connecting Abstract—An agricultural single cylinder four stroke engine rod mass, connecting rod inertia, engine speed, engine experienced failure at customer location. This had to be taken acceleration, piston diameter, piston and pin mass, pressure care of immediately as it had affected the engine sales. To inside cylinder diagram, and any other variables of the engine. investigate the reason for failure various conventional methods were employed which include static analysis, but as static These equations are derived in Appendix I. The equations analysis could not explain the appropriate cause, dynamic provided the values of velocity and acceleration of the piston [5] analysis was considered. The process was divided into two stages and forces at the connecting rod crankshaft bearing . It first being determination of gas force, inertia force, bending force should be pointed out that in this analysis it was assumed that and torsional force through extensive excel sheet calculations the crankshaft rotates at a constant angular velocity, which considering the engine to be a single degree of freedom slider- means the angular acceleration was not included in the crank mechanism. The loads acting on the engine for varied [4] crankshaft angles were thus determined. A plot of these loads analysis . was presented to define the characteristics of the engine. For stage two a unique methodology known as superposition theory II. -
11. Crankcase/Crankshaft People/People S 250
11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 11 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CRANKCASE/CRANKSHAFT ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 11-1 SERVICE INFORMATION----------------------------------------------------------------------- 11-2 TROUBLESHOOTING --------------------------------------------------------------------------- 11-2 CRANKCASE SEPARATION------------------------------------------------------------------- 11-3 CRANKSHAFT INSPECTION ------------------------------------------------------------------ 11-4 CRANKCASE ASSEMBLY---------------------------------------------------------------------- 11-5 11 11-0 11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 SCHEMATIC DRAWING 11-1 11. CRANKCASE/CRANKSHAFT PEOPLE/PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces. • When installing -
Poppet Valve
POPPET VALVE A poppet valve is a valve consisting of a hole, usually round or oval, and a tapered plug, usually a disk shape on the end of a shaft also called a valve stem. The shaft guides the plug portion by sliding through a valve guide. In most applications a pressure differential helps to seal the valve and in some applications also open it. Other types Presta and Schrader valves used on tires are examples of poppet valves. The Presta valve has no spring and relies on a pressure differential for opening and closing while being inflated. Uses Poppet valves are used in most piston engines to open and close the intake and exhaust ports. Poppet valves are also used in many industrial process from controlling the flow of rocket fuel to controlling the flow of milk[[1]]. The poppet valve was also used in a limited fashion in steam engines, particularly steam locomotives. Most steam locomotives used slide valves or piston valves, but these designs, although mechanically simpler and very rugged, were significantly less efficient than the poppet valve. A number of designs of locomotive poppet valve system were tried, the most popular being the Italian Caprotti valve gear[[2]], the British Caprotti valve gear[[3]] (an improvement of the Italian one), the German Lentz rotary-cam valve gear, and two American versions by Franklin, their oscillating-cam valve gear and rotary-cam valve gear. They were used with some success, but they were less ruggedly reliable than traditional valve gear and did not see widespread adoption. In internal combustion engine poppet valve The valve is usually a flat disk of metal with a long rod known as the valve stem out one end. -
Installation Instructions Cloyes® 3-Keyway Crank Sprockets
