Recherche Ye tebe ntedchahiie ahd 3. Start, stop and operation 3A. geen if the crankshaft ‘Turning is performed by means of an electrically driven turning device built on the engine, ‘The turning device consists of an electric motor which drives the t ning gear through a gear drive and a worm gear. There is a control ve including a cable, which allows the turning to be accomplished from any Position near the engine. The turning speed is about 1/3 rev/min. ‘The engaging and disengaging of the turning gear is made byt the (). The lever is secured by a locking pin (6). (Fig. 3.1.) ‘The turning device is provided with a stop valve which prev -engine from peice see ereM: ni The turning device needs no other maintenance than a change of the gear box lubricating oil once during the first year of operation. For approved lubricating oils, see section 2.2.6. After that, the oil should be rears according to chapter 04, Check also that the vent hole (3) is Train old oil, preferably when warm, through the drain hole (4) EB Rinse the gear box with clean. thin fluid oil EXFitl the gear box with oiltaccording tothe table in section 22,6.) through the filling hole (5) until the oil level reaches the level screw. Utmost cleanliness must be observed. Ei close the oil hol Elicheck the oil level and fill, if necessary. and drive the turning device a few revolutions. Start 3.2.1. Start, general ——————__________ Before starting the engine, check that + the fuel system is in running order (correct preheating, correct pres- sure, sufficient precirculation to heat the fuel injection pumps), + the LT- and HT-circulating systems and the raw water system are in running order (correct pressures, circulating water preheated and pre—circulated sufficiently to heat the engine), . the oil level in the turbocharger is correct, + the oil level in the governor is correct, «the starting air pressure exceeds 15 bar (normally, 10 baris still suff ient to start the engine), 5Gicheck that the automatic alarm and stop devices in the installation are set in operation, HAcheck that the stop lever is in work position (normal) (sce Fig. 3.2.) *n the starting air valve and shut the blow-off valve when there is no more condensateEee eu ke eta Cry) engine has reached the adjusted speed. More detailed information in section —_ If the engine stops during the slow turning period do not try to start again. The engine must be inspected to find the rea- son for stopping. SS [DD During the starting procedure a mechanical starting fuel limiter(see Fig 3.4, ) limits the fuel rack movement to avoid overspeeding and unnecessary _ smoke. The limiter is automatically disconnected when the engine has achieved idle speed.« ETT) Sr Luk cl 03 Emergency start ayStart, stop and operation Perey it more than 8h as Eicheck the lubricating oil level in the oil tank the lubricating oil pressure the circulating water level in the expansion tank LT/HT water pressure the raw water supply the fuel oil level in the day tank the fuel oil pressure the cae air pressure min, 15 bar eee tas at both ends)A Cor Broek od Check the cooling water system for leakage. especially + the lower part of the cylinder liner + the oil cooler e the charge air cooler Echeck/adjustthe vaive clearances. Ifthe camshattor ts driving mechu- nism have been touched, check the valve timing of one cylinder, atleast. For guid ance values, see chapter 06. GH Start the priming pump. Adjust the pressure such that oil appears from all the bearings and lubricating nozzles, from the piston cooling oil outlet and from the valve mechanism, Adjust the oil pressure to nominal (see section 1.2.) “and check that there is no leakage from the pipe connections inside or outside the Is left in the crankcase untensioned or unlocked screws or re to be locked), worn-out self-locking nuts, M/ /N. Well cleaned oil spaces (oil sump andStart, stop and operation SeOmeUOCMtO Tl See section 3.5.2.1. Bil Switch the engine on local control. EWstop the engine by pushing the stop button at the local manoeuvring panel Stop solenoid at speed governor is energized and the fuel rack moves to stop— position. Stop signal is automatically on for 100 s which is long enough to stop the engine, For more detailed information see chapter 23, section SPEMOS. od sRemotestop. Elisce section 3.5.2.1. ~ Blo energize the remote stop see the manual for installation. Function on the engine is the same as when using local stop. eeeCeryr) Buc) 3. hours Hii Read all thermometers, pressure gauges and, at the same time, the load of the engine. All temperatures are more or less dependent on the load. Therefore. always compare the values read