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123 views323 pagesME ABC Maintenance Manual DZC Version
Main engine abc manual
Uploaded by
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© © All Rights Reserved
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/ 323
MAINTENANCE MANUAL
FOR DIESEL ENGINES A.B.C.
type DZC
ANGLO BELGIAN CORPORATION.
Wiedauwkaai 43 ,B9000 GENT/BELGIUM.
tel. 09-267 00 00
fax. 09-267 00 67 — emaurintoaabedicseLbe
Webs " It shall not be copied or disclosed without the prier consent of ABC
ABC ové the copyright of this docume
8) Maintenance manual
DZC engines
PREFACE
The first A.B.C. internal combustion engines left the factory in
1912. The present engines are the result of about 75 years of
research and experiment.
Thanks to their excellent design, their robustness and their
thorough standardisation, A.B8.C. engines are easy and inexpensive
to maintain, provided that they are treated properly.
This manual contains the instructions necessary for the maintenance
of diesel engines type DZC.
This book has been compiled to assist the operator to look after
the engine, by giving detailed information where it is likely to be
needed, assuming that the operator will at all times and in all
matters follow good engineering practice.
The manual supplied with each engine has a sticker inside the front
cover bearing the number of that particular engine.
A copy of the manual supplied subsequently may be a ater edition
and consequently not apply to the engine concerned.
Some differences may be noted between the descriptions given in this
manual and the engine as received. This is because an engine may be
supplied incorporating non-standard components at the Client's re-
quest or according to the application.
Our technical department "APPLICATIONS" will be pleased to answer
questions or give advice in case there is no specific documentation.
Our after-sales department and our service stations in Belgium and
abroad are at your disposal to ensure efficacious maintenance.
IMPORTANT
- Before undertaking maintenance work on the engine, this manual
should be read carefully.
- This Maintenance Manual has been prepared using the manufacturer's
best knowledge and experience, taking into account safety and
environmental aspects.
~ To assure the best efficiency, reliability and lifetime of the
engine and its components, only original spare parts should be
used.
- Failure to comply with this Maintenance Manual may result in
malfunction of the engine, short lifetime of components, personal
injury or damage to property or environment for which the manu
facturer takes no responsibility.
Edition Maintenance manual
DZC engines
- Make sure that everyone involved in the maintenance of the engine
has this Manual available, reads it and understands it.
~ Machine components such as springs, clips, retaining rings, electric
equipment, pipes, etc., involve a risk of damage or personal injury
if opened, taken apart, fitted, lifted or transported in an im-
proper way. It is therefore essential that no one attempts to do
any work on the engine unless he has the necessary experience of
the various tools and commonly used elements, materials and methods
in machinery.
- Make sure that all equipment and tools for maintenance are in good
condition.
~ The maintenance work described in this Manual shall only be carried
out by trained personnel except where otherwise stated.
~ The manufacturer will not be responsible for any consequences
resulting from incorrect translation or interpretation of the
original text handed to the customer or user.
1
consent of ABC.
i
3
i fof this document, It shall not be copied or disclosed without the prior consent of ABC.
ABC owns the copyrg
Maintenance manual
DZC engines
GENERAL
CHAPTER
CHAPTER
CHAPTER
CHAPTER
CHAPTER
Ll.
eae
gel
22s
4...
4.2.
4.3.
CONTENTS
DEFINITIONS AND TERMINOLOGY
TECHNICAL DATA
GENERAL MAINTENANCE RECOMMENDATIONS
MAINTENANCE PROGRAMME
TIGHTENING TORQUES
CYLINDER HEAD
cylinder head
The valves and their mechanism
PISTON - CONNECTING ROD
Piston
Connecting rod
CYLINDER HOUSING
Cylinder housing or cylinder block
INJECTION
Nozzle holder and nozzle ‘or injector’
Injection pump
Injection pump drive mechanism
GOVERNOR
The governor
The governor drive mechanism
Injection pump control mechanism ABC ovns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.
Maintenance manual
DZC engines
CHAPTER
CHAPTER
CHAPTER
CHAPTER
CHAPTER
6
6.1.
6.2.
6.3.
6.4.
ele
Wear
Tee
8.1.
sear
9.1.
9.2.
9.3.
9.4.
9.5.
9.6.
10
10.1.
10.2.
10.3.
10.4.
10.5.
CRANKCASE
Crankcase
The studs of the main bearing caps
The main bearing shells
Cylinder block holding down studs
CRANKSHAFT
Crankshaft
Vibration damper
Flexible gear driving coupling
TIMING GEAR
Camshaft
Timing gearwheels
PUMPS
Pump gear case
Presh water pump
Sea water pump
Fuel feed pump
Lubricating oil pump/pressure valves
Hand pump
STARTING DEVICE
Pneumatic starting motors
Lubricator
Electro-valve
Automatic stop device
Compressed air receiver shall not be copied of disclosed without the prior consent of ABC
ABC ovne the copyright of this document.
AJB
Maintenance manual
DZC engines
CHAPTER
CHAPTER
a
Adee
12
flaletey
12.2.
12.3.
SUPERCHARGER
Supercharger or turbo charger
COOLERS
Combined cooler oil-freshwater to sea water
Oil cooler
Charge air cooler consent of ABC
wad the copyright af this document, It shall ot be copied or disclosed without the prior «
a
Maintenance manual
DZC engines
GENERAL ABC ovis the copyright of this document. I shall nat be copied or disclosed withaut the roe consent of ABC.
Maintenance manual
General DZC engines
1. DEF
1.4. TYPE
vue oo EO
pac
1000
166
NITIONS AND TERMINOLOGY
ENGINE INDICATION
7)
(8)
(B) Dzc = 1000 - 166 ie
(1)
(P)
number of cylinders
marine propulsion engine
generator set for see-going vessels
industrial generator set
railway traction diesel
pumpset or compressor set
type of engine, 4 stroke, in line, supercharged
engine with intercooler
+ engine speed : rpm
: code number for the mean effective pressure
(Pe), given as follows :
CODE NUMBER Pe (bar)
120 12
135 13,5
150 15
166 16,6
179 17,9
direction of rotation counter-clockwise, as
seen by an observer facing the flywheel end
of the engine
direction of rotation clockwise, as seen by
an observer facing the flywheel end of the
engine
Fditinns 4 Maintenance manual
General DZC engines
4.2. NUMBERING OF THE CYLINDERS
The numbering of the cylinders begins with the cylinder
closest to the flywheel.
1.3. DEFINITION OF THE DEAD CENTRES
In the following explanations and diagrams, the dead
centres of piston travel are indicated by means of the
following symbols :
T.D.C. top dead centre
B.D.C. bottom dead centre
[ABC owns the copyright of this document. I shall nob be copied oF disclosed witbout the prior consent of ABC. ABC ous the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.
