Item Description Engine Model 211249L Turbocharger
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SV470-SV620 Service Manual
SV470-SV620 Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. 2 Safety 3 Maintenance 5 Specifi cations 13 Tools and Aids 16 Troubleshooting 20 Air Cleaner/Intake 21 Fuel System 31 Governor System 33 Lubrication System 35 Electrical System 44 Starter System 47 Emission Compliant Systems 50 Disassembly/Inspection and Service 63 Reassembly 20 690 01 Rev. F KohlerEngines.com 1 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING WARNING CAUTION Explosive Fuel can cause Accidental Starts can Electrical Shock can fi res and severe burns. cause severe injury or cause injury. Do not fi ll fuel tank while death. Do not touch wires while engine is hot or running. Disconnect and ground engine is running. Gasoline is extremely fl ammable spark plug lead(s) before and its vapors can explode if servicing. CAUTION ignited. Store gasoline only in approved containers, in well Before working on engine or Damaging Crankshaft ventilated, unoccupied buildings, equipment, disable engine as and Flywheel can cause away from sparks or fl ames. follows: 1) Disconnect spark plug personal injury. Spilled fuel could ignite if it comes lead(s). 2) Disconnect negative (–) in contact with hot parts or sparks battery cable from battery. -
The Starting System Includes the Battery, Starter Motor, Solenoid, Ignition Switch and in Some Cases, a Starter Relay
UNIT II STARTING SYSTEM &CHARGING SYSTEM The starting system: The starting system includes the battery, starter motor, solenoid, ignition switch and in some cases, a starter relay. An inhibitor or a neutral safety switch is included in the starting system circuit to prevent the vehicle from being started while in gear. When the ignition key is turned to the start position, current flows and energizes the starter's solenoid coil. The energized coil becomes an electromagnet which pulls the plunger into the coil. The plunger closes a set of contacts which allow high current to reach the starter motor. The charging system: The charging system consists of an alternator (generator), drive belt, battery, voltage regulator and the associated wiring. The charging system, like the starting system is a series circuit with the battery wired in parallel. After the engine is started and running, the alternator takes over as the source of power and the battery then becomes part of the load on the charging system. The alternator, which is driven by the belt, consists of a rotating coil of laminated wire called the rotor. Surrounding the rotor are more coils of laminated wire that remain stationary (called stator) just inside the alternator case. When current is passed through the rotor via the slip rings and brushes, the rotor becomes a rotating magnet having a magnetic field. When a magnetic field passes through a conductor (the stator), alternating current (A/C) is generated. This A/C current is rectified, turned into direct current (D/C), by the diodes located within the alternator. -
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. -
Development of Two-Stage Electric Turbocharging System for Automobiles
Mitsubishi Heavy Industries Technical Review Vol. 52 No. 1 (March 2015) 71 Development of Two-stage Electric Turbocharging system for Automobiles BYEONGIL AN*1 NAOMICHI SHIBATA*2 HIROSHI SUZUKI*3 MOTOKI EBISU*1 Engine downsizing using supercharging is progressing to cope with tightening global environmental regulations. In addition, further improvement in fuel consumption is expected with such applications as ultra-high EGR, Miller cycle, and lean combustion. Mitsubishi Heavy Industries, Ltd. (MHI) has developed a two-stage electric turbocharging system to balance better drivability and improved fuel consumption by increasing the turbocharging pressure and improving the transient response. |1. Introduction Engine downsizing/downspeeding through supercharging is progressing to cope with annually enhanced improvement in fuel consumption and exhaust gas. Downsizing through direct injection and supercharging has been developed mainly in European countries where the CO2 regulations are the most stringent, and it