帕金斯柴油发动机凸轮轴的维修技术资料

帕金斯柴油发动机凸轮轴的维修技术资料

Camshaft

To remove and to fit

Special requirements

Operation -0

Special tools		Consumable products
Description	Part number	Description	Part number
Engine turning tool	CH48	Thread lock compound ( 0 ml)	2820 7
Guide stud	GE5009
Cradle tool	GE5008
Camshaft guide	GE5007
Pilot	GE5005
Lifting hooks	GE50025
Alignment sleeve	GE5006

To remove

  Remove the radiator, Operation 2.

2  Remove the fan, Operation 2-5.

  Remove the gear case cover, Operation 6-.

4  Remove the rocker cover, Operation -.

5  Remove the rocker lever and shaft assemblies, Operation -2.

6  Remove the cover (A2) from the flywheel housing. The top bolt (A) is the timing bolt.

7  Remove the plug (A) from the timing bolt location in the flywheel housing and fit the timing bolt.

Note: There are two locations for the timing bolt, one at each side of the flywheel housing. Use the location

which is the most convenient.

Continued

2800

1

8  Insert the engine turning tool, CH48, into the fly wheel housing through the aperture behind the cover

(A2). Us e a  /2 inch drive ratchet with the turning tool to rotate the engine flywheel in the normal direction of

rotation (anti-clock wise when viewed on the flywheel) until the timing bolt engages with the threaded hole in

the flywheel. The piston of number  cylinder is now at TDC (top dead centre). When the number one piston

is at top dead centre on its  compression stroke, the mark on the camshaft gear is be aligned with the mark on

the gear case. If the mark  is not aligned, withdraw the timing bolt, rotate the crankshaft a further 60 degrees

in the normal direction of rotation and insert the timing bolt again.

Cautions:

l  If the flywheel is turned past the threaded hole, the fly wheel must be turned in the opposite direction for

approximately 45 degrees and then back in the normal direction of rotation until the timing bolt engages

with the threaded hole. This is  to eliminate backlash.

l  Do not rotate the cranks haft with the camshaft gear or any of the idler gears removed and the rocker shaft

assemblies installed. Damage can be caused to the pistons and valves, or to both.

9  Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case.

0 Remove one bolt from the camshaft gear and install the guide stud, GE5009. Remove the five bolts which

remain.

  Attach a hoist to the camshaft gear and withdraw the gear from the camshaft. Remove the guide stud.

2  Remove three bolts and withdraw the thrust plate, the adaptor plate and the seal assembly.

Note: Take care during removal of the camshaft to ensure that the surfaces of both the camshaft and the

camshaft bearings are not damaged. Use the procedure which follows, together with the relevant special tools,

to av oid damage to the engine and components.

  Use the bolts of the rocker shaft to retain the cradle tool (B), GE5008, at the position shown (B).

Continued

2800

4  Remove the rear cover (C), complete with s eal (C).

5 Fit the camshaft guide (D), GE5007, to the gear case. Do not tighten the bolts for the guide at this stage.

Note: It is necessary to install two pilots, GE5005, on the rear end of the camshaft. The second pilot will

support the rear of the camshaft as it is moved from the cylinder head and into the guide, GE5007.

6 Install a pilot tool, GE5005, into the threaded hole at the rear end of the camshaft. Then attach the second

pilot tool, GE5005, to the first.

7  Withdraw the camshaft until it enters the bore of the camshaft guide. Tighten the bolts which retain the

guide on the gear case.

8  Use the lifting hooks, GE50025, to move the camshaft toward the front of the engine.

Caution: During use of the lifting hooks  do not raise the camshaft; the camshaft should be supported by the

cradle, GE5008. If the camshaft is rais ed, damage to the camshaft bearings can occur.

9  Withdraw the camshaft from the cylinder head just enough for a strap and hoist to be attached. Attach a

suitable strap and hoist to support the camshaft, ensure that the camshaft is kept level and withdraw it from

the cylinder head. The camshaft weighs approximately 9 kg (85 lb).

To fit

2800

  Fit the two pilot tools, GE5005, to the rear end of the camshaft. Ensure that the camshaft and camshaft

bearings have been cleaned thoroughly. Apply clean engine oil to the lobes and journals of the camshaft. Apply

a thin coat of clean engine oil to the camshaft bearings.