General
Maintenance manual
DZC engines
TECHNICAL DATA
TECHNICAL FEATURES (according engine type and application)
~ Continuous rating power 1S03046/1 Ne = — kW( metric HP)
= Nominal rpm =) cpm
- Mean effective pressure PL = bart kp/cm2)
- Maximum combustion pressure Pl. = — bar( kp/cm2)
- Mean piston speed at nominal
engine speed Coad eee =)
CONSUMPTION (according engine type and application)
= Fuel consumption at rated output, Hin = 42MJ/kg (10030kcal/kg)
fuel according to 1503046 /1 : g/kwh ( g/HP/h)
tol. + 3%
- Oil consumption at full load ~ kg/h
NOMINAL MEASUREMENTS
- Number of cylinders
- Swept volume per cylinder
- Compression
= Total swept
- Bore
- Stroke
~ Diameter of
of
of
- Diameter of
of
- Screw thread
6 or 8 in line
: 15,95 dm3
ratio 2 12,1/1
volume 6 cyl. + 95,7 dm3
cyl. + 127,6 dm3
mm
256
310
the main bearing shell 184
the big end bearing shell 178
the gudgeon pin 10
the camshaft bearing 82
the injection pump piston 20
of the cylinder block stud M27 x 2
of the cylinder head stud M24 x 2
- Length of connecting rod (centre to centre) 620
non Ge)
Maintenance manual
General DZC engines
am
Width of the main bearing shell 88
of the big end bearing shell 79
of the small end bearing sleeve LL
of the camshaft bearing 65
Lenght of the push rods 738
of the cylinder block studs 376
Height of the chrome-plated fire ring 5
of the compression ring 4
of the oil scraper ring 8
Lift of the inlet valve 20,40
of the exhaust valve 20,40
of the injector nozzle needle 0,6
of the inlet cam 18,3
of the exhaust cam 18,3
of the injection cam 18
Spacing of the cylinders 380
Spacing of the centre cylinders 400
Number per cylinder :
= inlet valve 2
- exhaust valve 2
= chromed top piston ring 1
- compression ring 2
- oil scraper ring 1
Edition: 1 00-04
ABC ouns the copyright of this document, It shall not be copied oF disclosed without the prior consent of ABC. [ABC owné the copyright of this document. It shal not be copied or disclosed without the prior consent of ABC.
General
Maintenance manual
ZC engines
VALVE TIMING : THEORETICAL FIGURES
Practical opening and closing times
in degrees crank angle (CA)
6DZc 8DzC
- Inlet +: opens before T.D.c. ~ 1.0. 60° 70°
closes after B.D.C. T.c. 40° 40°
- Exhaust : opens before B.D.C. EO. 62° 62°
closes after T.D.c. BC. 55° 65°
- Overlap : 115° 135°
For these angles the valve clearance$in cold condition have
been taken into account. These are +
outlet : 0,15 mm
inlet +: 0,20 mm
T.D.C.
B.D.C.
B.I.
I.0.
I.c.
E.0.
Top dead centre
Bottom dead centre
Beginning injection
Early inlet opening
Late inlet closing
Early exhaust
opening
Late exhaust opening
Set value "B beginning
injection
Engine | rpm x
type cyl [Seyl-
T0750 ° 2
u7s0 | 19,5°| 18,5)
(mypzc | 900 | 21° | 20°
tooo | 21° | 20° ec General Maintenance manual
DZC engines
Remarks ?
- The set values mentioned "B.I." have been determined
according to the "last drop" method
~ Adjustment tolerance = +0,5° in function of thickness
difference of shims (0,1 mm)
- As the cam profile of the inlet and outlet cams is
provided with a starting inclination according to a
harmonic curve, it is very difficult, in practice, to
measure the above-mentioned opening and closing times.
The control can be limited to the measurement of the
crank position with regard to the T.D.C. when both
valve bridges have the same lifting.
With the valve bridges at the same height, is the
theoretical crank measured at the crankshaft for
6DzC : 2°30' before T.D.C. - lifting ca- 12 mm
apzc ; 2°30' before T.D.C. - lifting ca. 16 mm
2.5. FIRING ORDER
Number of . Direction of rotation
Crea Counterclockwise (A) | Clockwise (kK)
6 1-2-4-6-5-3-1 1-3-5-6-4-2-1
8 1-4-7-3-8-5-2-6-1 1-6-2-5-8-3-7-4-1
2.66 CRITICAL SPEED
ABC owns the copyright of this document, It shall not be copied or disclosed without the pri consent of ABC
Every installation is checked for critical engine speeds.
These tests indicate if, at particular engine speeds,
dangerous torsional vibrations occur, which can lead to
catastrophic failure of the crankshaft, coupling, propeller
shaft or generator shaft, damage to gears and bearings, over-
heating of the vibration damper or inadmissible irregularity
of the driven electric machines.
tina 4 00. it not be copied of dsclosed without the prior consent of ABC
ABC ouns the copyright of
e
Maintenance manual
General DZC engines
Continuous running at those engine speeds is very danger~
ous and those speeds must be marked on the engine speed
indicator as forbidden areas.
A.B.C. cannot be responsible for failures arising from the
non-observance of these forbidden areas. In case of modi-
fications to the installation effected subsequently such
as, for example, alteration of the propeller or gears, the
complete installation has to be tested again for critical
speeds.
For this purpose, it isnecessary to contact A-B.C.
TEMPERATURES (in °C)
Exhaust gases : cylinder heads
before turbine
after turbine eee
test sheet
Supercharging air : before air cooler
after air cooler
)
)
»
)
)
)
Double cooling| Single cooling
circuit (HT + | circuit
Cooling system (engine outlet)
LT)
= Normal working 80 to 85°C 80 to 85°C
- Warning signal gore gore
= Stop signal 9s°c 95°C
Lubrication circuit (engine
inlet)
- Normal working 71 to 75°C 77 to 82°C
- Warning signal 80°C asec
~ Stop signal asec gore
Faition
1
90-07 ets General Maintenance manual
DZC engines
2.8. PRESSURES
Description Pressure (bar)
Opening] Working Test
Cylinder head
- Combustion chamber - max. 120 160
- Cooling water space - 2,5 5
Cylinder block
- Jacket cooling water - 2,5 5
Air cooler
- Water side - 2,5
- Air side - ’
Fresh water cooler
- Sea water side - 2,5 8
- Fresh water side - 2,5 10
041 cooler
- Water side - 2,5 8
= 041 side - 5 10
Bryce fuel pump
- Piston and sleeve - max.1095
- Body - - 7
Gasoil max.2,5
Fuel feed _ Tro mand 5
Injection pipe - max. 1095 o
Opening of. injector nozzle 275
needle 7 -
Safety valve (cyl.head) 15042 - =
Safety valve (crankcase) 0,05 - -
Lubrication (engine inlet)
720 and 750 rpm - 4,85 -
900 and 1000 rpm - 5,00 -
Idling speed 6cy 14 8cy.
300 rpm - — |2t02,5 fipto2 -
330 rpm - — |2,5t03 |2to2,2 -
Starting air - max. 30 -
Edition: 1 ane
ABC ovns the copyright of this document. I shall not be copied or disclosed without the prior consent of ABC ABC ouns the copyright of this document, It shall nat be copied or disclosed without the prior consent of ABC.