has expedited the increase of the turbocharger installation rate in other areas. Diesel vehicles are supposed to satisfy the CO2 and exhaust gas regulation standards in 2021. However, gasoline vehicles are still not able to meet the standards even in the case of low-fuel consumption vehicles with supercharged downsizing, and further measures are required. The adoption of WLTC (Worldwide harmonized Light duty driving Test Cycle) is planned globally in and after 2017, and new regulations taking actual driving conditions into consideration are being discussed. Turbochargers are required to provide a further boost pressure and better response, as well as robust and easy to operate characteristics, for this purpose. Existing turbochargers have a time-lag and EGR response delay, and proper control is difficult. -
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. -
Starters & Alternators
Starters & Alternators Technical Manual www.denso-am.eu n UK & IE n RU n DACH n Eastern Europe n Export n Iberia, France, Italy DENSO Europe B.V. After Market and Industrial Solutions Business Unit Sales Representation European Headquarters Albania Hungary Portugal Weesp, Netherlands Austria Ireland Romania Belarus Israel Russia (Moscow) Belgium Italy Russia (Novosibirsk) Distribution warehouses Bosnia and Herzegovina Kaliningrad Slovakia Bulgaria Kazakhstan Slovenia Gennevilliers, France Cyprus Latvia Spain Leipzig, Germany Czech Republic Lithuania Sweden Madrid, Spain Denmark Luxembourg Switzerland Milton Keynes, UK Estonia Macedonia Turkey Moscow, Russia Finland Moldova United Kingdom Polrino, Italy France Montenegro Ukraine Weesp, Netherlands Georgia Netherlands Germany Norway Greece Poland DENSO Starters & Alternators Table of Content DENSO in Europe > The Aftermarket Originals 04 Introduction > About This Publication 04 > Product Range 05 PART 1 – DENSO Starters PART 2 – DENSO Alternators Characteristics Characteristics > System outline 08 > System outline 42 > How Starters work 09 > How Alternators work 43 Types Types > Pinion Shift Type 11 > Conventional Type 45 > Reduction Type 14 > Type III 46 > Planetary Type 17 > SC Type 47 Wall Chart 21 Wall Chart 53 Stop & Start Technology 22 Replacement Guide 54 Replacement Guide 28 Troubleshooting > Diagnostic Chart 55 Troubleshooting > Inspection 56 > Diagnostic Chart 29 > Q&A 58 > Inspection 30 > Q&A 37 Edition: 1, date of publication: August 2016 All rights reserved by DENSO EUROPE B.V. This document may not be reproduced or copied, in Edition: 2, date of publication: October 2016 whole or in part, without the written permission of the publisher. DENSO EUROPE B.V. reserves Editorial dept, staff: DNEU AMIS Technical Service, K. -
Diesel Engine Starting Systems Are As Follows: a Diesel Engine Needs to Rotate Between 150 and 250 Rpm
chapter 7 DIESEL ENGINE STARTING SYSTEMS LEARNING OBJECTIVES KEY TERMS After reading this chapter, the student should Armature 220 Hold in 240 be able to: Field coil 220 Starter interlock 234 1. Identify all main components of a diesel engine Brushes 220 Starter relay 225 starting system Commutator 223 Disconnect switch 237 2. Describe the similarities and differences Pull in 240 between air, hydraulic, and electric starting systems 3. Identify all main components of an electric starter motor assembly 4. Describe how electrical current flows through an electric starter motor 5. Explain the purpose of starting systems interlocks 6. Identify the main components of a pneumatic starting system 7. Identify the main components of a hydraulic starting system 8. Describe a step-by-step diagnostic procedure for a slow cranking problem 9. Describe a step-by-step diagnostic procedure for a no crank problem 10. Explain how to test for excessive voltage drop in a starter circuit 216 M07_HEAR3623_01_SE_C07.indd 216 07/01/15 8:26 PM INTRODUCTION able to get the job done. Many large diesel engines will use a 24V starting system for even greater cranking power. ● SEE FIGURE 7–2 for a typical arrangement of a heavy-duty electric SAFETY FIRST Some specific safety concerns related to starter on a diesel engine. diesel engine starting systems are as follows: A diesel engine needs to rotate between 150 and 250 rpm ■ Battery explosion risk to start. The purpose of the starting system is to provide the torque needed to achieve the necessary minimum cranking ■ Burns from high current flow through battery cables speed. -
