Synchronization of the pulse wheels of the crankshaft and the gearbox shaft of the injection pump drive D-245E3
The need to install (reinstall) the pulse wheels of the crankshaft and the fuel injection pump drive gearbox shaft to synchronize them may be caused by dismantling the fuel injection pump drive gearbox during routine diesel repairs
The installation of pulse wheels according to the proposed scheme is carried out to synchronize the signals from the crankshaft speed sensors and the input shaft of the injection pump drive and is ensured by binding the sensor signals to the common reference point of the shaft position at the moment the piston of the first cylinder passes the top dead center (TDC).
To ensure correct installation of the impulse wheels, it is necessary to make a device for fixing the gear pin of the gearbox in accordance with the sketch (Figure 1).
Remove the cylinder head cover.
Install the piston of the first cylinder to the TDC position by turning the crankshaft clockwise using bolt 4 (Figures 4a, 4b) until it matches (depending on the design of the impulse wheel):
- a) – the gap in the “crown” of the impulse wheel is made in the form of a segment of depressions;
- b) - the gap in the “crown” of the impulse wheel is made in the form of a solid segment):
- - a) the axis of the 16th tooth of the “crown” of the pulse wheel (when counting counterclockwise from the gap segment in the “crown” of the pulse wheel) with the axis of sensor 1 Figure 4a;
- - b) the axis of the 16th cavity of the “crown” of the pulse wheel (when counting counterclockwise from the segment of the gap in the “crown” of the pulse wheel) with the axis of sensor 1, Figure 4b;
Make sure that the intake and exhaust valves of the 1st cylinder are closed; if the exhaust valve is open, turn the crankshaft a full turn and recheck the condition of the valves.
Install the piston of the first cylinder on the compression stroke (beyond ≈ 60° of the crankshaft rotation angle before TDC), for which:
c) for diesel engines with a crankshaft position lock:
- turn the crankshaft clockwise using bolt 4 (Figures 4a, 4b) approximately two turns; on the second turn, in accordance with Figure 2, unscrew the retainer from the threaded hole of the rear sheet, insert it with the reverse side into the same hole all the way into the flywheel and turn the crankshaft until the lock matches the hole in the flywheel;
In this case, the impulse wheel 2 (Figures 4a, 4b), mounted on the crankshaft pulley 3, will be positioned in such a way that the axis of sensor 1 will pass along the axis of the sixth tooth of the “crown” (design – a), or along the axis of the sixth cavity “crown” (design – b), impulse wheel (when counting counterclockwise from the gap segment in the “crown” of the impulse wheel).
d) for diesel engines without a crankshaft position lock:
- turn the crankshaft clockwise using bolt 4 (Figures 4a, 4b) approximately two turns; on the second turn, turn the crankshaft until the alignment marks on the impulse wheel 1 (Figures 3a, 3b) coincide with the front support 2.
In this case, pulse wheel 2 (Figures 4a, 4b), mounted on the crankshaft pulley 3, will be positioned in such a way that the axis of sensor 1 will pass along the axis of the sixth tooth of the “crown”
- (design – a), or along the axis of the sixth cavity of the “crown”
- (design – b), impulse wheel (when counting counterclockwise from the gap segment in the “crown” of the impulse wheel).
With the gearbox removed, turn drive coupling half 5 clockwise (Figure 7) (in Figure 5 the gearbox is shown with the gear drive gear installed on the drive coupling half) until two consecutive pulse pins appear in the window for installing the sensor.
By slightly turning the drive in the opposite direction, position the alignment pin (the first one in the direction of shaft rotation) in the center of the window (see Figure 5).
Install the gearbox shaft frequency sensor installation window (Figure 5) with a device to fix the position of the alignment pin 1 (Figure 6).
Remove the hatch cover 1 (Figure 7) and, supporting the drive gear 6 through the hatch window, insert the pins 3 of the drive coupling halves 5 into the grooves of the drive gear, thus installing the gearbox.
Attach the gearbox to the distribution board.
Install and tighten nuts 2 to a torque of 35-50 Nm.
Remove the installation fixture.
Install the gearbox shaft speed sensor and the hatch cover and secure them.
Remove the flywheel retainer (on engines with a crankshaft position clamp) and screw its threaded part into the rear sheet.
Install the cylinder head cover.
