How to protect heavy-engine components

Diesel fuel produces higher torque than pure petrol. This is critical for low-speed pulling power over rough terrain, which is why heavy engines are powered by diesel. Compared to a petrol engine, a diesel engine runs at a much slower RPM (revolutions per minute).

Not only does this reduce engine wear and tear, but it can move through gears quicker, using less fuel than a petrol engine and reducing costs.

Contamination: the enemy of heavy engineering

In the heavy engineering industry, ensuring reliability is the first priority. This goes for every stage of the engine’s life, which includes:

• Manufacturing
• Painting or powder coating (masking)
• Transportation
• Storage
• End use

Water and dirt can threaten the integrity of your heavy engine, causing corrosion and rust, filter blockage and wear on pumps and injectors.

Diesel engines naturally contain some water, but this occurs through condensation and as long as it’s below 0.05%, it’s harmless. The danger is when unacceptable levels of water enter. Where excessive water goes, so does microbial growth, which ruins fuel quality.

Dust in particular attacks moving parts in the fuel system. This affects starting, causes idling, leads to poor performance and can even result in engine failure.

Engine paint can present another potential hazard. Painting a diesel engine can provide protection against corrosion and rust – in addition to adding an aesthetic touch – but the job must be done properly.

Does contamination harm electric heavy engineering equipment?

Yes. Electric construction and mining vehicles are especially gaining in popularity, so special attention needs to be given to protecting critical components. EV motors don’t have the same number of rotating parts common in diesel engines, but they do have oil pumps and connectors that need protecting. The damage that contaminants can create in diesel engines is the same for EV motors: corrosion, abrasive wear and tear and poor lubrication.

Heavy engine components

Let’s look at the engine components that need protection.

Cylinder block and head assemblies

The engine’s cylinder block is critical for providing lubrication, temperature control and stability. Also called the engine block – or simply “block,” it is fundamental to the structure of the engine and involves multiple components that need protection.

The cylinder head assembly sits on top of the cylinder block, housing components that include the intake and exhaust valves, combustion chamber, and springs and lifters. Air and fuel flow through the passages – called ports or tracts – in the cylinder head,while permitting the exhaust gases to flow out.

Oil pan

The oil pan holds the oil that is circulated under pressure over the crank shaft and other moving parts, such as rotating bearings, the sliding pistons and the engine’s camshaft. In essence, the oil pan is part of the engine’s lubrication system while helping to cool the engine.

Fly wheel

Attached to a rotating shaft, the flywheel acts as an energy-storing device. It maintains consistent energy where the normal energy source is intermittent. The flywheel stores rotational energy when torque is applied, and when the torque is absent, it ensures smooth delivery of power applying torque to the drive shaft. The result is an engine with consistent power output.

Fuel system assembly

The fuel system delivers fuel to the engine. In heavy engine vehicles, the system comprises of the fuel tank, pump, filter and injectors, although you’re likely to find a carburettor instead in older diesel engines. The illustration here is typical of the fuel system assembly in a construction vehicle. It’s critical that each component is protected at each stage of your processes if the system is to perform up to expectations.

Caps, plugs and tapes

Critical components must be protected against ingress to deliver the performance you demand. Caps, plugs and tapes have different applications, but they all serve one purpose: to provide protection, whether it’s against dirt, dust and liquid ingress, damage, the masking process or all of these.

There are many different varieties of caps and plugs, but generally, these are the types you’ll find:

Caps for heavy engine protection

Caps fit outside diameters (O.D.) snugly on critical profiles.

• Push-fit caps are quick to apply
• Pull-tab caps are fast to remove without the need for tools
• Masking caps have wide flanges to make removal easy
• Threaded caps are used on threaded O.Ds. on the engine
• Tapered caps can be used as either a cap or plug and fits multiple diameters due to its taper design

Plugs for heavy engine protection

Plugs fit inside diameters to protect parts such as ports and hose fittings.

• Masking plugs mask threaded and plain through holes. Silicone caps and silicone plugs are ideal for high-temperature masking, but EPDM tapered plugs are an economical option at slightly reduced temperatures
• Pull plugs provide tab for quick and easy removal
• Threaded plugs are used on threaded holes in the engine and can be quickly removed with a pull tab. These can also be push-fit plugs for easy insertion.
• Tapered plugs can sometimes be used as caps and provide a snug fit against multiple diameters

Masking tape for heavy engine protection

If you need to mask irregular shapes, then masking tapes and discs might be the right solution. Removing masking tape is fast, easy and leaves no residue. You can also choose different coloured masking tape. Colours are based on tape thickness, not identification.

Other solutions for heavy engine protection

This article is only concerned with engines, but it’s worth noting that heavy engineering vehicles often rely on end-use solutions such as fire protection sleeves and hose-wear protectors. To learn more about protecting other parts of vehicles with heavy engines, don’t miss Quick Guide: hydraulics and pneumatics protection in specialist vehicles.

Protecting your heavy engine from manufacturing to end use

Some caps and plugs that protect engines during manufacturing can sometimes provide protection during other processes, such as transportation and storage. The question is, what type of protection does each process demand? Below are our recommendations for keeping your heavy engine performing to your customers’ high expectations.

All recommendations apply to diesel, but we’ve noted where relevant to heavy electric vehicle machinery.

• Manufacturing
• Transportation & storage
• Masking
• End use

Manufacturing

Protection for the critical threads and ports of a heavy engine needs to be reliable. But when we’re talking about manufacturing, protection also needs fast application and removal so that the production process doesn’t slow down. Consider these solutions:

Transportation & storage

You can’t control rough handling, accidents or the threat of corrosion once your heavy engine leaves the manufacturing plant. You can still provide protection, however, with these high-quality caps and plugs.

Masking

You have to find the balance between keeping costs down while not sacrificing on the quality of the paint job. Poor quality or ill-applied masking products add time to the schedule and drains money to correct the problems. Get it right the first time with these masking solutions:

End use

Protection still plays a role long after customers have taken possession of your heavy engines. Handing off a high-quality product so that it still gives satisfaction years later is your goal. Here’s how to do that:

Download free CADs and try before you buy

Download free CADs and request free samples, which are available for most of our solutions. It’s a great way to ensure you’ve chosen exactly what you need. If you’re not quite sure which product will work best for you, our experts are always happy to advise you. Whatever it is you need, you can depend on fast despatch.

Request your free samples or download free CADs now.

Questions?

Email us at sales@essentracomponents.co.uk or speak to one of our experts for further information on the ideal solution for your application 0345 528 0474.

Download heavy engine protection PDF guide