2  Fit the camshaft guide (E), GE5007, to the gear case cover, but do not tighten the bolts fully.

 Insert the alignment sleeve (E2), GE5006, through the camshaft guide (E) and into the camshaft bearings

to align the camshaft guide correctly. Tighten the bolts which retain the camshaft guide, GE5007, on the gear

case. Remove the alignment sleeve; the sleeve should move freely from the bore of the camshaft guide,

GE5007.

4  Fit the cradle tool (F), GE5008, at the position shown (F).

Note: Rotate the camshaft in both directions during installation to prevent binding.

5  Use a suitable strap and hoist to support the camshaft. Insert the camshaft through the guide and into the

cylinder head. Move the camshaft into the head as far as the strap and hoist will allow.

6  Remove the strap and hoist. Rotate the camshaft during installation. Do not allow the end of the camshaft

to drop during removal of the hoist as the bearings can be damaged. Use the lifting hooks, GE50025, to

support the camshaft during installation.

7  Remove the pilot tools and push the camshaft fully into its bore.

8  Inspect the seal (G) and renew if necessary. Fit the rear cover (G), complete with seal (G).

Continued2800

9  Remove the cradle tool and the camshaft guide.

0  Fit new ‘O’ ring seals  to the camshaft front seal plate. Apply a small amount of engine lubricating oil to the

‘O’ ring seal on the outside of the plate. Fit the seal plate with the face seal against the c ylinder head. Insert

the adapter plate and fit the thrust plate. Apply thread lock c ompound, 2820 7, to the three bolts, fit the

bolts and tighten.

Note: Camshaft timing is very important. During installation of the camshaft assembly, ensure that the timing

marks on the camshaft gear and the gear case cover are aligned when number one cylinder is at top centre

(TDC).

  Fit the guide stud, GE5009, to the camshaft.

2  Fit the camshaft gear; align the hole in the gear with the dowel pin on the adapter plate. If the timing mark

on gear does not align with the pointer at the top of the gear case, remove the gear and rotate the camshaft

until the gear can be installed with the marks aligned.

  Fit the bolts which retain the gear, remov e the guide stud and fit the bolt which remains. Tighten the bolts

to a torque of 240 +/- 40 Nm (77 +/- 0 lbf ft).

4  Fit the camshaft timing sensor to its location behind the top of the gear case and connect the lead.

5  Fit the gear case cover, Operation 6-.

6  Remove the timing bolt from the flywheel and fit the cover and plug.

7  Install the rocker lever and shaft assemblies, Operation -2.

2800

How to set the backlash for the camshaft gear

Operation -

If the cylinder head or the camshaft is removed, the backlash between the camshaft gear (A) and the

adjustable idler gear (A2) must be checked and, if necessary, adjusted. The backlash between the camshaft

gear and the adjustable idler gear, and also between the adjustable idler gear (A2) and the main idler gear

(A), must be 0,25 +/- 0,08 mm (0.00 +/- 0.00 in).

Note: This procedure must be performed before the rocker lever and shaft ass emblies are fitted.

  Remove the main idler gear (A). Hold the camshaft gear stationary and use a dial tes t indicator (DTI),

mounted on the gear case, to check the backlash of the adjustable idler gear.

2 Fit the main idler gear (A), hold the main idler gear stationary and measure the backlash on the adjustable

idler gear.

  To adjust the backlash, remove the three bolts and thrust plate which retain the adjustable idler gear (A2)

and remove the gear. Loosen the five nuts (B) and the bolt (B) which retain the stub axle (B2) and move the

stub axle by the relevant amount. Tighten the nuts and bolt to a torque of 47 +/- 9 Nm (5 +/- 7 lbf ft).

4  Fit the idler gear. Retain with the thrust plate and three bolts. Check again the backlash between the

adjustable idler gear and the camshaft gear, and also between the adjustable idler gear (A2) and the main idler

gear (A), as given in steps  and 2. Repeat the procedure if necessary until the correct backlash settings have

been obtained.

5  When the correct backlash settings have been obtained, remove the adjustable idler gear and proceed as

follows: Remove one of the nuts which retains the idler axle, apply a s mall amount of Loctite 542 to the threads

of the stud, fit the nut and tighten to a torque of 47 +/- 9 Nm (5 +/- 7 lbf ft). Repeat this procedure for the other

four nuts and the bolt; work on one nut or bolt at a time so that the pos ition of the stub axle is not affected.

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