with those at corresponding load and speed in the : are ‘Test Records and curves. Guidance values are stated in chap- ter O1. Eicheck the indicator for pressure drop over the lubricating oil fil- tS. Too high Pressure drop over the filters results in bad oil filtration and increased wear, Clean the filter cartridges if necessary. Check that the lubricating oil automatic filters and separators are working properly. Eiicheck the oil level in the oil tank. Estimate the appearance and consistency _ of the oil. A simple check of the water content is to place a of oil on a hot Surface (about 150°C), e. ahot-plate. If the drop keeps “quiet”, it does not con- t if it frizzles” it contains water. Compensate for oil consumption by nin;Start, stop and operation Cra AMB air 80 tempera- 50 ture °CBr eu oe vi cr every 250 runnin: hours Hi clean the centrifugal lubricating oil filter Eiikeep the injection pump racks clean (free from sticky deposits). check that the parts of the fuel control shaft system move easily. Ell Clean the turbine side of the turbocharger by injecting water. See chapter 15 and the instruction book of the turbocharger. fer ev runi cylinder pressures. At the same time, note the load of the ion, turbine speed, charge air pressure and inlet air ter imation of the engine load. “es _—Bi kuch sus r overhaul Oa the first start, listen carefully for possible jarring sounds. If anything is ine immediately, otherwise stop the engine after 5 min- idling at normal speed. Check at least the temperatures of the main and big fend bearing and of all other bearings which have been opened. Make visual inspection from below to the cylinder liners and piston skirts which have been ‘opened. If everything is in order, restart Bilcheck that there is no leakage of gas, water fuel or lubrivating oil. Espe- tially observe the fuel Lines, injection pumps and injection valves. Watch the "quantities emerging from the leak oil pipes! tA Check that te starting air distributing pipe isnot hott any cylinder eaky starting valve). Maj ares errission owing in instructions are especially important: — ture gauges46 93 09 SCR cl) 3.8 UM Geel meee DiAtter piston overhaul, follow program A in Fig. 3.7.as closely as possible. ‘The piston rings have slid into new positions and need time to refit. If the program cannot be followed, do not load the engine fully for 4h, atleast. [After changing piston rings, pistons or cylinder liners, after hon- ing of cylinder liners, follow program B in Fig. 3.7. as closely as possible. _ Ifthe program cannot be followed, do not load the engine fully forStart, stop and operation See Fig. 3.8, ‘The engine can be loaded, after it has been preheated as follows: HT water temperatures >60°C Lubrication oil temperatures > 40°C Ifthe temperatures are lower the loading time must be two times longe loading is automatically controlled by the engine or pr3 09 REE) 4. Maintenance schedule ral The maintenance necessary for the engine depends primarily on the perating conditions, The periods stated in this schedule are guidance values only but must not be exceeded during the ‘guarantee period. See also the instruction books of the turbocharger and the governor, sepa- rate instructions for additional equipment and chapter 03. Ul Before any steps are taken, carefully read the corresponding section in nanual mentioned after every row of the me ance Ww oe eS,CUE Te Tr Cea Interval: 50 operating hours Check draining of air coolers Check that the draining pipe is open, check for any leak- age. ‘Check water level in cooling system Check the water level in the expansion tank(s) and/or the static pressure in the engine cooling circuits. (Gauges and indicators | Take readings Read and record (using eg. form No. WV98V009) all ter- perature and pressure gauges, at the same time and at the same load of the engine. Governo Check oil level in governor kes 0 Check oil level, and look for leaks Inje Check leak fuel quantity Check the amount of leak fuel from the injection pumps and nozzles,46 93 09 Dari) ° [Cylinder pressure Check cylinder pressure Record firing pressures of all cylinders. Lubricating olf Take oil sample In a new installation or after changing to a new lubricating oil brand, take samples for analyzing. 0 [Turbocharger I’Pee a ead Id The first time check and perhaps clean the watersides. If in | good condition and deposits insignit 4000 running hours. ‘Test the opening pressure. Dismantle and clean nozzles. Check the effective needle lift. Check the springs. Replace the O-rings. Check the nozzle condition in a test pump. Replace the complete injection valve if necessary.