Maintenance manual
General DZC engines
GENERAL MAINTENANCE RECOMMENDATIONS
WARNINGS
- It is forbidden to disassemble or readjust speed governors,
overspeed devices or any other component which controls
or limits the dynamic conditions of the engine unless this
expressly allowed and the procedure is described in the
Manual.
SAFETY
- Prevent the engine from starting or turning during any
maintenance.
= Open the decompression valves before beginning any repairs
to moving parts.
- Make certain that the crankshaft can turn without danger
to the men working on the engine or driven machines
(alternators, reversing gear, etc.).
Beware of the rotation of the crankshaft when unbalanced
after removal of piston / connecting-rod assemblies.
- Inspect the nuts and bolts and their attachments and the
air, water and oil pipework before starting the engine.
- Make certain that all moving parts are free, by turning
the engine by bar.
- Fill the starting bottles with air or carbon dioxide
(Co,). Never use oxygen or hydrogen.
- When testing the nozzles outside the engine with the
nozzle tester, precautionary measures have to be observed;
in particular
* KEEP HANDS AWAY FROM THE NOZZLE SPRAY
The spray from a nozzle can penetrate deep into the
flesh of the fingers or hand and destroy the tissues.
Fuel oil entering the blood stream can cause blood
poisioning.
« IN ANY CASE clean gasoil or test oil should be used for
testing.
* Do not test the nozzle near a flame or a glowing object.
TOOLING
The necessary tools include :
- ordinary tools on the market : flat, tubular, and ring
spanners, screwdrivers, etc.
~ special tools delivered with the engine ;
ed
- special tools designed by A.B.C. and to be ord
separately ;
= lifting equipment : hoisting tackle, slings, etc.
Edition:
1
no-no ce General Maintenance manual
DZC engines
3.4. MASSES OF THE MOST IMPORTANT PARTS
3.4.1. Masses of the components specific to each type of engine
1 toti Mass in kg.
Section | Description 6 cyl. 8 cyl.
o1 Crankcase with bearings, 2144 2685
caps and tie bolts
06 Crankshaft complete with 980 1386
counter weights and gear-
wheels
08 Cylinder block with liners | 1685 2238
and studs
15 - Gear case pump driving 181 181
with intermediate shafts
and shaft driving fuel
pump
- Intermediate plate 22,5 -
- Intermediate case - 79
20 Turbo compressor VTR 200H 176 -
VIR 250H 311 e
VIR 251 - 483
21 Protection plate 76 72 + 57
exhaust manifolds
Exhaust manifolds 80
22 Inlet air manifold 62 83
23 Supercharging air cooler 232 232
27 Flywheel with starter al
28 pee econ ace-to application
29 - Vibration damper
= type D72/20/2 320 -
- type Dé0/2 and D80/3 - 557
- Flexible driving with 38,5 38,5
gear
Edition: 1
ABC owns the copyright of this document. I shall not be copied or disclosed without the prior consent of ABC @) con neem
DZC engines
3.4.2.
Section | Description Mass in kg.
on Crankcase
= Bearing cap - normal 14,6
- wide 18,25
- guide 16,90
o - Main bearing stud 0,52
s - Cylinder block stud 4,52
i 04 Main bearings
5 = Upper 1/2 shell 0,84
al = Lower 1/2 shell 0,92
3 ~ Ring guide bearing 0,45
3 08 Cylinder block
3 - Liner 69,50
2 - Cylinder head stud 1,61
= 09 Piston
5 - Piston in nodular cast 30 40,5
a iron (GGG)
2 - Gudgeon pin 12,55
i = Set of piston rings 0,75
: 10 Connecting rod
3 = Connecting rod complete with [39,7 or 40,9
zB bush, bearings, cap and
: bolts
A - Connecting rod cap 11,00
i - Connecting rod bolt 0,55
z - Small end bearing bush 1,60
~ Connecting rod bearings
+ Upper 1/2 shell 0,72
+ Lower 1/2 shell 0,65
09/10 Gearing
Gearing complete with piston, 83,00
gudgeon pin, piston rings, cir- or
clips, connecting rod with bush,| 84,20
bearings, cap and bolts Maintenance manual
General DZC engines
Section | Description Mass in kg.
Per Cylinder head
- Cylinder head complwith valves, 134,50
brackets, rockers and support
with shaft
- Cylinder head with valve seats 105 ,00
and valve guide
- Inlet valve 1,10
- Exhaust valve 1,25
= Rockér bridge with grain and 1,30
adjusting screw
- Rockers with shaft and bracket 15,15
- Valve guide 0,27
- Rocker with bush and grain 2,52
12 Governor
= Woodward UG&D governor with 22,80
servo motor
- Woodward UG8L governor 19,60
- Assembly gearwheel boxes driving 12,00
Woodward
13 Driving mechanism injection pumps
- Assembly lever regulating injec-
tion pump 0,53
14 Fuel circuit
= Injection pump 9,08
- Nozzle holder with nozzle 2,30
15 Pump driving
- Intermediate shaft with gear 4,80
driving soft water pump
- Intermediate shaft with gear 6,90
driving sea water pump
- Intermediate shaft with gear 10,30
driving oil pumps
~ Shaft driving fuel pump with 5,70
gearwheel and half coupling
16 Distribution
- Two-part distribution gearwheel 10,35
on crankshaft
- Gearwheel on camshaft 19,10
ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC ABC owns the copyright of this document. It shall nat be copied or disclosed vithout the prior consent of ABC.
General
Maintenance manual
DZC engines
Section
Description
Mass in kg.
17
18
30
- Bearing bracket with gear-
wheels.
= Casing cover distribution
gearwheels
Camshaft
- Guide bearing
- Bearing
- Camshaft
+ cylinder stub
+ begin of stub
+ end of stub
+ intermediate flange
appet_mechanism
= Tappet support
- Tappet with roller (valves)
~ Tappet with roller (injec-
tion pump)
- Push rod assembly
Exhaust system
- Expansion compensator
Oil circuit
= Lubricating pump & gear
wheel
= Scavenge pump & gearwheel
- Lubricating ofl relief
valve
Oil filter
= Support oil filter
- Duplex oil filter
- Centrifugal oil filter
(gasoil operation)
Service oil tank
33,25
47,00
3,98
3,80
18,60
8,00
15,30
1,70
11,30
0,94
1,46
140
37,20
36,50
9,02
50,00
112,00
3,87
203,00 Maintenance manual
General DZC engines
Section | Description Mass in kg.
40/45 Soft water circuit
- Soft water pump & gearwheel 33,60
= Thermostatic regulating valve 19,6
aa Sea water circuit
- Self-priming sea water pump 70,40
with gearwheel & adaptor
50/51 Fuel feeding
= Fuel pump and half coupling 7,15
- Duplex fuel filter 18
60 Electric starting
- Electric starter Bosch 42,50
type TB
61 Pneumatic starting
- Pneumatic starter Gali A24 10,80
nS, 27
- Support starters Gali A24 12,50
A45, 7
66 Control
= Monitoring and safety panel 22,3
DEUTA
= Monitoring panel on engine 15
of ABC
be prier conse
ot be copied oF di
3
:
ABC ovne ABC ouns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC
Maintenance manual
General DZC engines
HANDLING OF COMPONENTS
Use always a lifting apparatus for handling important
pieces, such as cylinder heads, piston- and connecting
rods and cylinders.
