Cylinder Head Porting Modifications
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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 -
Harrop Camshaft Grind Specifications
Harrop Engineering Australia Pty Ltd www.harrop.com.au ABN: 87 134 196 080 Phone: +61 3 9474 - 0900 96 Bell Street, Preston, Fax: +61 3 9474 – 0999 Melbourne, VIC, 3072, Australia Email: [email protected] Harrop Camshaft Grind Specifications Harrop HO1 Camshaft 226/232 .607”/.602” @ 112 LSA Great NA camshaft Lumpy idle but acceptable driveability, Great power and torque Manual or auto standard gear ratios are ok but 3.7 or 3.9 would be preferred. Automatic may require stall converter. Could be used in boosted application but due to low LSA Would require smaller pulley to be increase boost. Harrop HO2 camshaft 224/232 .610” / .610” @ 114 LSA Great blower camshaft offering acceptably lumpy idle and great drivability, this camshaft will give great power through the mid to high RPM range. As this camshaft is more aggressive then the H05. Normally this would require a stall converter, it can be run on a standard converter but it may push on it slightly. Sound clip: https://www.youtube.com/watch?v=NvOGohRd7-k Harrop H03 Camshaft 232/233 .610” / .602” @ 112 LSA Will give great lumpy cammed affect, Low LSA would take boost out of a forced induction motor. Largest recommend camshaft for a 5.7 N/A , Acceptable in 6.0L and 6.2L square port engines, Must have 3.7 (square port) or 3.9 (LS1) for the best results in a manual car. Auto would require stall converter. 1 / 2 File: Harrop Letter Head “Commercial in Confidence” Issue:12th January 2018 designdevelop deliver Print: Friday, 25 September 2020 ` Harrop HO4 camshaft 234/238 .593” / .595” @ 114 LSA The H04 is designed with Forced induction in mind but can be used as a naturally aspirated camshaft as well. -
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. -
Where the Rubber Meets the Road ……. Part III the Cylinder Head by Dave Barnett Vintage MG Club of Southern California
Where the Rubber Meets the Road ……. Part III The Cylinder Head By Dave Barnett Vintage MG Club of Southern California "The Torque Output of an The inherent design characteristics of Engine is limited by just how a stock XPAG cylinder head effectively we can make it There is no question that the cylinder Breathe" David Vizard 1985 head is where the power is made, it is in fact the "Heart and Soul" of the engine. The design of the XPAG head dates back to September of 1939 and was first used on the TB. There are two basic design types. The "early" "Banana Head" with short 1/2-inch spark plugs. Then starting with XPAG/TD2/22735 a round water hole head with used with longer-reach 3/4-inch plugs. The thickness of a stock TC head is 76.65mm (3.018-inches) TD and TF XPAG 75.16mm (2.959-inch) TF XPEG 76.75mm (3.021-inch) (Source: MG Racers News Letter Code 106 by Mike Lewis, Bayou Racing) This month I will cover the XPAG Understanding that in its simplest form, cylinder head. We will examine stock and the XPAG engine is nothing more or less than modified heads, to increase power, reliability an air pump. A useful step toward appreciating and yes even economy. For most of us, an engines ultimate power limitation is air flow. rebuilding and modifying the cylinder head When an engines ability to draw in more air should be left up to experienced engine with increasing R.P.M. ceases, so does the rise builders. -
Executive Order D-425-50 Toyota Racing Development
State of California AIR RESOURCES BOARD EXECUTIVE ORDER D—425—50 Relating to Exemptions Under Section 27156 of the California Vehicle Code Toyota Racing Development TRD Supercharger System Pursuant to the authority vested in the Air Resources Board by Section 27156 of the Vehicle Code; and Pursuant to the authority vested in the undersigned by Section 39515 and Section 39516 of the Health and Safety Code and Executive Order G—14—012; IT IS ORDERED AND RESOLVED: That the installation of the TRD Supercharger System, manufactured and marketed by Toyota Racing Development, 19001 South Western Avenue, Torrance, California, has been found not to reduce the effectiveness of the applicable vehicle pollution control systems and, therefore, is exempt from the prohibitions of Section 27156 of the Vehicle Code for the following Toyota truck applications: Part No. Model Year Engine Disp. Model PTR29—34070 2007 to 2013 5.7L (3UR—FE) Tundra PTR29—00140 2014 to 2015 5.7L (3UR—FE) Tundra PTR29—34070 2008 to 2013 5.7L (3UR—FE) Sequoia PTR29—00140 2014 to 2015 5.7L (3UR—FE) Sequoia PTR29—60140 2008 to 2015 5.7L (3UR—FE) Land Cruiser/LX570 PTR29—35090 2005 to 2015 4.0L (1GR—FE) Tacoma PTR29—35090 2007 to 2009 4.0L (1GR—FE) FJ Cruiser PTR29—35090 2003 to 2009 4.0L (1GR—FE) 4—Runner PTR29—00130 2010 to 2014 4.0L (1GR—FE) FJ Cruiser PTR29—00130 2010 to 2015 4.0L (1GR—FE) 4—Runner The 5.7L Supercharger System includes a Magnuson supercharger (rated at a maximum boost of 8.5 psi.) with a 2.45 inch diameter supercharger pulley and the stock crankshaft pulley, high flow injectors to replace the stock injectors, a new ECU calibration, intercooler, intake manifold, an air bypass valve, and a new replacement fuel pump which is located in the fuel tank. -
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. -
The Achates Power Opposed-Piston Two-Stroke Engine