| ears Inspection contact faces of camshaft ‘Check the contact faces of the cams and tappet rollers. ‘Check that the rollers rotate. Rotate the engine with the turning gear. Check control mechanism Check for wear in all connecting links between the gover- nor and all injection pumps. ‘Check crankshaft alignment [Check alignment, use form No. 4611VO0SGB. Alignment [check is performed on a warm engine. Check thrust bearing clearance Check axial clearance,cued OTeY Interval: 8000 — 12000 operating hours [Camshaft diving gear Inspect camshaft driving gear Replace parts if nevessary, Inspect the big end bearing Dismantle the big end bearing. Inspect mating surfaces. Measure the big end bore, use form 4611 03GB. Overhaul of cylinder head Dismantle and clean the underside, inlet and exhaust valves and ports. Inspect cooling spaces and clean, if ‘necessary. Grind the valves (often lapping by hand is enough). Replace the O-rings in the valve guides. ‘Check the starting valves. Replace parts if necessary. ‘Check the safety valves. using form No. 4610VO0IGB, replace |06 Hone the liners.CFE) ncaa) Interval: 16000 operating hours Camshaft Inspect camshaft bearings Replace if necessary Inspect main bearings Check condition, Note the type of bearing in use and do 06 the inspection accordingly. a" ‘Check governor drive bearing Check governor driving shaft bearing clearance in place. Overhaul of injection pumps [Clean and inspect injection pumps, replace worn parts. Replace the erosion plug. ia5. Maintenance tools Maintenance of a diesel engine requires some special tools developed in the course of engine design. Some of these tools are supplied with the engine and others are available through our service stations or for direct purchase by the customer. Tool ments for a particular on the use and service area, to meet basic requirements. installation may vary greatly Standard tool sets are therefore t represents a comprehensive selection of tools for the VASA 46Maintenance tools (Chapter 12)CSTE Cnc urc nr 395 9308DE auc ee) Lifting tool for eylinder cover eye Mprvuauire tgpeaauegyeye} Cor 2VR4B0139Pence Bred 46 94 22 ‘Valve clearance Feeler gaugeEre} Deere) Ca 5.3. Piston (Chapter 11) Description Code] Weight No (kg) 835001 | 8 Lifting tool for piston Tee Pus nepnhug el) UHCe Cu cue raed Code it e) _ ele Pliers for piston rings: 800002 4VE4I 8-4 Aus nopanebo* 0 Koutty If kg)Care Daren 05 peeeemeeconnectingrod (Chapter 11) Hydraulic tightening tool for M72x6 | Noll42 screwsrica ulcaonandCee) Stud remover (M72x6, M90x6)DCU aCe Mounting device for big end bearing | 836026 upper half 1, Frame complete 1¥83C139 836038,Coxe} Dearie a)SommmeeeGylindeline: = = = =F (Chapter 10) Lifting tool for linerCTE) Support for cylinder liner lifting deviceDee ned ri (Chapter 10) aS ‘Stud remover screw for mounting | 803004 | 0.9 ‘and dismantling device (M56) eexr er) Dene ney ‘Turning tool for thrust washer and bearing shell | oe |Co Lucu un a ere Code No 860083, (0535ch06002errr Teun Lr} Description ‘ode | Weight Dimensions No (kg) Hydraulic tightening tool for M56 | 861100 | 13 | 3V86B79 screws 8185Cee rcd rrr 831003, 4V83C118Tecuck cra Injection e (Chapter 16)cy rf 2 r 8 € s iH s = a E ‘Special Key for main nozzle cap nuteT e} Donne a} Special socket wrench for main fuel valve connection piece (36 mm)DCU lee rd ceed a 5.8. Miscellaneous toolsCorr ery Measure gauge for crankshait for fuel ra eer Code | Weight No | (kg) " . 4801 ‘Code | VCena acd Hydraulic tensionExT er nn) Mounting devive for overspeed [| ceylinder and elastic link rodDean ‘Mounting and removing device for ‘camshaft bearingsayer} Cua)Deuces Corres ‘ode No (60170 4V86B 107@ 51 Optional tools Code No 836024 [34.6 [2V83C0160Lede ka ao Lifting device for end piece of cam- | 836018 | 6.5 [2vedG02aT shaft P oe | "ioLifting device for camshaft drive ‘gear 7 GEE ce(3 DC CTTeT Er] (eicur uence) SS... $+ Removing tool for exhaust valve 845002 4V83E0093 seat rings. Removing tool for inlet valve seat ringske CC unr) eer 5B Description Co No Lifting tool for rocker arm 836031Eee} Honing machine with crane 842010 45 /4Vv84c002546 9416 CIC k Cal 6. Adjustments, clearances and wear limits Goeememendiusiments Valve timing, Economy timing: * Inlet valve opens _46° before TDC, closes 22° after BDC + Exhaust valve opens 50° before BDC, closes 46° after TDC Valve clearance, cold engine: inlet valves exhaust valvesCF ee nu uk md a 6.2. Clearances and wear limits a Part, measuring point Drawing dimension | Nominal (mm) [Crankshaft journal, diameter ‘Crankshaft journal, ovality [0020 _| [Crankshsft journal, taper— 46 9416 ura kay 06 Part, measuring point pane | ak pin eter] Crank pin, ovality