On pages 16 and 17 it is shown schematically how the
engine can be lifted as a whole :
- The lifting lugs must be placed as indicated and
therefore the cylinder head covers must be taken away.
- The nuts must be tightened to a torque of 705 Nm
(Jo kgm) (the lifting lugs and the nuts are supplied
by A.B.C.).
- As some cylinder head covers have been taken away,
take care that no dirt, strange objects or others
can fall into the engine.
= The cables or chains, lug and hook must be appropriate
for lifting and handling the indicated weight.
~ With the indicated measures of cables and chains the
engine will hang horizontally in longitudinal line.
In transverse line there can be a deviation of 10 to
415 mm, depending from the type of oil and water cooler.
Fudition
1 Maintenance manual
DZC engines
General
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3.642.
PRECAUTIONS TO BE TAKEN IN ASSEMBLY AND DISMANTLING
Assembly and dismantling must be undertaken under stringent
conditions of cleanliness.
Before dismantling
- Verify that the markings necessary for the reassembly
are in place. If not, mark them as described in this
manual.
- Empty the oil, water and fuel circuits, depending upon
the parts to be dismantled.
When dismantling
- Keep the components for each cylinder separate ;
~ Label each of the components which cannot be marked
(piston rings, bearing shells, etc.) ;
- Protect the dismantled parts from impact, oxidation
and dust. Securely attach the machined parts to a
plank. In that way you will reduce the risk of damage
by impact, by other parts or concrete;
- Avoid dropping metal filings or other dirt into the
crankcase ;
= Clean each piece before examining it ;
- Keep the pipes and openings in the components plugged
during the dismantling ;
= Coat all items which are not to be re-used immediately
with a rust-proof product and clean them just before
reassembly.
When assembling
- Clean all the parts. If steam is used for cleaning,
dry the parts with compressed air 3
= Systematically renew all joints or gaskets
ASSEMBLY DIMENSIONS AND WEAR LIMITS
The original, minimum and maximum dimensions of each
part subject to wear are indicated.
Also specified are the maximum limits of wear at which
the parts must be either exchanged or reconditioned.
These figures are the result of long experience, they
represent the point at which it is considered that safety
and proper functioning become endangered.
Those figures are given in the OD (original dimensions)
and LW (limit of wear) columns.
nna
It stall not be copied or disclosed withuut the prior consent of ABC
i
: ‘ABC owns the copyright of this document, I shall not be copled or disclosed without the prior concent of ABC.
oS
Maintenance manual
General DZC engines
3.8.
3.10.
STANDARDISED DIMENSIONS FOR RECONDITIONING
Parts which can be reconditioned (e.g. crankshafts, piston-
ring grooves, etc.) have standardised dimensions and
tolerances.
If the parts are reworked to those dimensions, parts to be
fit (bearing shells, piston-rings, etc.) can be supplied
from stock.
The dimensions for the first reworking are marked R1, those
for the second R2, and so on.
SPARE PARTS
Spare parts for A.B.C.-engines types 6 and 8DZC are
available.
The parts may be ordered on the basis of the Spare Parts
List.
Note :
When ordering, never quote the numbers from the drawings
and illustrations given in this Manual.
Those numbers and figures indicate only the principles of
the assembly, dismantling and functioning of the various
components.
Mention following data for each order of spare parts :
- 1. the engine number (marked on the constructor's plate );
~ 2. the code number and description of the part, according
to the Spare Parts List.
TOOLS
The tools necessary for assembly and dismantling and for
the maintenance of the various components may be ordered
by quoting the numbers given in this Manual.
Fditian 1
nn19 3
i
ABC oune the copyright of thie document
Ge Maintenance manual
eral DZC engines
MAINTENANCE PROGRAMME
The maintenance schedule and periodicity intervals are
the manufacturer's recommendations in order to achieve
best efficiency and reliability of the engine and life~
time of components. Periodicity intervals are based on
manufacturer's experience.
All the maintenance jobs set out in this programme are of
a periodical nature. At regular intervals, usually ex-
pressed in hours of service of the engine, they have to
be repeated.
In order to facilitate the maintenance and to limit as
much as possible the time when the engine is out of service,
the operations are grouped as a small number of maintenance
jobs and overhauls.
They have to be undertaken after periods of service which
are multiples of one another.
The jobs of the same frequency in each group are set out
in the following pages.
It is pointed out that in each group only the job (main-
tenance or overhaul) which frequency is that of the group
itself is cited. Jobs, which frequencies should be twice,
three times etc. to belong to that group also have to be
carried out at the same time. The repetition does not
appear in each case in the text.
MAINTENANCE AND OVERHAUL
The several groupes of maintenance jobs are classified
under one or the other of the two classes below :
1. Normal maintenance jobs involving partial dismantling,
which may be carried out by the operation staff.
Five types of maintenance jobs are distinguished for
the DZ-engines +
Frequency Code
Each week (about 100 hours) M1
At intervals of 500 hours M2
At intervals of 1000 hours M3
At intervals of 1500 hours M4
At intervals of 3000 hours MS
Edition:
7
00-21 Maintenance manual
General DZC engines
After each maintenance job, the checks C1 have to be
carried out.
The partial and complete overhauls involve substantial
dismantling and more specialized work, which usually
entails taking the engine out of service temporarily.
There are three overhauls for the DZC-engines :
Frequency Code
Minor overhaul at intervals of
6000 hours 0.1
Partial overhaul at intervals
of 12000 hours 0.2
Complete overhaul at intervals
of 24000 hours 0.3
A.B.C. permits a maximum tolerance of approximately
20% on the periodicity of maintenance and a maximum
tolerance of 3000 hours on the periodicity of over-
hauls.
NOTE :
The hours of running read off the meter or stated in
the log book may in some cases be replaced by units
that vary more or less linearly therewith (kilometers
travelled by traction units, energy produced by pumping
installations or by electricity generating sets).
is document, It shall not be copied or dcclosed without the prior consent of ABC.
‘ABC ouns the copyright o Jed without the prior consent of ABC.
bbe copled or dhec
‘ABC ovns the copyright of this document. IH shall a
aa
Maintenance manual
ene
General DZC engines
service, | coae Conponent to be maintained or checked
Before each | ci-01 | check the water and oil levels in the engine.
Beare or at | "707 | check the ofl level in the hydraulic governor.
oP hours it | Gheck the oil level in the turbo-compresor.
ineerval ite | Gheck the starting iz pressure,
its | brain off any water in the service fuel tank.
it | Check the fue level in the service tank.
zach week | 1-01 | top-up the automatic Iubricator on the starting air pipe.
or about “02 | Beein'the compressed air bottles of wat
ook 203 | Gitan the sea water ciiters (acc. to capecity or dimensions)
rei | Control position of contamination indicator on oil filters,
With nomiaal working temperature and nominal speed.