February 2, 2009 Installation Instructions Cloyes ® 3-Keyway Crank Sprockets The Cloyes® Patented 3-Keyway crank sprocket allows adjustment of the crankshaft timing by ± 4°. Remember: The camshaft angle is half of the crankshaft angle, therefore the camshaft will correspondingly advance or retard by ± 2°. By changing the cam timing, enhancements to the camshaft characteristics can be achieved. For example, retarding the cam timing will increase high RPM horsepower, and advancing the cam timing will increase low-end torque. The following examples illustrate which timing mark is used with its corresponding keyway: GM and Chrysler Ford Retard keyway To retard the camshaft timing, use the timing mark on the crank sprocket and the retard keyway shown above. GM and Chrysler Ford Factory keyway For factory specified timing, use the Ο timing mark on the crank sprocket and the factory keyway shown above. GM and Chrysler Ford Advance keyway To advance the camshaft timing, use the ∆ timing mark on the crank sprocket and the advance keyway shown above. Notes: After determining which setting to use, we advise marking (with white marker or similar) the corresponding timing mark and keyway. This will make them easier to identify during installation. Some high performance camshafts are ground with advance or retard built in. In this case the cam manufacturer intends the cam to be set at the factory specified timing. Also, during and after installation, observe for any interference between the timing set and engine block. If interference is found, remove or grind that area of the block so adequate clearance is obtained. When removing a press fit crank sprocket, a proper pulling tool should be used. -
Vvt Solenoid
PROGRAM SPOTLIGHT VVT SOLENOID What does a Variable Valve Timing Solenoid do? The Variable Valve Timing Solenoid (VVTS) controls the oil flow to control the action of the Sprocket, which shifts the position of the camshaft. The position is varied based on the car’s computer commands to increase or decrease the engine’s valve timing. Where are Variable Valve Timing Solenoids located? The VVTS are usually located on or around the cylinder head block. Will a malfunctioning Variable Valve Timing Solenoid illuminate the check engine light or affect vehicle operation? Yes, a malfunctioning VVTS may cause the check engine light to be illuminated and may trigger multiple codes. What are the common causes of failure? VVTS can fail due to low engine oil levels, clogs due to oil sludge, and/or irregularly changed engine oil and filters. How to determine if Variable Valve Timing Solenoids are malfunctioning: Possible indications of a malfunctioning or failed VVTS include: an illuminated check engine light, engine noise and/or stalling, rough idling, and general poor performance. What makes Holstein Variable Valve Timing Solenoids the best? • Holstein focuses on using only the highest quality materials, manufactured to exacting standards for an aftermarket product that is truly built to match or exceed the OE part • Holstein Variable Valve Position Sensor line has superior coverage for domestic and import applications • Designed to maximize engine performance and fuel efficiency • 3 Year / 36,000 Mile Warranty on all Holstein Parts VVT Sensors HOLSTEINPARTS.COM | 1-800-893-8299. -
Locomotive Troubleshooting
Locomotive Troubleshooting Celebrating the legacy of the Feather River Route Paul Finnegan www.wplives.org Last revised 03/23/18 0 Introduction This section covers operational problems that may occur on the road and suggests action that may be taken by the operator in response to the trouble. Safety devices automatically protect equipment in case of faulty operation of almost any component. In general this protection is obtained by one of the following methods: 1. Complete shutdown of the diesel engine. 2. Unloading of the diesel engine. 3. Unloading of the diesel engine and restriction to idle engine speed. 1 Condition/Probable Cause/Action - 1 Hot engine light and Temporary Operating Check cooling water alarm Condition level. Check that shutters are open and fan is operating. Hot engine light and Low water Level Check cooling water alarm followed by low oil level, and check low light and engine water detector and shutdown governor low oil trip plunger for trip indications. If cooling water level is low, check for leaks. Add water as required. Reset the governor low oil pressure trip plunger and the low water reset button. 2 Condition/Probable Cause/Action - 2 Low oil light and alarm. Engine Low oil pressure. Check the governor low oil trip shut down. plunger and engine oil level. If oil level is satisfactory and no other reason for low oil trip is apparent (engine is not over- heated, and the crankcase pressure and low water trip buttons are set) restart the engine. If low oil shutdown occurs again, do not restart the engine. -
DEUTZ Pose Also Implies Compliance with the Con- Original Parts Is Prescribed