nd bearing shellCU i aku ora am, ‘measuring point Drawing dimension (mm) os fem | Bee Piston clearance at bottom i i a tion of engine [coneponiing pion dane ‘soso [STI [| pe46 94 16 PUM ue dhe | Intermediate gear of camshaft drive, bearing clearance | (see Fig. 6.1.) axial clearance 2 [eo9T1_| [Gamshattcrving gearbackiasne | [| ~ [Cranks gear wheel ermediate gear wheel i caalCF uuu ketal Cea 15063 [Pancerseanees Tpepindamees (S990 [9971 | clearance tappet-tappet pin 6 bearing bush—tappet pin 7 al diameter 8 Gee ig 63) [105 5a5 [109Secure alin Part, measuring point Drawing dimension | Nominal (mm) clearance [ Nx. [| mm) Nozzle needle lift (see Fig. 6.4.) main 0.70 65 pilotEO marl Re Part, measuring point Nominal | Wear (mm) (see Fig. 6.5.) [enviar cay | | [Control stCa LR ee ery 07 7. Tightening torques and use of hydrau- lic tools in rques for screws and nuts ‘Threads and contact faces of nuts and screw heads should be oiled with lubricating oil unless otherwise stated, Note that locking fluids are used in certain cases, Molycote or similar low friction lubricants must not be used for any screws or nuts. Due to the risk of overtensioning the screws. 1Nm = 0.102 kpmDe cnn React eeu ee kuab cicero ra re Governor drive (see Fig. 7.2.) [_ TorqueNm | ‘Hexagon socket head screw M 10x 130, ryTXT ETS Tightening torques and use of hydraulic tools Cylinder head (see Fig. 7.4) Connection piece to nozzle holder (M2: Main injection valve fastening nuts Pilot injection valve fastening nuts (M16) Injection pipe nut rE 50£3 7 Rocker arm console fastening serew (M24) _ i Serew for valve clearance adjusting screw (M12) Injection pipe nut with guiding ring “ :hd Crd Re ane en nee final [Pox] Starting valve, safety valve (ee ig, 73) [14 [Fastening nuts for cylinder head safety valve (M16) [Fascning nos forwarine ave (MTG) | “sos | Nat for starting valve spindle,469416 Tightening torques and use of hydraulic tools 7.1.4. Injection pump, type L’Orange Injection pump (see Fig. 7.7.) cki Tew (M12) for injection pump adjusting screw (locked with Pee locking fluid) Tnjection pump element fastening screws M14 [ Rovzs 3] Pilot injection pipe fastening nut eas aN | aan e * A 2Tightening torques and use of hydra rk Main injection nozale cap nut G00=15 Molykote Gn plus | ~ [Pilot injection nozzle cap nut 150 Molykote G-n plus46 94 16 in kon kak ka 7, General torqu: We recommend the use of torque measuring tools al other screws and nuts. The following torque values apply to the strength class 8.8; when oiled with lubricating oil or treated with Loctite. When using locking fluid (Loctite), clean parts carefully in degreasing fluid and let them dry completely before applying locking fluid. num hydrzTightening torques and use of hydraulic tools ero 7.3.2. Hydraulically tightened connections, in-line am [34 [Cylinder head screws M90 x 6 ~ " [35 __[Main bearing screws M90 x6 400 =40 [36 _| Thrust bearing screws MS6 300 +30 serews of main bear- Byhand [861 — {ings and thrust bearing M56Corey Tightening torques and use of hydraulic tools Use of hydraulic cylinders: 3.3. Dismantling hydraulically tightened screw co’ ions [i Attach distance sleeves and hydraulic cylinders according to Fig. 7.11. A. Screw on cylinders by hand. EX connect the hoses to the pump and cylinders according to scheme 7.11. B. Open the release valve (2) and screw cylinders in clockwise direction to expel possible oil. Ellscrew the cylinders in counterclockwise direction about half a revolution (180°), M72x6 thread sleeve 3/4 revolution (270°). Otherwise the nut is locked by the eylinder and impossible to loosen. a Close the release valve and pump pressure to the stated value d pressure in both manometers (6).Di screw on nuts and attach distance sleeves. hand. g to Fig. 7.11 ck that the release valve (2) is open and screw the cylinders in clo direction to expel possible oil, Eliciose the release valve (2) and pump pressure to the stated value. Escrow the nuts inelockwise direction u intil close contact to face. Keep pres- fe constant at the stated value. Relieve the pressure. Repump to the stated pressure and check the nut tightness. Open the release valve slowly and remove the hydraulic tool set, ance of hig ‘The hydraulic tool set consists of a high pressure hand pump with inte: Srated oil container, hoses fitted with quick—connections and non— re: furn valves, eylinders and a pressure gauge mounted on the han _and another mounted after the last hydraulic jack. See Fig. 711, [ie components are connected in series, the pressure gauge being th nent thus ensuring that every cylinder is fed with the e oil with a visi high pressure pumy schem46 