-ose| Gisen'the rotor of che turboccompressor by vater injection.
78g" | Gheck free passage of blow off hole on air cooler.
itr | Clean the centrifugal filter.
zach aonth | na-o1+| Clean the air filters.
or about <02" | Check quality of the water treatnent
300 h. TH | GEER Taging 5 Eegtenely neavily loaded, or if ehe fuel is
see tecy Zicans renew the elements of the fuel filters. (see H3-02)
noi | Rebrieate levers, shaft of the fuel pump driving and Linkage of
the hyaraulic governor.
Check’ freedon of fuel pump control rod.
Tous hours | w3-01 | change the ofl in che curbo-compressor.
Gh | GRADS® ER Cehents of the fuel filters (depending prefiltration
Sr degree of fuel cleanliness)»
1500 hours |w4-01 | Replace the elements of the ofl filter.
<03 | TePeiteeas replace the elesent of the vater
trentnont filter.
aos | SRSRE"Ehs falve Clearances, adjust if necessary.
7S) | GRESE ERS Coating prescure of the noseies and spray pattern.
3000 hours |us-o1 | change che engine oil, clean the crankcase,
Ganga he epficseion/Working conditions/Oil analysis may indicate
tee neceaelty to repigce the oll charge at a thoreer interval.
noze | EBSAR*ERE*EEY Soeoe" circuit’ water, ail and air coolers, sea
water punp)-
03 | TRESECE2RD eateey devices (overspeed, thermostats and presno-
seats:
-04 | Gihge'ehe oft in the hydraulte governor.
* pepending the surzounding conditions, 4.8, applications air
Depending £°5 angine rou ventilacion/ water" poliution ABC owns the copyright of this document, It shall not be copled or disclosed vilhout the prior consent of ABC.
ATB
General Maintenance manual
DZC engines
—
acres code Component to be maintained or checked.
interval >
6000 hours | o1-01 | ‘thoroughly examine the nozzles and their holders. Replace
the nozeles if necessary.
-o2 | Inspect gear driving of governor. Measure backlash.
[03 | Check combustion pressure by fuli lead and idling speed.
Adjust if necessary.
Inapect the distribution : gearvheels, cams, camshaft bearing
taps and bearings
[nepect valve mechanism : push rods, tappets, shafts and rollers.
Inspect gearwheels pump driving.
Clean the air intake circuit.
{clean the rotor of the turbo-compressor)
~o8* | Clean the exhaust system.
(clean turbine turbo-compressor) .
~09 | check deflection of all the cylinders.
Tio | Pneumatic or electric starting + check crown gear and pinion(s).
Measure backlash.
wie | Clean completely water, oil and air coolers.
12000 hours | 02-01 | Remove the cylinder heads - clean them.
Remove the valves, if necessary grind then and/or machine
the seat ring
Check, valve springs and collars.
Complete control of valve mechanism on cylinder head.
(bridge rockers, bushes and shaft).
Renew all gaskets (water, oil, air and exhaust gases)
Check the opening pressure on the relief valve
-02 | check the injection timing. Check the injection pumps, the
tightness of pistons and valves.
~03 | Renew the turbo charger ball bearings.
Toa | Inspect the fresh water~, sea water-, ofl- and fuel feeding pumps.
24000 hours | 03-01 | take out the pistons and measure the clearances and wear of the
iston rings
02 | Ressure the wear, conicity and ovaity of the liners. Renove and
hone then if necessary. Replace seal O-rings.
~03 | Wack out the cylinder block, eventually remove the devosit and
Fepaint interiorly if necessary.
~o4 | Gheck connecting fod bearing - measure clearance.
70s | check main bearings - measure clearancs
sas | check, the nydraulic governor. Eventually, return to the asker
verification.
-07 | Renew elements of fuel pumps if a test bench for pumps is not
available for verification.
-o8 | Carefully check geerwheels pump casing and measure axial clearance
of the roller bearings
-09 | Complete inspection of damper and flexible pump driving.
(*) pepending the surrounding conditions, i.e. application/ air
Pollution and engine room ventilation/ water pollution.
Fdition: 4
00-24 ABC ovis the copyright of this document, It shall nat be copied or disclosed without the prior consent of ABC.
Gay
G ral DZC engines
Maintenance manual
SEQUENCE OF THE MAINTENANCE JOBS AND OVERHAULS
Service
interval
Code : C = Check, M =
© = Overhaul
Maintenance,
Each week
(100 he
approx.)
Every 500h
1000h
1500h
3000h
6000h
12000h
24000h
M1 + M2
M1 + M2 + M3
M1 + M2 + M4
M1 + M2 + M3 + M4 + MS
M1 + M2 + M3 + M4 + MS + 01
M1 + M2 + M3 + M4 + M5 + 01 + 02
M1 + M2 + M3 + MS + O1 + 02 + 03
Feition: 1
0n.78 Maintenance manual
DZC engines
General
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vs HjseMop 9
Maintenance manual
DZC engines
General
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BOIANSS_JO_SUNOH _ 4 the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.
AC ov
Maintenance manual
General DZC engines
TIGHTENING TORQUES
All dynamically strained bolts and nuts as well as
functionally important fastening bolts are tightened by
means of a torque wrench on a predetermined tightening
torque as described in the "tightening torque table”
p- 00-31.
The nuts for fastening the cylinder block on the crankcase
and for fastening of cylinder head are tightened according
to the angular displacement method.
The nuts of the connecting rod bolts are tightened on
elongation.
Both specific tightening methods are described in detail
in the Operating Manual (§ 6.6.). ABC ouns the copyright of this document, t shall not be copled or disclosed without the prior consent of ABC.
Maintenance manual
General i
DZC engines
5.1. TIGHTENING TORQUE TABLE
conPowenr 10 8b TZGHTENED we oF
70, 85 iG BEG | tzoueunng roraue nemanis
NATEREAL " om
ANAS
te Bearing studs reo,s | vso bas
Geeks eae)
2. searing stud nuts aoxt,s | 390-410 |aons2
caanksuars
1. Counterweight bolts wane sw | se
Guith Motykote)
2. dlstetbution gearuneei boits |wtoxa,2s | 40 ‘
‘cuumpg auocx
4. Cylinder Block studs wore 100 | 1
(tece.n 245)
2. cylinder block stud nuts Mo7K2 295+ | 30+ |see operating manual
core coe corseot | iten Gxeedets oF 6:5.2.2.