Gratis copy for Gerhard Regner Copyright 2011 SAE International E-mailing, copying and internet posting are prohibited Downloaded Wednesday, August 31, 2011 08:49:32 PM The Achates Power Opposed-Piston Two-Stroke 2011-01-2221 Published Engine: Performance and Emissions Results in a 09/13/2011 Medium-Duty Application Gerhard Regner, Randy E. Herold, Michael H. Wahl, Eric Dion, Fabien Redon, David Johnson, Brian J. Callahan and Shauna McIntyre Achates Power Inc Copyright © 2011 SAE International doi:10.4271/2011-01-2221 technical challenges related to emissions, fuel efficiency, cost ABSTRACT and durability - to name a few - and these challenges have Historically, the opposed-piston two-stroke diesel engine set been more easily met by four-stroke engines, as demonstrated combined records for fuel efficiency and power density that by their widespread use. However, the limited availability of have yet to be met by any other engine type. In the latter half fossil fuels and the corresponding rise in fuel cost has led to a of the twentieth century, the advent of modern emissions re-examination of the fundamental limits of fuel efficiency in regulations stopped the wide-spread development of two- internal combustion (IC) engines, and opposed-piston stroke engine for on-highway use. At Achates Power, modern engines, with their inherent thermodynamic advantage, have analytical tools, materials, and engineering methods have emerged as a promising alternative. This paper discusses the been applied to the development process of an opposed- potential of opposed-piston two-stroke engines in light of piston two-stroke engine, resulting in an engine design that today's market and regulatory requirements, the methodology has demonstrated a 15.5% fuel consumption improvement used by Achates Power in applying state-of-the-art tools and compared to a state-of-the-art 2010 medium-duty diesel methods to the opposed-piston two-stroke engine engine at similar engine-out emissions levels. -
F69ATC Multi Purpose CNC Maching Center with Automatic Tool Changer
F69ATC Multi Purpose CNC Maching Center with Automatic Tool Changer Machining Equipment Created for Performance Racing & Engine Remanufacturing. So Advanced, It’s Simple. F69ATC MULTI-PURPOSE CNC MACHING CENTER Windows Operating System Rottler uses Windows Touch Screen Technology through 19” (483mm) touch panel. The Windows software has many advantages such as a common user reduces operator learning curve. Touch Screen Control Automatic Tool Changer INDUSTRY EXCLUSIVE The 24 Space Automatic Tool Changer Two Operating Systems! for CAT40 Taper can handle up to a 10" 1: Rottler System for simple, fast and easy (250mm)diameter tool weighing programming of common jobs such as boring, 15.5 lbs (7kgs). surfacing and line boring. Anyone can learn in a few hours! Spindle 2: Rottler CAM System for advanced CNC Super hard finish resists wear for years of programming for making parts, engraving operation. 0-5000 RPM Spindle Rotation names, and much more. with quick change CAT40 Taper. Electronic Hand Wheel Vertical Box Way Offers operator infinite control of machine Precision Ground, Hardened Box Way movement in all axes for quick and easy Slideways are 28" (700mm) wide for setup. Also controls variable feed rate during increased rigidity and years of heavy duty automatic cycles. production machining. Brushless Servo Motors with Sliding Side Doors BISS Encoders Side doors slide up for access, reducing The F69ATC has the latest technology servo footprint. motors with BISS encoders offering 100 times finer resolution compared to previous models. Chip Auger These new Servo motors give maximum Automatically removes chips from enclosure torque and performance throughout the RPM and deposits chips in wheeled disposal cart. -
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 -
Understanding Overhead-Valve Engines Once Unheard of These Engines Now Supply the Power for Nearly All of Your Equipment
Understanding Overhead-Valve Engines Once unheard of these engines now supply the power for nearly all of your equipment. By ROBERT SOKOL Intertec Publishing Corp., Technical Manuals Division You've all heard about overhead valves when shopping Valve-Design Characteristics for power equipment, but what do they mean to you? Do The valves consist of a round head, a stem and a groove you need overhead valves? Do they cost more? What will at the top of the valve. The head of the valve is the larger they do for you? Twenty years ago, overhead valves were end that opens and closes the passageway to and from the unheard of in any type of power equipment. Nowadays, it combustion chamber. The stem guides the valve up and is difficult to find a small engine without them. down and supports the valve spring. The groove at the top In an engine with overhead valves, the intake and of the valve stem holds the valve spring in place with a exhaust valve(s) is located in the cylinder head, as opposed retainer lock. The valves must open and close for the air- to being mounted in the engine block. Many of the larger and-fuel mix to enter, then exit, the combustion chamber. engine manufacturers still offer "standard" engines that Proper timing of the opening and closing of the valves is have the valves in the block. Their "deluxe" engines have required for the engine to run smoothly. The camshaft con- overhead valves and stronger construction. Overhead trols valve sequence and timing. -
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.