9416 Tightening torques and use of hydraulic tools 7.4. Use of hydraulic extractor cylinder For some power demanding operations a hydraulic ext (834050) is used. In connection with this cylinder the hydrau pressure hand pump is utilized, connection scheme acc. to Fig. 7.12Tightening torques and use of hydraulic tools Tay According to the design of the cylinder, the outer cylinder (1) must not be loaded, but the force is created between the surfaces A and B in Fig. 7.12. ‘The piston is prevented from running out of the cylinder by an expan- sion ring (2). The strength of this ring is limited and it is recommended that care be taken when operating at the end of the stroke. lift special low pressure pump (150 bar, 860050) is delivered for lifting the main bearing cap in the crankcase. Normal engine oil, which is used in the engine lubricating system (sump) must be used in this pum ‘if the drain oil from the tools is led to ip of the engine. Howev ei inte ynnect the drain .e main bearing ect the46 94 16 Tightening torques and use of hydraulic tools Torque wrench settings must be recalculated when using tools 806054 and 806058 together with torque wrench 820009 or 820008. Tool 806054 for main injection nozzle cap nut. 1 806058 for high pressure line.Exe Cc ce oer) 08 8: Operating problems, emergency operation For preventive action, see chapter 3 and 4. Some possible operating problems require prompt action. Operators should acquire knowledge of this chapter for immediate action when needed. |. - _ Trouble, possible reason n turning device is connected. that turning device is removed.Cee hist uous Ae aakuul rrr fa) See points 1F, 2F. gh, k. 1. 4d, ) Injection pump control rack wrongly adjusted. Injection pump control sleeve does not mesh properly with rack (may ise overspeed if set in direction towards increased fuel quantity). pump faulty (plunger or tappet sticking; delivery valve delivery valve sticking). faulty; nozzle holes clogged. too low compression pressure. Z snes, It may be troublesome to make these fire on due to the small quantity of fuel required. n this is engina) Engine badly overloaded (check injection pump rack positions and exhaust gas temperatures), b) Late injection. /wrongly set camshaft drive). 1c) See points 3b, 6. de. }4) Insufficient charge and scavenging air pressure | — charge air filter clogged arger compressor dirty sed on air side badly fouled g on heavy fuel may smoke if left idling. Test Records 15.2.2, 15.2.2. 15.6.2.Ce hu ud Gu kel yr es) fd) Late injection, refer to engine setting table Je) Fuel supply insufficient (fuel filter clogged) feed pressure: too small flow injection pumps (see points nay cause great load differences between cylinders on pump rack positions are the same. vrongly s¢ onnectionsror) Operating problems, emergency operation ) Leakage at cylinder liner O-rings (always pressure test when cooling ‘water system has been drained or cylinder liners have been dismantled)hit seu us koe ea Pyro on pump control rack ey set (3b, ¢). gine, if possit ly, e.g. by means: case fuel filter three-way cock. ing engine is hard to stop. Therefore, check regularly the control mechanism in stop position or the overspeed trip device speed governor at max. fuel admission. ion and op position. always when the contol mechanism or therious Ga kc 8.2.2. Operation with defective turbocharger(s) A defective turbocharger is to be treated in accordance with the service instructions given in the turbocharger instruction book (blocking or removing the rotor etc.) Available load from the engine with blocked turbocharger(s) is about 20% of full load. The engine output must, however, be limited so that the normal full load exhaust temperatures are not exceeded. Maximum allowable exhaust gas temperature after cylinder at continuous opera- tion with blocked turbocharger is 500°C. also section 15.5. 1e camshaft piece with its damaged cams cannot be removed and | by a new one, the engine can be kept running by the following i :Cx a ae rs .2.4. Operation with removed piston and connectin, a Tf damage to the piston, connecting rod or big end bearing cannot be repaired, the following can be done to allow emergency operation Ti Remove the piston, connecting rod and big end bearing. Bil Cover lubricating oil bore in crank pin with a suitable hose clip, { and secure, EiiFit completely assembled cylinder head but omit valve push rods. Prevent starting air entry to the cylinder head by removing the ot air pipe. Shut down injection pump (chapter 16). NOTE! With regards to torsional vibrations and other vibrations, see chapter 08, section 8.2.5. With one cylinder out of