Forklift engine maintenance is divided into four parts: first, dismantle the engine. Two. Cleaning parts. Three. Check the wear and tear. Four. Assemble the engine.
How do you disassemble the engine?
First, the engine must be removed from the forklift truck under the condition that the engine is completely cooled, otherwise it will cause deformation of some parts.
1. Water is discharged from the engine cooling system, and oil and hydraulic oil are released from the engine and hydraulic transmission.
2. Unload the safety shed and seat, remove the radiator cover and remove the exhaust pipe muffler.
3, remove the pedal, remove the radiator, exhaust pipe and accessories.
4, dismantle the connecting parts of engine and hydraulic transmission with other systems (hoses, pipes, etc.).
5, decompose the connection between engine and main drive (universal joint, etc.).
6. Hang the engine on the lifting equipment and screw down the screw bolt connected with the frame.
7. Use lifting equipment to hoist the engine and place the engine on the platform.
How to disintegrate the forklift engine?
1, remove the cylinder head and liner, remove the cylinder head, do not use screwdrivers or other sharp appliances, so as not to damage the liner of cylinder head.
2, remove the clutch from the engine, check the clutch cover and the flywheel before disassembling the clutch. If no, we should mark the clutch and remove the clutch fixed bolt.
3. Remove the oil pan, liner, tubing and oil pump.
4. Remove the valve. All valves are marked to prevent reverse position, and the valve seat has corresponding markings on the cylinder head.
(1) check the top of the valve or not, for example, the mark should be marked with the steel head in the top of the valve, in order to mark the valve at the top of the valve (the mark must be done when the valve is closed, not allowed on the top edge of the valve or the valve rod, and the file is marked with a file).
2. Press down the spring sill and spring, and use the tongs to remove the locking pin.
Take out the valve, valve spring and spring mat.
5, remove the piston rod group. Each piston and connecting rod group shall be dismantled separately to be accurate at the time of installation. The head and cover of the connecting rod should be marked with the cylinder number, and the number sequence is extended from the front of the engine pump.
Remove the connecting rod nut and remove the connecting rod end cover, gasket and bearing.
2. Push the connecting rod upwards to separate the connecting rod from the journal. The piston connecting rod group should be pushed out (for example, if the cylinder is worn into a step, it should be scraped flat) to avoid damaging the piston ring.
2. After the piston connecting rod is removed, the connecting rods, covers, pads, bolts and nuts should be loaded back as usual, so as to prevent confusion.
6, remove the starting claw and crankshaft pulley, then pull the crankshaft belt wheel hub with push-pull device.
7. Remove the cover, case and timing gear of the distributor. When the timing gear is removed, it is first to check whether there is a sign on the timing gear, for example, a mark should be marked on the two gear (when the first cylinder is at the top of the stop).
8. Remove the oil pump, oil pipe, valve tappet, distributor shaft and draw camshaft.
9. Remove the crankshaft. Check that bearing covers are marked, if marked, should be marked in sequence. Remove the fixed bolt and lift the crankshaft. Then install the bearing cap and liner back in place and tighten the retaining bolts a little.
10. Spin off the flywheel retaining bolt and remove the flywheel from the flange of the crankshaft.
11. Remove the rear end oil seal and flywheel shell of the crankshaft.
12, decompose the oil plug connecting rod group.
(1) remove the piston ring from the piston.
Remove the piston pin and put it on the top of the piston.
First release the oil and then decompose the valve cover and the rocker arm from top to bottom. Large pump, cylinder head, timing gear flywheel, flywheel shell and then open the oil bottom, unload the oil pump, first unload the small tiles and do a good job of marking the piston, then unload the big tiles for marking. The crankshaft, the eccentric shaft is removed, and the cylinder sleeve is poked out.
Cleaning parts
Use brush to clean the parts removed under the soaking of diesel or detergent.
Scrape the sealant out of the adhesive place.
The cleaned parts are filtered and classified.
Inspection of wear and tear
1, first look at the color and quality of the oil, whether there are iron scraps on the surface, see the oil viscosity. For example, there are many iron filings in the engine oil, which means to wear the crankshaft or connecting rod tiles or even crankshaft wear. If the machine is very thick, it means that the oil has not been replaced for a long time.
2, when the crankshaft of the connecting rod piston is disassembled, the condition of the connecting rod and crankshafts is observed, such as the finding that the whole connecting rod can not be reused, and if the crankshaft is not very seriously worn, it can be reused after grinding the shaft.
3. Observe the wear of the cylinder liner. Notice that when the cylinder liner is disassembled, do not hit the engine body to prevent damage.
Assembly engine
Installation generally follows the order from inside to outside, from bottom to top, from back to front, from left to right (that is, the reverse order of dismantling).
1, crankshaft, crankshaft tile surface, connecting rod, piston, piston and camshaft should be smeared with oil when installing.
2, when installing the camshaft and high pressure fuel injection pump gear, pay attention to the alignment of one cylinder mark on the gear.
3. The piston ring should be installed from the third ring to the first one by a special worker. The piston ring is a complete set and can not be damaged at will.
4, the opening of each ring should be staggered one hundred and twenty degrees, nor vertically and horizontally.
5, when installing the cylinder liner, apply the grease on the O ring, and do not knock the cylinder liner directly.
6, the installation of piston rod in the general use of special tools, and to install the original direction of the piston, not iron directly percussion piston, on the connecting rod tile (with the crankshaft contact surface) smear oil
7, install the cylinder pad on two sides to apply oil
8. When installing the cylinder cover, you should use a kilo spanner from the middle to the four round to tighten it from two to three times. The force of the filament is two hundred and fifty to three hundred N, each of which is the same force to tighten the connecting rod, and tighten it from the middle to the end of two to three times.
