Detailed Assembly Process of Cummins C Engine

The assembly of Cummins C engine involves six key procedures: fixing and sub-assembling the cylinder block on the repair bench, pressing cylinder liners, installing piston cooling nozzles, fitting upper main bearings and thrust bearings, assembling tappet bodies, and mounting the crankshaft assembly. Dingbo Diesel Generator Manufacturer will provide a detailed explanation of each step below.

1. Fixing and Sub-assembling the Cylinder Block on the Repair Bench

Clean all sealing surfaces and mounting surfaces of the cylinder block. Inspect the cylinder block for damages, burrs, or dirt, and clean with emery cloth. Check the flatness of the cylinder block surface using feeler gauges and straightedges. Clean the oil passages and water passages of the engine with clean silk cloth and blow dry with compressed air. Install various cup plugs of the engine using special punches, applying glue on the mounting surfaces of the cup plugs.

2. Pressing Cylinder Liners

Before installation, inspect the sealing surfaces, locating surfaces, and cylinder liners for cracks, dirt, or burrs. Apply engine oil to the cylinder liner installation grooves. Press-fit the cylinder liners using special tools and measure the protrusion of the cylinder liners with a dial indicator. Check the gaps at the four casting points between the bottom of the cylinder liner and the cylinder block using feeler gauges.

3. Installing Piston Cooling Nozzles

The piston cooling nozzles are located below the surface of the main bearing seat. Install the cooling nozzles using special tools such as nozzle punches and rubber hammers. Ensure the cooling nozzles are unobstructed, undamaged, and not missing.

4. Fitting Upper Main Bearings and Thrust Bearings

Inspect the bearing surfaces for cleanliness and damages. Assemble according to the marks and apply lubricating oil on the bearing surfaces. Note that under no circumstances should oil be applied to the back of the bearings.

5. Assembling Tappet Bodies

When reusing the camshaft and tappet bodies, mark and place the tappet bodies properly. If no marks were made during disassembly, these tappet bodies must not be reused. Do not use old tappet bodies on new cams. Lubricate with engine oil. The tappet bodies should seat freely in the tappet body holes and rotate freely.

6. Mounting the Crankshaft Assembly

Sub-assemble the crankshaft gear: heat the gear in an electric heating box to 180°C for half a minute, then install using a special crankshaft gear press or a copper hammer. Wipe clean each journal of the crankshaft, clean the oil passages with compressed air, and lubricate each journal with engine oil. Install the lower bearings and main bearing caps. Note the marks on the back of the main bearings: the standard thickness mark is "STD", and the oversize thickness mark is "OS". Use standard bearings for unprocessed crankshafts and oversize bearings for processed crankshafts. Lubricate the bearing surfaces with engine oil and check that the bearings are correctly seated in the locating grooves. Lubricate the threaded parts of the main bearing cap bolts with clean engine oil. The main bearing caps are marked and must not be installed incorrectly. Each main bearing cap has a "BACK" mark facing the rear end of the engine.

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