operation, reduce load to prevent exhaust tem- perature of the remaining cylinders from exceeding normal full load | temperatures. If the turbocharger(s) surge, reduce load further to avoid continuous __ Operation with removed piston and connecting rod, from one or more c lers, should be performed only in absolute emergency conditions are no other means of proceeding under own power. the engine is disturbed and severe or even dangerous The vibration conditions are in practice depen- he installation. As a general advice, when there are =>EYEE ok Lad Ed m7 10. Engine block with bearings, cylinder and oil sump cast iron engine is cast in one piece. The jacket water dis- are incorporated in the engine bfock. The crankcase cov- other covers tighten against the engine block by rubber and four screws each. Some of the crankcase covers are with safety valves which relieve the overpressure in case of a e explosion. The number of relief valves depends on the crank- The crankcase is also provided with a vent pipe including drain connection. This vent pipe should be ym, i é a rsiliapTT ea ka) 46 93 189318 Engine block with bearings, cylinder and oil sump 40 Lift the hydraulic jack (861143) inside the engine by using the mounting "¢ (861040) connected to the tackle. See Fig. 10.4.10 ra Screw on the hydraulic jack by using a wrench when at the right posi- tion. Repeat the procedure with the other screw by fitting the hydraulic jack from the other side of the engine. —————————— NOTE! Hydraulic jack can also be lifted in two parts. Use lifting device for lifting the cylinder in position and lock it together with the nut by using two pins or bolts (see Fig. 10.5,). The inside part of the hydraulic jack can then be lifted by hand and screwed into position. Inside 851143 Lifted by hand Fig. 10.5. IB Connect the hoses of the hydraulic pump (860170) to hydraulic {Jacks according to Fig, 10.6. and open the pump valve. 1860170.EAU Lowering the main bearing cap: ED Connect the hoses of the hydraulic pump (360050) to the hydraulic jack, the supplying hose set to the side marked "DOWN". From the connection “UP”, the hose is preferred to be connected back to the pump chamber. See Fig 10.7, Use clean engine oil. Remove the side screws to be able to lower the main bearing cap. Use stud remover (803004),gine block with bearings, cylinder and oil sump Piro Removing the bearing shells: “y EB) Remove the tower bearing shell by hand. EG insert the turning too! (851001) into the main bearing journal radial oil hole, see Fig. 10.9. Fig. 10.9. li EQ Turn the crankshaft carefully until the bearing shell has turned 180° and can be removed. i Cover the two main bearing journal radial oil holes with tape. ‘Every second main bearing should be in place at the same time to support the crankshaft. Clean the bearing shells and check for wear, scoring and other QU) bearing shells are of TRIMETAL~type and can be used until wor off. When the underlaying nickel-bartier or the lining n he bearing must be replaced. (To evaluate the46 93 18 Engine block with bearings, cylinder and oil sump 10.2.4. Assembling the main bearing 200 Fit the bearing shells: [Di Clean the main bearing shells, the cap and the journal very carefully EB Take off the protecting tape from the journal oil holes and lubricate the ‘journal with clean engine oil EllLubricate the bearing surface, back side and end faces of the upper bear ing shell with clean lubricating oil. fo Pees ji ‘The bearing shell can be completely destroyed (deformed) during the assembly, if it is not lubricated properly. Place the end of the bearing shell in the slot between the journal, ‘and the bearing bore, with the lug guiding in the oil groove (see Fig. 10.10. and push it by hand as far as possible (recommended 2/3 of its length).ree) ey 3 = fa 3 2 = S s 2EST oa Re) 10 Fit the side screws: HD Clean the side screws properly and lubricate the threads (the threads towards the bearing cap). Fit the screws and tighten to bottom by hand or by using the tool (803004), I Tighten the side screw nuts by hand. Pretighten the side screws: EE Littthe distance steeve (861009) into position on the side screw on the rear side of the in-line engine. Screw on the hydraulic tool (861100) and connect the hoses. (Fig 10.13.) 