3. cylinder block screws 20 xs} 7
6 80
SONNESTING ROD etongetton _|#ee chapter 2 (taint.manval)
1. Big end stud nuts ne0x1,5 glongation | 3° SheFsting manual
‘Leom 5-6-4-1-
CYLINDER HEAD
4. Cylinder head studs weaxe 100 10
(hioce. x 222)
2. Cylinder head nuts wea 24s + | 25+ | see chapter 1 (waint-manvat)
a5%+ 95° 5° + as°| item 1.2:2.8, a) b) or ©)
WSO nS
3. Studs for the rocker brackets] M16
(tect. W245)
4. stud nuts for the rocker ™ 155 16
brackets,
5. Rocker shaft locking bolts m2 as 86
6. Nozzle holder muffle nut — | ws6x2 195 20
(ect. N°542)
7. Safety valve in cylinder | m39x1.5 37 [14a
head
PUEL_ FEEDING
4. Injection punp bolts mae 50
2, Cap nut fixing nozele holder | w76x2 540 55
in cylinder head
3. Nozzle nut. 237 24,7
4. Coupling nut inject.pipe | w2axt,5 60 6
5. Fixing nut pressure valve 13-861 | 83-90
holder inject-pump (ith Molykote)
6. Hexagon socket screws mi0x30 was] 35
clamping flange H.-P. pipe
FLYWHEEL
1. Flywheel bolts 30% aseo | tat
STARTING HOTOR GALT TYPE A4S
Ls Fixing bolts support mae 340 35
Editinn- 4 00-31 (Ae) wiser nace
ets General Maintenance
DZC engines
COMPONENT TO BE TIGHTENED rye oF | rrGHTENING TORQUE
‘OR INSERTED THREAD Ne kon a
IMaTERTAL
CAMSHAFT ~ prsrerBUTION
| 2. cansnate ttange coupting norte] a2 ws | a6
3. canmtaft bearing soles ine ww | oo
Bs 3 | ks
5] totes clamping essenoty -
6. Fouing notes camshare gears | a2 ew | as :
fast oerestneae ;
1. Goupting bolts intermediate | Wi2 2 | as ;
= (ices we2ed} i
6. Botts ftxing cap on Dearing L
topror Tneacaestate gene m0 ws las :
9. Bolts fixing bearing support cecenasso)) a
intermediate gears on crank- 2
casa ms | 2s | as
PUMP DRIVING GEAR castNG 5
1. Casing bolts m2 85 86 3
2. Bolts driving gear on ™10 so 4,8 i
Sense stage Boe. wsel} i
Mfeteies noesYinee ee tee lt ee 7 2
bs se 1 48 . :
4. S010 locking puts intecunt sutte| mao | aso | as
5 ee | oe et i
a cioce. nosed} 2
6. Self-locking nut driving gear=| M20 150 as 3
wheel oil] pump 5
1, Seifatocking nut ftxing éziving] wo | aso | a8 i
peaesanifuateei cs a
8. belts clonping esay éetving | ng | ta .
40, Coupling botts PP0 shart on | ane | sas | os F
feselesae 3
GOVERNOR _ORIVE
1s Bolts driving gearwheel on ms 25 25
camshaft gearwheel (oct. e222)
2. Bolts RESITEX gear Me. 2s 2,5
(loct.. n*222}
3. Self locking nuts fixing conical
gears governor type UGS m0 30 3
type PG m2 50 5
‘TURBOCHARGER & EXHAUST MANEFOLDS
1. Nuts fixing turbo type viR250 | M20 400 a1
type ytRZ00 | mis 210 21
ype VaReot | Hep 599 H
2. Nuts fixing turbo support nie 2
3. Bolts, exhaust manifold flames| m6 140 4
and expansion bellows :
i
4
Maintenance manual
ZC engines
CHAPTER 1
CYLINDER HEAD
Assembly 11 ABC ouns the copyright of this document. It shall nat be copied or disclosed without the prior consent of ABC.
(8)
CHAPTER 1
, Maintenance manual
Cylinder-head DZC engines
1.
rede
CYLINDER HEAD
DESCRIPTION - Figures 1a and 1b
The cylinder head (1) in lamellar cast iron, alloyed with
CU - Ni - Mo is fitted with two inlet valves (48) and two
exhaust valves (49) sliding inside valve guides (4) around
the centrally-mounted nozzle (14/3-11).
The inserts, inlet (2) and exhaust (3), in special cast
iron, are fitted by contraction of the inserts in liquid
nitrogen.
The cylinder head is fastened by means of 6 dynamic-elastic
studs screwed in the cylinder-block.
Tightness of the combustion room is obtained by a flat
brass gasket (65).
seeeeees 98 kg
20 9134,5eq
- bare cylinder head «
- complete cylinder head with rockers -
RECAPITULATION OF THE MAINTENANCE JOBS
Overhaul Job
o2 - O21 Remove cylinder heads, remove deposits and
clean them
Check valve guides
Check valves
Hydraulic test of the water chamber Maintenance manual
DZC engines
CHAPTER 1
Cylinder-head
> q Jou jeus Hy -yusuDP 5H
av
69 12 19 ZL 09 1 Gt AL ZL
07 Maintenance manual
DZC engines
CHAPTER 1
Cylinder-head
on
|_—_—s
L
-——"
Wy esa
BE o ah
E ES \ eta
5 | ——2
}-——| 7 Aa ee 19
ZL-0/ 4b
a
€L-0/ 41
EF
oy
Fig. 1b. CHAPTER 1
g2 Cylinder-head pecleaoet mansal
Gleflggo SPARE PARTS
Figen? | Ref-n® Description Number/|
cyl.
ta 4 Valve guide 4
ta 2 Insert (inlet) 2
ta 3 Insert (exhaust) 2
tb 65 Cylinder head gasket 1
1b 14/0211 | Precision seal-O-ring 1
tb 14/o-12 | Precision seal-O-ring 1
1b 14/0-13 | Precision seal-O-ring 1
tb 14/0-8 Joint 1
ta 60 Joint 1
ta 72 Joint 1
ta nn Joint 4
ta 16 Joint 1
ta 17 Joint 8
ta 18 Joint 1
ta 19 Joint 2
1b 62 Seal-O-ring cylinder head 1
cover
ta 22—4 Joint (air intake cylinder 1
head)
ta 21-16 Joint (exhaust flange cylinder] 1
head)
1b 15 Seal O-ring nozzle holder 2
sleeve
‘OC owns the copyright of this document, It shall not be copied or disclosed without the priar consent of ABC
This table only deals with spares for cylinder head.
Joints and washers for the pipes connected to it are
mentioned in the spare parts list. wt be coped or disclosed without the prior consent of ABC.
ABC ovns the copyright of this document. It shal
CHAPTER 1
Maintenance manual
Cylinder-head aes
11.4. TooLs
Code Description
620.083.1200.02 Tool for mounting and dismounting
valve spring
620.083.1300.01 Tool for extracting nozzle holder
100.933.012.000 Lifting eye bolt
620.083.7200.01 | spindle
620.083.1601.01 Torque wrench
620.083.1602.01 Extension Components
620.083. 1603.01 Reversible ratchet from
620.084.1303.01 Socket assembly
620.083.1600.01
620.083.1615.01 Reference pin
620.083 9007.01 Magnetic base
+620.084.2200.01 | Tool for recutting inserts (inlet
and exhaust)
+620.084.2400.01 | Tool for mounting and dismounting
valve guides
+620.084.9010.01 | Tool for lapping collar cylinder liner
and cylinder head
620.084 .2100.01 Tool for cylinder head hydraulic test
*620.084.2300.02 | Tool for mounting, removing & lapping
the nozzle holder sleeve in cylinder-
head
+ special tools, not Standard delivered with engine
(only delivered on request)
1.1.5. DISMOUNTING
Required staff : one service man
1.1.5.1. Removing cylinder head
= Drain partly thi
head is free fr
- Remove the cyli
(63)
~ Remove exhaust
e soft water circuit so that the cylinder
om water
nder head cover by unscrewing the handle
gas thermometer 8)
CHAPTER 1
i Maintenance manual
Cylinder-head ZC engines
1-1-6614.