ELECTROMAGNETIC OSCILLATING ENGINE Prof.S V Deshpande ¹,Vishal Navanath Wadavkar², Vikas Vilas Sawant³, Kishor Kundalik Satpute4, Ganesh Bhagwan Pise5 1 Asst
ELECTROMAGNETIC OSCILLATING ENGINE Prof.S V Deshpande ¹,Vishal Navanath Wadavkar², Vikas Vilas Sawant³, Kishor Kundalik Satpute4, Ganesh Bhagwan Pise5 1 2,3,4,5 Asst. Professor, Student, Dept.of Mechanical Engg, GSMCOE, Balewadi, Pune (India) ABSTRACT An electromagnetic oscillating engine by using rocker crank mechanism is capable to produce mechanical power from oscillating motion of rocker (arm). The rocker crank mechanisms are mainly used for converting circular motion into reciprocating or oscillating motion of rocker (arm), but here we use rocker crank mechanism for converting oscillating motion of rocker (arm) into rotary motion crank. The present engine runs by using principle of magnetic repulsion between same poles. The present electromagnetic engine in which crank having 3600 rotation in order to forward and backward motion of rocker from its fix position. This mechanism is entirely different from the IC engine mechanism. It requires less component compared to IC engines or recently developed electromagnetic engines, that’s reason it having less weight and high power output. The present engine consist two electromagnets and one permanent magnet (block or disc shape). The engine provided with the cylinder which made up of magnetic shielding materials or ceramic. The present engine by using rocker crank mechanism is design in such way that time taken to complete forward stroke is more than the time taken to complete return stroke. The rocker (arm) allow to swing left dead center to right dead center or right dead center to left dead center with help of bearing support. The permanent magnet is fixed at topmost position of rocker; also electromagnets are screwed to left and right side of cylinder instead of placing at cylinder head. -
Technical Instructions for Assembled & Bare Head Part Numbers
Technical instructions for assembled & bare head part numbers: 014150 I-038 Bare head, 23°valve angle, 220cc intake runner, 64cc chamber, angle plug 014150 - 1 Assembled head, for Hydraulic flat tappet camshaft 014150 - 2 Assembled head, for Mechanical flat tappet or hydraulic roller camshaft 014150 - 3 Assembled head, for Solid roller camshaft 014250 I-038 Bare head, 23°valve angle, 220cc intake runner, 64cc chamber, straight plug 014250 - 1 Assembled head, for Hydraulic flat tappet camshaft 014250 - 2 Assembled head, for Mechanical flat tappet or hydraulic roller camshaft 014250 - 3 Assembled head, for Solid roller camshaft Specifications: Intake Runners: 220cc Port Dimension: 2.140” x 1.220” Exhaust Runners: 70cc Port Dimension: 1.440” x 1.410” Combustion Chamber Volume: 64cc Port Dimension: 1.440” x 1.400” Valve Guides: Integral cast iron guide Valve Guide Spacing: Ctr-Ctr 1.900” (Intake stock location / Exhaust is moved .040”) Valve Seats: Intake = integral cast iron seat, Exhaust = Durabond Powdered metal seat .006” press fit Valve Seat Dimension: Exhaust = O.D. 1.650” x 1.280 x .375” Valve Seat Angles: Intake = 38°-(45°(.040”))-60°-75° Exhaust = 38°(45°(.060))-.500radius NOTE: Hardened pushrods MUST be used with guideplates. The plates MUST be adjusted to obtain proper rocker/ valve tip alignment. Pushrods: To obtain proper rocker geometry, pushrod length will need to be determined by using an adjustable checking pushrod. Rocker Arms: Motown 220 heads utilize a standard offset rocker arm designed for the Small Block Chevy. NOTE: When using rocker arms greater than a 1.5 ratio, it may be necessary to elongate the pushrod guide holes in the cylinder head. -
SINGLE STAGE SNOW ENGINE SERVICE MANUAL LC154FS / LC154FDS (87Cc)