860170 al £51003 861100 Shut the pump valve and pump tothe pretightening pressure of 200 bar. Tighten the nuts by the pin, Beier oe) for main bearings into position by _ ), see Fig. 10.14. hiPau ne hale a CTeE Fig. 10.14. ce BB connect the hoses of the hydraulic pump (860170) Keep on turning ___ the hydraulic jack as far as it rotates. Shut the pump valve. } rua to stated pressure, (sce 7.3.2.) and tighten the nuts by the pin (Go101 t ll the temperature sensor. of the side screws: nce sleeve (861009) into position on the side screwon RED sane mnnect the hos ne eeeTERT) Engine block with bearings, cylinder and oil sump 10 10.3. Flywheel / thrust bearings A combined flywheel/thrust bearing is located at the driving end. The flywheel bearing shells are of the same type as the main bearings, only different size. The two pairs of thrust washers guide the crankshaft axially. nance of flywheel / thrust bearings For maintenance intervals see chapter 04, Maintenance schedule. If abnormal temperatures appear, the bearing has to be inspected .2. Dismantling of flywheel / thrust bearin: Loosening of side screws: i Remove the two crankcase covers next to the flywheel end, on both sides of the engine. Remove the caps of the side screws on the flywheel / thrust bearing. Lift the distance sleeves (861009) into position on the side screws. (Gee 10.15.). Both sides can be loosened simultaneously. (Fig. 10.3.) 861009 on the hydraulic tool (861100), connect the hoses of the hydraulic 0) according to Fig. 10.15, and open the pump valve. | the hydraulic tool until the piston and the cylinder endit SE i a Cu) i sump CER) Opening of flywheel! / thrust bearing nuts: 1) Littthe distance sleeve (861009) into position on the flywheel bear- ing nut and hang it by inserting the pin (861010), see Fig. 10.16. Screw on the hydraulic tools (461100), connect the hoses of the hydraulic pump (860170) according to Fig. 10.17. and open the pump valve. J Fig. 10.16.PONS 10 Lowering the flywheel / thrust bearing cap: of the hydraulic pump (860050) to the hydraulic jack, the supplying hose set to the side marked "DOWN", from the connection “UP” the hose is preferred to be connected back to the pump chamber, see Fig. 10.18, Fig. 10.18. Remove the side screws of the flywheel/thrust bearing to be able to lower the bearing cap. If necessary, use stud remover (803004). 803004Engine block with bearings, cylinder and oil sump rea Removing the flywheel/thrust bearing shells BX) Remove the lower bearing shell and the lower thrust washers. To remove the thrust washer next to the driving end an MB screw or eyebolt can. be fitted to each end of the washer to help the removing, see Fig. 10.20. Note the guide pins (c), EB insert the turning tool (851020) into the bearing journal radial oil hole to remove the upper bearing shells. See Fig. 10.21rey GIoe roe mbt flywheel / thrust bearin, @ Fitting the ywheel / thrust bearings: [i Ciean the bearing shells, washers, cap and journal very caretully EXiTake off the protecting tape from the bearing journal radial oil holes and lubricate the journal with clean engine oil EllLubricate the upper bearing shell running surface and place the end of the bearing shell in the slot between the journal and the bearing bore. The axial location of the shell is to be secured by keeping the bearing shell end recesses (A) at the same level with the axial faces (B) of the engine block, see Fig. 10,22. SO OO eo es ee ‘completely destroyed (deformed) duringEngine block with bearings, cylinder and oil sump BARKS tate the mounting of the washeruaeee ng shell Tunning surface and place shell in bear- ofthe shell sto be secured by keeping the bearing shell level with the axial faces (B) of the cap, see Fig.Engine block with bearings, cylinder and oil sump Crea@ Fig. 10.27, HG Keep on turning the hydraulic tool until the piston and cylinder end faces are at the same level. TX Shut the pump valve and pump to the pretightening pressure of 200 bar. Tighten the nut with the pin (861010). Tightening of the flywheel / thrust bearing: | Lift the distance sleeve (861009) into position on the flywheel bear- aut and hang it by inserting the pin (861010) (see Fig. 10.28. ). Screw onthe ydraulic tools (861100), connect the hoses of the hydraulic pump (860170) according to Fig. 10.29. and open the pump valve.Cru eeu kee Py318 Engine block with beat PER duce) alld 10 aft bearings ‘The camshaft bearing bushes are fitted in housings directly machined in the engine block. Bushing can be inspected and measured either by removing the camshaft journal or opening one connection in the cam- shaft and sliding the complete shaft towards the free end of the engine Maintenance shaft _bearin: For maintenance intervals see chapter 04, Maintenance schedule .4.2. Inspection of shaft bearin: hin: When the camshaft bearing journal has been removed, the inner diame- ter of the bearing bushing can be measured at site, by using a ball anvil micrometer screw. The wear limit is stated in table 10, section 6.2. If the wear limit for