= Disconnect cylinder head pipings, (fuel injection piping,
fuel drain piping and lube oil piping valve gear)
and remove elbow-water outlet (44-4)
- Remove the complete rocker levers (20 & 24) with bracket
(27) and bridges (33), and push rods (18-A/1). Remove
also nozzle holder (14/3-A) with tool (620-083. 1300.01),
after having taken away the injection pipe coupling piece
(14/1-1), hexagon cap nut (14/1-3) and cap (14/1-4).
After extracting nozzle holder, screw back hexagon cap
nut (14/1-3) in the cylinder head.
- Release cylinder head from gas outlet manifold and air
intake manifold.
The exhaust manifold shielding plate has to be removed in
advance from engines, which are provided with it.
- Unscrew fixing nuts from cylinder head in 2 times (1st
time, about 90°).
~ Lift cylinder head by means of eye bolt (100.933.012.000),
which will be screwed in the hexagon cap nut (14/1-3).
REMARK : Do not damage the sealing surface at the cylinder
head gasket side. Thus, :always put the cylinder
head on a wooden object.
MAINTENANCE
Required staff : one service man
Cleaning cylinder head
- Dismantle cylinder head assembly, except valve guides
(4), inserts (2 & 3) and nozzle holder sleeve (6)
- Clean in petrol or white spirit
- Remove deposits from exhaust ducts using a blunt
scraper, Or a chemical recommended by the engine builder.
- Examine carefully the state of the inner walls of the
water jacket through water inlet and outlet ports and
plug holes.
Any deposit thicker than 0,4mm shall be removed. This
can be done either using a special product, or a mixture
of 1 part of hydrochloric acid (20° - 21° Baumé, i.e.
gravity 1.16 and 35% concentrating-vol.) for 6 parts of
water (pour acid into water)
= Close all, except one of the openings of the water jackets
by means of wooden or plastic plugs. Pour tne mixture
into the cylinder head
editian
tone
woul the peor consent of ABC.
1 copyright of this document. It shall not be copied or decosed Wi
ABC oun. ‘ABC uns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.
CHAPTER 1
., Maintenance manual
Cylinder-head DzC engines
Water connection _[
female thread
V/2'C
~ Be careful of the gas which is produced ; it is flammable
(no open flames in the vicinity). Empty the cylinder head
when no more gas is produced or if none is present.
- Rinse the cylinder head with running water when the
deposit has disappeared ; if not, start the process again
~ After rinsing, dry the cylinder head with compressed air.
Hydraulic test of the cylinder head
After cleaning and the removal of the deposit, the water
jackets have to undergo a hydraulic test at 7 bar for 15
minutes.
Fig. 2 shows the arrangements with tool 620.084.2100.01
for the test.
While the cylinder head is under pressure, examine care—
fully its lower surface, the in- and outlet ducts and
plugs closing the water jackets, particularly on the upper
surface of the cylinder head (contamination of the oil ii
case of a water leak) and around the nozzle holder sleeve.
No seepage may be tolerated, at the risk of damage of the
cylinder ("water hammer") or to the timing gear (oil conta~
mination).
In case of water leakage around the nozzle holder sleeve,
we refer to 1.1.6.6.
Desaeration
te --g- oS
CHAPTER 1
i Maintenance manual
Cylinder-head zc engines
161-623.
1.1.6.4.
Inspecting cylinder head sealing surface
Using a colour and a surface table, check the sealing
condition on the cylinder head gasket side.
Check also the sealing surface of the cylinder liner with
a lapping ring (620.084.9010.01).
In case of faulty sealing, it shall be lightly lapped with
above mentioned tool in order to obtain a perfect mating
between cylinder head gasket, cylinder head and liner.
Inspecting and replacing, if necessary valve quides
Remark +
The valve guides should only be removed for replacement
because of damage or attaining the wear limit.
- The valve guides being in place in the cylinder head,
measure inner diameter A for comparison to the values
in the table of original measures and wear limits
(fig. 3).
| yi| *
| Lr, op LW
| Yee
| | a | 18,000
\ = 18.038 | 18,250
In
I 5
ae + Fig 3
- If the wear limit is exceeded at one of the measuring
points, extract the valve guides from the cylinder head
with tool 620.084.2400.01 = (fig. 4a).
Before inserting the new valve guide using the adequate
tool (fig. 4b), it is recommended to measure bore (B)
in cylinder head and outer diameter (C) of the valve guide,
making sure that initial conditions are met, that is :
+0,021
-0
+0,035
B = 625H7 101022
C = 625p6
[ABC owns the copyright of this document, It shall not be copied oF disclosed without the prior consent of ABC [ABC owns the copyright of this document, I shall not be copied or disclosed without the prior consent of ABC.
CHAPTER 1
Cylinder-head
Maintenance manual
ZC engines
y
;
An
Tool LR
620.084.2400.01 1
fa i
&
Fig. 4a
Extracting valve guide
:
She
te
Fig. &b
Inserting valve guide (B38) CHAPTER 1
<5, Maintenance manda
Cylinder-head DZC engines
After inserting, measure the valve guide inner diameter,
which has to correspond with the original measures
(see table fig. 3).
Inspection, grinding and replacing inserts if necessar'
1. Inspection :
After a number of hours of operation, the insert working
surface takes a characteristical aspect. The inserts can
have a marble aspect, quite different from a new insert.
This is due to very small surface unevenness, though
unadequate for jeopardizing the insert or valve.
This aspect does not entail rectification of the insert,
which would only result in a loss of material.
Rectification is only justified in following cases :
A. damages such as : — burnings
= mechanical shocks
- gas leaks
B. geometrical defects that is to say, when a feeler
gauge of 0,02 or 0,03 mm can be inserted between
a valve and the insert (in good condition and pressed
in by hand).
2. Grinding of inserts
If grinding is justified, it will be made by removing
the minimum of material.
For this, use tool 620.084.2200.01.
The success of this operation supposes that the valve
guides are in a good state and do not exceed the wear
limit (see fig. 3).
After grinding inserts, check whether the rectification
imits are not exceeded.
3. Insert_rectification limit
a) Inlet = figure 5
Original insert Max. rectification limit
(inlet) insert (inlet)
02 max. = 86,5 20,10
‘ABC ovns the copyright of this document. Ir shall not be copied or disclosed without the prior consent of ABC és document. It shall not be copied or disclosed without the prior consent of ABC.
