2013/08/22 Basic Engine (KENR6757-16)
SMCS - 1201 i05341828
Cylinder Block
Illustration 1 g03383792
The cylinder block is the main housing of the engine and supports the other main parts. The cylinder block is a tunnel block design.
The cylinder block is made of cast iron and includes complete passages for coolant and lubricating oil.
Note: These engines do not have cylinder liners. The cylinder walls are honed.
Illustration 2 g02789553
The cylinder block has a hollow core already cast inside the cylinder to cylinder water jacket.
In this core, there is a pair of vertical cooling passages (right and left) as well as multiple horizontal cooling channels that
interconnect these cooling passages. This design allows smoother cooling water flow through the cylinder block, which cools down a
wider range between the cylinders more effectively.
Half-Floating Valve Cover
Illustration 3 g02789565
(1) Valve Cover
(2) Rubber Packing
The rubber packing is attached to keep the cylinder head cover approximately 0.5 mm (0.02 inch) off the cylinder head. The rubber
packing decreases the noise from the cylinder head.
Closed Crankcase Breather
Illustration 4 g02789572
(3) Breather
(4) Breather Tube
Illustration 5 g02789573
(5) Breather Valve
(6) Oil Shield
Closed breather system has been adopted to prevent the release of blow-by gas into the atmosphere.
After the oil content is filtered by oil shield (6), the blow-by gas is fed back to the intake manifold through breather valve (5) to be used
for combustion.
Crankshaft
Illustration 6 g02792771
The crankshaft converts the up-and-down motion of the pistons into rotary motion. The crankshaft ties together the reactions of all
the pistons into one rotary force that drives the machine.
The crankshaft is made of tough special alloy steel, and the journals, pins, and oil seal sliding portions are induction hardened to
increase the hardness for higher wear resistance.
The front journal is supported by a solid type bearing (tunnel type cylinder block) or by a split type (hanger type cylinder block), and
the intermediate journal by a split type, and the rear journal by a split type with thrust bearings.
The crankshaft is provided with an oil gallery, through which engine oil is fed to the crankpin portion, and lubricates.
Camshaft
Illustration 7 g03394099
(7) Camshaft Gear
(8) Camshaft
The camshaft (8) is normally driven by gearing from the crankshaft (7).
The camshaft is made of special cast iron, and the journal and cam sections are chilled to resist wear. One intake and one exhaust
cam is provided for each cylinder.
Note: On some models, the camshaft may also drive oil pump using a gear.
The journal diameters are large to permit removal of the shaft from the bore. The journal sections are force-lubricated.
Note: There are no camshaft bearings for these engines.
Timing Gears
Illustration 8 g03411247
(9) Injection Pump GearGovernor Gear
(10) Idler Gear
(11) Camshaft Gear
(12) Crankshaft Gear
(13) Oil pump drive gear
The crankshaft is the hub around which other parts of the engine can be timed and driven. This is done by the meshing of gears as
shown in the Illustration 8.
The timing gears transmit torque from the crankshaft to the oil pump and injection pump and, at the same time, correctly control fuel
injection to the cylinders and valve timing.
Each gear has a mating mark inscribed on the gear for correct and easy assembly and is spherical with teeth set obliquely to the axis
of rotation to rotate smoothly and reduce noise.
Flywheel
Illustration 9 g03394119
(14) Crankshaft
(15) Flywheel Ring Gear
(16) Flywheel
The flywheel (16) is made of heavy cast iron or steel and has gear teeth around the outer rim (15), which mesh with the drive pinion of
starter.
The flywheel mounted on the rear of the crankshaft (14) is a stabilizer for the whole engine.
The flywheel stores the rotating force in the combustion stroke as inertial energy, reduces crankshaft rotating speed fluctuation and
maintains the smooth rotating conditions.
The flywheel periphery is inscribed with the marks showing fuel injection timing angle lines and top dead center mark "TC" for 1#
piston.
Rocker Arm
Illustration 10 g03394125
(17) Rocker Arm Shaft
(18) Rocker Arm
(19) Exhaust Valve
(20) Intake Valve
(21) Push Rod
(22) Adjusting Screw
The rocker arms (18) are mounted on a rocker arm shaft (17) at the top of the engine.
When the push rods (21) move up, the mating rocker arm is moved down, contacting the valve stem tip and opening the valve.
These engines possess 2 intake (20) and two exhaust valves (19) per cylinder.
Lubricating oil pressurized through the rocker arm bracket to the rocker arm shaft, which serves as a fulcrum so that the rocker arm
and the entire system are lubricated sufficiently.
Piston
Illustration 11 g03394192
(23) Concave Head Piston
The reciprocating motion of a piston in the engine cylinder creates the forces for the suction, compression, power, and exhaust
cycles.
To be strong yet light, pistons are constructed of cast iron or aluminum alloys. Reinforcing ribs are used to keep the piston as light as
possible.
The piston head shape depends on the combustion chamber of the engine. A relatively deep concave head (23) is used for direct
injection engines.
The ring grooves are cut around the piston to fit the piston rings. The grooves are shaped to the proper rings for good control of oil
and blow-by. The lower groove in which the oil ring is inserted has many holes for oil collected by oil ring to flow back to the
crankcase.
The piston lands are the areas between the ring grooves which hold and support the piston rings in the grooves. A fine groove called a
heat dam is provided on the top land to protect the top ring from high temperatures.
The skirt of the piston is the outside part below the ring grooves. The piston is kept in alignment by the skirt.
The piston is kept in alignment by the skirt. The piston skirt has a layer of molybdenum disulfide, which decreases the piston slap
noise.
The molybdenum disulfide is a solid lubricant, like Graphite or Teflon. This material helps not to wear the metal even with little lube oil.
Piston Rings
Illustration 12 g03394360
(24) Top Compression Ring
(25) Second Compression Ring
(26) Oil Control Piston Ring
Piston rings are classified as compression and oil control rings. A diesel engine has two or three compression rings around the piston
head and one oil ring just below the compression rings.
The compression rings prevent gases from leaking by the piston during the compression and expansion strokes. The compression
rings seal by expanding out against the cylinder wall. The rings expand by the tension of the ring and also by combustion pressure
behind the rings during the expansion stroke. The compression rings are split for easy assembly on the piston.
The top compression ring (24) is a keystone type ring to get durability against heavy load.
The second compression ring (25) is an undercut ring to prevent shortage of oil.
The main job of the oil control ring (26) is to wipe the excess oil from the cylinder walls. This oil is fed through slots in the rings to
holes in the piston groove, where it returns to the crankcase. For better oil control, spring expanders are often used under the oil
control ring.
The piston rings are made of hardened cast iron. To reduce the wearing, the rings are often plated with chrome on the contact faces,
or are coated the contact faces with molybdenum disulfide.
Connecting Rod
Illustration 13 g03394364
(27) Small End Bushing
(28) Connecting Rod
(29) Crankpin Bearing
The connecting rod (29) must be light and yet strong enough to transmit the thrust of the piston to crankshaft.
The large end of connecting rod has a crankpin bearing (split type) (29) and the small end has a small end bushing (solid type) (27).
Fuel Camshaft
Illustration 14 g03394371
(30) Injection Pump Gear
(31) Fuel Camshaft
The fuel camshaft (31) is driven by gearing from the crankshaft , and controls the reciprocating movement of the injection pump and
the fuel transfer pump (30).
The fuel camshaft is made of carbon steel and the cam sections are quenched and tempered to provide greater wear resistance.
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PSP-0001D91A
2022/09/25
08:18:03+06:30
i05341828
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