Synchronization of the impulse wheels of the crankshaft and the gear shaft of the injection pump drive D-245E3
The need to install (reinstall) the impulse wheels of the crankshaft and the shaft of the injection pump drive gearbox for their synchronization may be caused by the dismantling of the injection pump drive gearbox during the current repair of the diesel engine
The installation of impulse wheels according to the proposed scheme is carried out to synchronize the signals of the crankshaft speed sensors and the input shaft of the injection pump drive and is provided by linking the sensor signals to a common reference point of the shaft position at the moment the piston of the first cylinder of the top dead center (TDC) passes.
To ensure the correct installation of the impulse wheels, it is necessary to make a fixture for fixing the locating pin of the gearbox gear wheel in accordance with the sketch (Figure 1).
Figure 1 - Locating Pin Fixing Tool
Remove the cylinder head cover cap.
Set 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):
Figure 2 - Inserting the retainer into the hole in the rear sheet and flywheel.
- 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) axis of the 16th tooth of the "crown" of the impulse wheel (when counted counterclockwise from the segment of the gap in the "crown" of the impulse wheel) with the axis of the sensor 1 Figure 4a;
- - b) axis of the 16th cavity of the “crown” of the impulse wheel (when counted counterclockwise from the break segment in the “crown” of the impulse wheel) with sensor axis 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 re-check the condition of the valves.
Install the piston of the first cylinder on the compression stroke (for ≈ 60° of the angle of rotation of the crankshaft to TDC), for which:
Figure 4a - Installing the crankshaft speed sensor
Figure 4b - Installing the crankshaft speed sensor
c) for diesel engines with a crankshaft position lock:
- turn the crankshaft clockwise using bolt 4 (Figures 4a, 4b) by about two turns, while on the second turn, unscrew the retainer from the threaded hole of the rear sheet in accordance with Figure 2, insert it with the reverse side into the same hole against the stop in the flywheel and turn the crankshaft until the latch coincides with the hole in the flywheel;
In this case, the impulse wheel 2 (Figures 4a, 4b), fixed on the crankshaft pulley 3, will be located in such a way that the axis of the 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 counted counterclockwise from the gap segment in the "crown" of the impulse wheel).
Figure 3a - Installation marks.
d) for diesel engines without crankshaft position lock:
- turn the crankshaft clockwise using bolt 4 (Figures 4a, 4b) by approximately two turns, while on the second turn turn the crankshaft until the alignment marks on the impulse wheel 1 (Figures 3a, 3b) and the front support 2 coincide .
In this case, the impulse wheel 2 (Figures 4a, 4b), fixed on the crankshaft pulley 3, will be located in such a way that the axis of the 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 counted counterclockwise from the gap segment in the "crown" of the impulse wheel).
On the removed gearbox, turning the drive coupling half clockwise 5 (Figure 7) (in Figure 5 the gearbox is shown with the gearbox drive gear installed on the drive coupling half), achieve the appearance in the window for installing the sensor of two sequentially located impulse pins.
Slightly turn the actuator in the opposite direction to position the dowel pinalong the direction of rotation of the shaft) in the center of the window (see Figure 5).
Install the fixture for fixing the position of the locating pin 1 (Figure 6) in the gearbox shaft frequency sensor installation window (Figure 5).
Picture 5 - Injection pump drive gear
Figure 6 - Fixing the Gearbox
Figure 7 - Gear Drive
Remove the hatch cover 1 (Figure 7) and, supporting the drive gear 6 through the hatch window, insert the studs 3 of the drive coupling half 5 into the grooves of the drive gear, thus installing the gearbox.
Mount the reducer on the switchboard.
Install and tighten nuts 2 to 35...50 Nm.
Remove the installation tool.
Reinstall the gearbox shaft speed sensor, manhole cover and secure them.
Remove the flywheel lock (on engines with crankshaft position lock) and thread it into the rear plate.
Install the cylinder head cover cap.