RESIDENTIAL PRODUCTS SINGLE STAGE SNOW ENGINE SERVICE MANUAL LC154FS / LC154FDS (87cc) About this Manual This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual. An electronic version of this service manual is available on the Toro Dealer Portal. We are hopeful that you will find this manual a valuable addition to your service shop. If you have any questions or comments regarding this manual, please contact us at the following address: The Toro Company Residential and Landscape Contractor Service Training Department 8111 Lyndale Avenue South Bloomington, MN 55420 Chapter 1 – General Service Information 1 Chapter 2 - Engine Service / Maintenance 2 Chapter 3 - Engine Disassembly and Service 3 Chapter 4 - Electrical 4 NOTES: Chapter 1 – General Service Information 1 Safety 2 Service Rules 3 Engine Model / Serial Number Location 3 Engine Fastener Torque Specification 4 General Specifications 5 Engine Specifications 5 Troubleshooting 6 1 Safety Safety Information This symbol means WARNING or PERSONAL SAFETY INSTRUCTION – read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death. This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the Toro engine. The Toro operator’s manual contains safety information and operating tips for safe operating practices. -
Valve Rocker Arm and Push Rod Installation (6.2L LS3)
9. Tighten the cylinder head bolts: 10.1. Tighten the M11 cylinder head bolts (1-10) a first pass in sequence to 30 N·m (22 lb ft) . 10.2. Tighten the M11 cylinder head bolts (1-10) a second pass in sequence to 90 degrees using the J 45059 meter . 10.3. Tighten the M11 cylinder head bolts (1-10) a final pass in sequence to 70 degrees using the J 45059 meter . 10.4. Tighten the M8 cylinder head bolts (11-15) to 30 N·m (22 lb ft) . Begin with the center bolt (11) and alternating side-to-side, work outward tightening all of the bolts. Valve Rocker Arm and Push Rod Installation (6.2L LS3) Note: • When using the valve train components again, always install the components to the original location and position. • Valve lash is net build. No valve adjustment is required. 1. Lubricate the valve rocker arms and pushrods with clean engine oil. 2. Lubricate the flange of the valve rocker arm bolts with clean engine oil. 3. Install the valve rocker arm pivot support. Note: Ensure the pushrods seat properly to the valve lifter sockets. 4. Install the pushrods. Note: • Ensure the pushrods seat properly to the ends of the rocker arms. • DO NOT tighten the rocker arm bolts at this time. 5. Install the rocker arms and bolts. The intake rocker arms (1) have an offset design. 6. Rotate the crankshaft until number 1 piston is at top dead center of compression stroke. In this position, cylinder number 1 rocker arms will be off lobe lift, and the crankshaft sprocket key will be at the 1:30 position. -
Stock Rocker Vs Roller Rocker Introduction to Finite Elements December 2003
Stock Rocker Vs Roller Rocker Eric Palomaki Kyle Hoffman Introduction to Finite Elements MANE-4240, Professor Suvranu De Rensselaer Polytechnic Institute Troy, New York December 5, 2003 Executive Summary: Finite element analysis has become an important design and testing tool for the engineering community. When used correctly it can provide accurate results and can save time and money over the design and analysis of new products. This report involves the study of one of the major valve train components in a Chevrolet small block pushrod engine, namely the rocker arm assembly. The rocker arm is an extremely important component in the operation of an internal combustion engine because it is responsible for translating the profile of the camshaft into motion for opening and closing the intake and exhaust valves. This report focuses on two different types of rocker arms; the existing stock “from the factory” stamped steel rocker arm, and a roller rocker that is commonly used in a racing engine. Both the roller rocker and the stock rocker were modeled in Solid Works, and then analyzed using the finite element software Cosmos Works. The results for each rocker arm were completed and some of the various outputs are presented in this paper. The locations of stress concentrations were also studied in hopes of eliminating them and any possible flaws that could cause failure. As well as optimizing the design. Since entering the racing community this past year, it has become apparent that any edge one competitor has over another competitor can be greatly beneficial to the success the competitor.