13 Cylinder head spacing Regeneration process:
It is important to take a careful approach to rebuilding cylinder heads. The process of rebuilt heads has been introduced and improved for many years. During this time, experts in the field have received recycling cylinder heads up to science. The industry has developed a 13-step process for reconditioned heads, which provides high quality reconditioned cylinder heads, ready for the needs of the client.
Step 1: Disrupting the process for refurbished heads
The first step for remanufactured cylinder heads is the initial breakdown process. Technicians remove all valves, guides, seats, springs and nozzle cups. The remodelers then visually inspect each part, as well as conduct quality control and structural tests to check whether any of these parts can be reused. For example, with valves, reductants should inspect the entire valve to see if there are any erosion pits. Most rebuilt cylinder heads have erosion pits that need to be repaired. Later you have to repaint at the right angle, and then repaint the stems.
Step 2: Initial Cleaning and Magnafluxing
The second step in recovery is the initial cleaning and magnafluxing. The cleaning of remanufactured cylinder heads is a very important step during the remanufacturing process. Often used heads come to an object with dirty, mud, oil and lubricants embedded in cast iron. In order to correctly identify the cracks and assess structural integrity, the rebuilt cylinder head must be completely clean. At this stage, it is also important to measure surface thickness based on OEM specifications. For example, OEM specifications for regenerated Caterpillar D334 heads: The new height is 3,400 inches and the minimum height is 3.3940 inches. This gives the re-aligning bearing, where it is necessary to grind again in the process of the restored head. If the height of the re-alignments of the heads is below the minimum height, when the recovery team receives it, they should simply replace the entire head, since it is considered unsuitable for restoration. The reconstructor should also check the area of warping, compression and water.
Step 3: Deep cleaning of all reconditioned heads
The third stage of the head restoration process is deep cleaning. As soon as the restoration team removes the original dirt and dirt from the restored cylinder heads, the restorer should perform one of three deep cleaning processes. The remodeling team may place the reconfigured head in a hot tank, steam cleaning tank, or sink. A hot water tank heats the reconstructed heads to more than 200 degrees Fahrenheit and literally burns any component that is not part of the rebuilt head. As soon as deep cleaning is completed, the remover removes all holes in the bolts and repairs if necessary. Expert adjustment firmly believes that they will go the extra mile, cleaning the restored cylinder heads, as even a small amount of dirt can interfere with the process of grinding or repairing cracks.
Step 4: Check the pressure of the regenerated heads
The fourth step for recovered cylinder heads is a pressure test on the block for further structural integrity. Most rebuilds put the rebuilt cylinder heads into a Newclear pressure regulator machine for 20 minutes. Newclear pressure regulator machine exposes a 60 psi reconditioned head at 200 degrees Fahrenheit. What it does is it pulls water through any cracks that may be present. The quality manager has to check the guide thread in and around the seats and between the valves. After the rebuilt cylinder head is removed from the Newclear pressure regulator machine, it is important to check the rebuilt head for additional deformation and shrinkage, which will subsequently be removed during grinding.
Step 5: Examine the details of the regenerated heads.
The fifth step to making rebuilt cylinder heads is determining which parts need to be replaced. Then the reducing agent checks the quantity and part number. You can either use your own OEM-certified remanufactured parts, or replace them with new parts from repeat suppliers, if required by the customer. As a rule, you should replace worn seats, guides and valves for all reconditioned heads.
Step 6: Inventory Management Process for Restored Heads
The sixth step in the head restoration process is to fill in the material requirements form for the department. Most inventory management systems direct the head adjustment command to make the best decisions about which parts to use for the refurbished cylinder head process.
Step 7: Laying the deck of the regenerated heads
The seventh step in the restoration of the head is to apply the reconstructed head as needed. It is recommended to use the Berco grinding and milling machine on all restored cylinder heads. Berco Grinder uses a carbonate cutter that uses flat cutting technology. After that, the rebuilding machine completely drills the top of the rebuilt cylinder heads, which is called “deck-up”. Specialists in reorganization carry out both metal stitching and hot-welding technology to repair cracks in re-aligning heads. Metallic stitching involves boring a series of holes that completely remove the crack, cutting holes with pins / plugs, and then re-grinding the raised surface on the reconstructed cylinder heads.
Hot welding involves placing the entire recovered head in a hot furnace, heating the cast iron to 1100 degrees Fahrenheit, and then conducting arc welding while the entire head is hot. After arc welding, the reducing agent places all restored cylinder heads in the sandbox for 24-48 hours, so that the metal is compressed at the same speed in an isolated environment. Restored heads, reconstructed using hot furnace technology, must be cooled in an insulated environment, so that various metals in the casting retain the weld.
Step 8: Installing the injection pipes back to the reconstructed cylinder heads
Eight steps in the process of restoring the head - installation of injection tubes. Teams typically replace injector tubes during the head repair process. Most rearrangements use brass, copper or stainless steel pipes. The teams then use a punching machine to properly install the injector tube into the injector hole. The purpose of the injection tubes is to seal the refrigerant passages, as well as to seal the combustion chamber. Some rebuilt heads have O-rings located around the injector tube, others are not. The type of injector tube used depends on the composite head metal and what the OEM specification requires. An overhaul team can use OEM or Aftermarket injector tubes depending on customer preferences.
Step 9: Testing Pressure on Restored Heads a Second Time
The ninth step in the recovery process is to re-check the rebuilt cylinder heads a second time using the Newclear Pressure Regulator Machine. It is important to repeat the test of all completed restored cylinder heads a second time to ensure that the hot weld or cold weld procedure has retained its integrity. The quality control department should check for any leakage, using both visual checks through a glass magnifying screen and measurements of water under the head. The transparent pressure plate provides the ability to rotate 360 °, which allows you to adjust the center of gravity for the rebuilt cylinder heads. The system also contains an integrated heating system for cold hydraulic and hot hydraulic tests on reconditioned heads.
Step 10: Prepare the rebuilt heads for assembly
The tenth step for reconditioned heads is to prepare the head for assembly. As soon as the reconstructed cylinder heads are surfaced and pressure tested, it is time to assemble the head. Command wire wheels of all ports and surfaces, and then grinds and shields valves and seats. After that, the team checks the valve decay. Valve reduction check is crucial! Valves should be flush as the piston hits +.001 "or -.001". The quality control department checks and, if necessary, immediately eliminates valve reduction problems on all reconditioned heads.
Step 11: Final cleaning of all finished rebuilt heads
The eleventh step in the reconstructed head process is to clean the steam or use a sink. The steam cleaning process takes the reconstructed heads and pre-rinses it in a steam bath. Steam bath removes extra dirt and solvents that may accumulate during the grinding process. After the recovered heads are cleared, the regrouping team prints the serial number on the reconstructed heads, as well as the number of the assessment and the initials of the employee.
Step 12: Paint and pack all reconditioned heads
Step Twelve for rebuilt heads is to assemble the entire package. The team assembles seat holders, then paints or cast explosions and packaging. All rebuilt heads are then painted in OEM specifications using industrial paint. The paint that the team uses helps prevent rust and durability that sustains environmental change.
Step 13: Rust Prevention Measures and Preparation of Regenerated Delivery Heads
The thirteenth and final step for rebuilding the cylinder heads is to re-spray the oil and rust packing. The rebuilding team should supply individual boxes for each reconditioned head, then wrap with plastic and place the entire reconstructed cylinder head in a wooden box for transportation.