Operation Manual 914 Safety guidelines / Accident prevention ● Please read and observe the information given in this Operation Manual. This will ● Unauthorized engine modifications will in- enable you to avoid accidents, preserve the validate any liability claims against the manu- manufacturer’s warranty and maintain the facturer for resultant damage. engine in peak operating condition. Manipulations of the injection and regulating system may also influence the performance ● This engine has been built exclusively for of the engine, and its emissions. Adherence the application specified in the scope of to legislation on pollution cannot be guaran- supply, as described by the equipment manu- teed under such conditions. facturer and is to be used only for the intended purpose. Any use exceeding that ● Do not change, convert or adjust the cooling scope is considered to be contrary to the air intake area to the blower. intended purpose. The manufacturer will The manufacturer shall not be held respon- not assume responsibility for any damage sible for any damage which results from resulting therefrom. The risks involved are such work. to be borne solely by the user. ● When carrying out maintenance/repair op- ● Use in accordance with the intended pur- erations on the engine, the use of DEUTZ pose also implies compliance with the con- original parts is prescribed. These are spe- ditions laid down by the manufacturer for cially designed for your engine and guaran- operation, maintenance and servicing. The tee perfect operation. engine should only be operated by person- Non-compliance results in the expiry of the nel trained in its use and the hazards in- warranty! volved. -
2-Stroke Scavenging in Conventional and Minimally-Modified 4-Stroke
inventions Article 2-Stroke Scavenging in Conventional and Minimally-Modified 4-Stroke Engines for Heavy Duty Applications at Low to Medium Speeds Dirk Rueter Institute of Measurement and Sensor Technology, University of Applied Sciences Ruhr-West, D-45479 Muelheim an der Ruhr, Germany; [email protected] Received: 14 June 2019; Accepted: 7 August 2019; Published: 9 August 2019 Abstract: The transformation of a standard 4-stroke cylinder head into a torque-improved and gradually more efficient 2-stroke design is discussed. The concept with an effective loop scavenging via an extended inlet valve holds promise for engines at low- to medium-rotational speeds for typical designs of conventional 4-stroke cylinder heads. Calculations, flow simulations, and visualizations of experimental flows in relevant geometries and time scales indicate feasibility, followed by a small engine demonstration. Based on presumably long-forgotten and outdated patents, and the central topic of this contribution, an additional jockey rides on the inlet valve’s disk (facing away from the combustion chamber) and reshapes the in-cylinder flow into a reverted tumble. A quick gas exchange with a well-suppressed shortcut into the open exhaust is approached. For overall mechanical efficiency, the required charge pressure for scavenging is of paramount importance due to the short scavenging time and the intake’s reduced cross-section. Herein, still acceptable charging pressures are reported for scavenging periods equivalent to low or medium rotational speeds, as characteristic for heavy-duty applications. Using widely available components (charger, direct injection, variable camshaft angles) an increased engine efficiency is suggested due to the 2-stroke’s downsizing effect (relatively less internal friction as well as the promise of more torque and a decreased size). -
Ins 151 VW Timing Belt How to TDI BEW(PD)
PLEASEREAD THEFOLLOWING BULLETINBEFORE CONTINUING WITH YOUR TIMING BELT REPLACEMENT Bulletin: PreventPremature Water PumpFailure! BLAUfergnugen!Inc.recommendsthatan Audi VwFactory Trained ASECertified Technicianinstallyourparts toensureyoursafety. AlwaysreadRobertBentleyfactoryservicemanualsafetyinstructionsandguidelines. ALWAYS WEARSAFETY GLASSES ANDOTHERSAFETY ITEMS WHENPERFORMING THEFOLLOWING WORK! InstallersResponsibility: Blaupartsrecommendsthatinstallerstakethenecessarytimetothoroughlyfollowthestepsoutlinedinthisbulletintopreventfuturelabor costs,aswellasanyinconvenienceaftertheinstallationofthewaterpumpincludedinthistimingbeltkit.Ithasbeennotedthatduetotime constraints,inconvenience,andprofit,manyindividualsandmechanicsalike,donottaketheextratimeneededtothoroughlyflushtheentire vehiclecoolingsystempriortotheinstallationofthenewwaterpump.Justdrainingthecoolingsystemandrefillingthesystemisnotenough! Prematurewaterpumpfailure(waterpumpsealsandbearings)canoccurbecauseoffailingtotakethetimetoflushtheentirecoolingsystem anditsrelatedcomponents.Oftenwhenproblemsarise,suchasacoolantleak,thenewwaterpumpisblamedasthecausewheninfactthe oppositeistrue.Itisusuallybecausetheinstallerhasneglectedtofollowthesestepslistedbelow. FlushingtheCoolingSystem: Itisimperativethatthecoolingsystembethoroughlyflushedofallaccumulatedsiltandsedimentbuildup,includingallaftermarketcooling systemadditives,orstopleakproductsthatmayhavebeenaddedtothecoolingsystem,pastorpresent. Thiswouldentailflushingtheradiator, engineblock,heatercoreandhosesetc.UseOnlyTap Water