[ABC owns the copyright of
CHAPTER 1
Cylinder-head
Maintenance manual
DZC engines
GzZzzS
Mill cutter
62)
b) Exhaust = figure 6
Original insert
(exhaust)
Max. rectification limit
insert (exhaust)
84.8101.01 (inlet)
620.084.8201.01 (exhaust)
assy
ng ft
SH
Thrust bearing A~
Fig. 7
Mount the corresponding mill
cutter for inlet or exhaust
valve insert on the holder.
Slide holder with cutter through
the valve guide.
Place thrust bearing assy and
mount the high hexagon nut.
Place the twist bar and tighten
the hexagon nut untill the
cutter becomes rotating re-
sistance and bites in the
material.
Tighten further the hexagon
nut during the reworking ope-
ration.
Inspect after a few turns the
state of the insert and stop
operation as soon as the wor-
king face is clean.
check if the rectification limits
are not exceeded. AB CHAPTER 1
Maintenance manual
ccs Cylinder-head DzC engines
1.1.6.6. Removing and lapping the nozzle holder sleeve ~ Fig.8
When a hydraulic test has been done as described under
1.1.6.2. and some water leakage were seen around the
nozzle sleeve, then, the sleeve has to be removed and
the seal O-rings replaced.
Fig.8 shows the arrangements with tool 620.084.2300.02
for the mounting, removing and lapping the nozzle holder
sleeve. Therefore the nut above the nozzle holder sleeve
has to be removed first. Use tool 620.084.2301.02.
Without the seal O-rings, the sleeve has to be remounted
and the seat must be lapped to assure an adequate sealing.
Use therefore tool 620.084.2300.02, without the bridge,with
lapping paste N°2 and a cranked handle with $19 socket.
After lapping remove the sleeve for cleaning.
Put new seal O-rings and remount the sleeve.
Fit the special nut and tighten on torque. See table 5.1.
LAPPING
620.084.2300.02
ot be copied or disclosed without the prior consent of ABC
ABC ons the copyright of Hhis document. IF shall
\
y)
I
Fig. 8
{1 ABC ouns the copyright of this document. It shall nat be copled or disclosed withuut the prier consent of ABC.
(2)
CHAPTER 1
- Maintenance manual
Cylinder-head DZC engines
1.2.
4.2.4.
Blea ertayi)
iriorco
eorte se]
VALVES AND THEIR MECHANISM
ROCKER LEVER MECHANISM
Description = Figure 1a and ib
The two simple rocker levers (20 & 24) provided with
bushes (21) are mounted on a shaft (26), clamped in the
support (27) by means of 2 screws (31).
The support is aligned by the slotted spring pin (59) and
fastened on the cylinder head by means of the central
screw (56) and two studs (55) with nuts (57).
The rocker levers are pressure lubricated, the oil passing
through the shaft and returning to the crankcase by way
of the push-rod sheaths (18-A/4).
Both simple rocker levers (20 & 24) act on respectively
both inlet- and exhaust valves (48 & 49) by way of the
bridge (33).
er stkge
Mass : rocker levers with support ..
Recapitulation of the maintenance jobs
Overhaul Job
02-01 Clean oil ducts
Check bushes and shafts for dimensions
Spare parts
Optional
Fig.n?/ Par Number/
eeemne Description cyl
1/2 Bush a CHAPTER 1
® a
Cylinder-head DZC engines
1.2.1.4. Tools
Description
*620.084.2500.01 | Tool for mounting & dismounting valve
rocker bush
traight jaw external circlip pliers
for external circlips from 25 = 60 mm.
* special tools, not standard delivered with engine (only
delivered on request)
edie se
mantling
: one service man
Inscrew both nuts (57) and central screw (56) and remove
the rocker lever assembly
- Dismantle the rocker levers retained by circlips (30)
and remove shaft from support
- Clean ofl ducts in support, shaft and rocker levers
1.2.1.6. Maintenance
the rocker lever
oD, Lw
Outside | 49,975
Bearing 50,045
bush ¢ | 50,008
Fig. 10
ABC owns the copyright of thi dacunent, It shall not be copied or dlslosed without the prior consent of ABC. ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC
CHAPTER 1
ect> Cylinder-head DZC engines
+ Replat
Bushes should be removed only for replacement in case
of damaae or when the limits of wear have been exceeded.
- Extract and assemble bushes using tool 620.084.2500.01
(figure 11a and b).
620.086.250.071
Fig. 11a Fig. ta
Extracting a bush Inserting 2 bush
Assembly
Required staff : one service man
A E ;
- Put valve push-rods (18-A/3) in the seats.
- Place bridges (33) on the valve stems and remove
clearance between them.
Proceed as follows +
(always with cold engine)
-Unscrew lock nut (37) and turn set screw (35) back
-Place a dial gauge with magnetic foot, so that the
feeler gets in touch with the bridge (right or left)
Press manually the bridge on the valve and turn the
set screw till the gauge is moving (0,01 to 0,02 mm)
«Keep the set screw in this position and tighten the
lock mut
-Adiust the other bridge in the same way. CHAPTER 1
; Maintenance manual
Cylinder-head DZC engines
2. Installing the rocker levers
~ Before mounting rocker levers on cylinder head, check
whether
+ slotted spring pin (59) is placed
+ the lock nuts (32) are unscrewed and set screws (25)
are screwed back
+ the valve push-rods (18-A/3) are at their lowest
point (piston T.D.C. — injection)
= Place the valve lever assembly and support so that the
push-=rods are located in the middle of the sheaths.
Tighten both nuts (57) and central screw (56) according
to the tightening torque table.
- When starting the engine, check whether the oil
reaches all points to be lubricated.
Adj 9 i$ (fig-la)
When valves have been grinded or replaced, it is
necessary to adjust again the valve bridge. This adjust-
ment eliminates the clearance between valve bridge and
valve stems ends.
- Set the piston of concerning cylinder at TDC com-
pression stroke
~ Loose the lock nut (37) and turn the set screw (35)
slightly back
- Place the dial gauge with magnetic support in such a
way that the feeler is on the bridge
- Push down by hand the bridge on the valve stem and
turn the set screw down untill the dial moves of 0,01
to 0,02 mm
- Hold the set screw with the wrench in this position
and tighten the lock nut.
Adjustment _of _valye clearance (clearance_between_rocker
ge
Valve clearance is set with cold engine and measured
with thickness gauges. They are placed between set screw
(25) and pad (34) on the bridge.
- Set the piston of concerning cylinder at TDC com
pression stroke
- Grease lightly those surfaces before measurement
- Turn the set screw till the clearance between rocker
lever and bridge is 0,20 mm for the inlet and 0,15 mm
for outlet.
A certain resistance will be felt on the thickness
gauge, but it should not be jammed.
- Keep the set screw in this position with the wrench and
tighten the lock nut
- Check the clearance again.
docomeat, it shall oot be copied or disclosed without the pri consent of ABC
ABC oune the copyright of 1 CHAPTER 1