one camshaft bearing bushing is reached, all camshaft bearing bushes should bereplaced. For visual inspection of the camshaft bearing bushing, proceed as follows: [Bil Remove the both camshaft covers adjacent to the bearing concerned. BilRemove the cover from the starting air distributor, see chapter 14. EllLoosen the rocker arm bracket fastening nuts on the cylinders where the camshaft is to be moved axially. See chapter 14. ib FE Open the flange connection between the c: Journal on the driving end ofthe bearing concemed. ‘the camshaft towards the free end of the en table lever.Engine block with bearings, cylinder and oil sump reno Bearing bush @ state ‘in chapter 07, Fig. ‘ achieveFee orcas Cun eae) eT ou a 10 Mounting of camshaft bearing bush (Fig. 10.32. Dil Lubricate tightly the outer surface of a new bearing bushing with clean engine oil and put it on the guide sleeve (4). BAssemble the mounting device (834010) according to Fig. 10.32.A. or if the first bearing at the flywheel end is concerned according to Fig. 10.32.B. ph 4 2 1 2 4 Bearing bush 3 Bearing bush 10-25 A B Fig. 10.32. Tighten the hydraulic tool (2) by tensioning the pull screw (1) slightly. |Connect the hoses of the hydraulic pump (860100) to the hydra - tool according to Fig. 10.31. P pressure to the hydraulic tool to mount the bearing bushing. The re must not exceed the value stated in chapter 07, Fig. 7.13. pe eumevals disconnect the hoses of the hydraulic tool and dis-10 Ta oa) sump Ea 10.5, Cylinder liner Cylinder liner is centrifugally cast of special cast iron alloy. Collar is equipped with cooling bores and drillings for temperature monitoring 4 aintenance of the cylinder liner. Cylinder liner must be inspected always when overhauling the piston For maintenance schedule see chapter 04. Liner diameter is measured according to the measuring document 4610V001GB. To estimate the lifetime ofa cylinder liner it is very important to fill the document prop- erly. Measuring documents can be found in chapter "ATTACH- MENTS”. When overhauling the liner, if necessary, the cooling water space can be > cleaned from deposits by using a wire brush. The cooling bores in the collar can be cleaned by boring with a suitable drill. 5.2. ins linder Iii Loosen the cylinder liner fastening screw (1) and remove the holder Q). See Fig. 10.33. es : a ~ oS <} ss ~EE oa ylinder and oil su Lu the cylinder liner WENCOM-temperature sensors. the crankshaft so thatthe counterweights arépointing at the manoeu._ fit the support (836032) totl yunterweight fastening bolts rit ift to BDC and fit the hydraulic jack (834050) on theuum ont ngs, cylinder and oil sump CeKEr EX Connect the hoses of the hydraulic Pump (860100) to the hydraulic jack according to Fig. 10.36. 860100 Fig. 10.36. Bileump pressure to the hydraulic tool o push the cylinderliner out, When the liner starts to move freely, use crane to lift the liner out (Fig. 10.37.). The pressure must not exceed the value stated in chapter 07, Fig. 7.14,TET) TOE ca uu ie LL cmem aoe oa a 10 Bi Open the pump valve, disconnect the hoses of the hydraulic jacks and Temove them. 10.5.3, Mounting the cylinder liner Hil check that all the contact faces of the engine block and cylinder liner are clean and intact. Biicheck that the o-ring grooves of the cylinder liner are clean, and insert new o-rings. Lubricate the lower o-rings and the corresponding sealing faces ‘with vaseline or soft soap and assemble the lifting device, see Fig. 101.3%, Eipply sealing compound to the sealing faces between the upper part ‘Of the cylinder liner and the water space of the engine block. Ell Lower the liner carefully into the bore of the engine block. When the Towest o-ring touches the engine block align the liner so that the mark on the liner is directed towards the driving end of the engine, sec Fig. 8, Lower further until the liner column faces the engine block.bal Ue cu Ret a Cre tall the \ WENCOM- temperature sensors. Mt the iston with organ re od and cylinder head and refill thet Centre of gravity _ | Fig. 10.40, 10.5.4. Honing of Itis recommended to hone the: fos linder liner 10 cylinder liner whenever new piston rings are mounted. Normally a light honing is sufficient. For the honing pro- is cess the following instructions are prescribed: + Only ceramic hones with a coarseness of 80 and 400 should be used ows: mustbe used for about 30 strokes to give:be A AS LLU ale al CERT) 10.5.5. Cleaning of the cylinder liner water side ‘The water side of the cylinder liner can be cleaned of deposits with a wire brush. The cooling bores in the collar can be cleaned by boring with a suitable drill (diam. 18 and 25 mm).