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Inspe Inspect ct camshaft bearings. camshaft bearings.

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Replace bearings if necessary. Replace bearings if necessary.

1.

1.

Remove camshaft bearing journal. Remove camshaft bearing journal.

2.

2.

Measure inner diameter of bearing bush. Measure inner diameter of bearing bush.

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Measure three diamete Measure three diameters in a position 120° rs in a position 120° from each other. The average diamet from each other. The average diameter to er to be compared wi

be compared with th wear limit. The wear limit wear limit. The wear limit is stated in is stated in chapter clearance and wear chapter clearance and wear limits.

limits.

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If the wear limit for one If the wear limit for one camshaft bearing bush is reached, all camshaft bearing bushes camshaft bearing bush is reached, all camshaft bearing bushes should be replaced.

should be replaced.

3.

3.

For visual inspection of the camshaft bear For visual inspection of the camshaft bearing bush has the camshaft piece ing bush has the camshaft piece and bearing and bearing  journal to

 journal to be removed. be removed.

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 Components:Components: 01 Crankshaft gear, 02 Bigger intermediate gear, 03 Smaller intermediate gear, 0401 Crankshaft gear, 02 Bigger intermediate gear, 03 Smaller intermediate gear, 04 Camshaft gear 

Camshaft gear 

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 Inspect inInspect in termediate getermediate gearsars  An

 An early deearly detection tection of anof any tooth y tooth damage damage can prevent can prevent serious serious damage. damage. Checking Checking intermediate, intermediate, camshaftcamshaft gears and other parts condition.

gears and other parts condition.

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 ReReplace conneplace connectinctin g rod g rod screwsscrews

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 Replace connecting rod screws by new ones at every second overhaul when doing pistonReplace connecting rod screws by new ones at every second overhaul when doing piston overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer intervals than 16 000 h.

intervals than 16 000 h.

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 The nuts for the connecting rod screws do not need changing, unless they appear damage.The nuts for the connecting rod screws do not need changing, unless they appear damage.

Clean and examine the nuts carefully at every overhaul Clean and examine the nuts carefully at every overhaul

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 ReReplace place connecting rod connecting rod shimsshims

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 Replace connecting rod shims by new ones at every second overhaul when doing pistonReplace connecting rod shims by new ones at every second overhaul when doing piston overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer intervals than 16 000 h.

intervals than 16 000 h.

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 Replace Replace big end bbig end b eaearinrin gsgs

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 Replace big end bearings.Replace big end bearings.

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 Inspect mating surfaces.Inspect mating surfaces.

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 Measure the big end bore, use measurement record.Measure the big end bore, use measurement record.

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 When measurinWhen measuring, upper and lower screws must bg, upper and lower screws must be tightened to the stated pressure.e tightened to the stated pressure.

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 Inspect the small end bearingsInspect the small end bearings

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 Inspect the small end bearings clearance byInspect the small end bearings clearance by

measuring the gudgeon pin diameter and small end bearing bores separately.

measuring the gudgeon pin diameter and small end bearing bores separately.

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 Replace if necessary.Replace if necessary.

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 Turning tool of main bearingTurning tool of main bearing

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 Inspect main bearings.Inspect main bearings.

1.

1. Dismantle side screws and mDismantle side screws and m ain bearing nuts.ain bearing nuts.

2.

2. Lower the main bearing cap by hydraulic jack.Lower the main bearing cap by hydraulic jack.

3.

3. Remove the lower bearing shell.Remove the lower bearing shell.

4.

4. Insert the turning tool into the main bearing journal radial oil hole.Insert the turning tool into the main bearing journal radial oil hole.

5.

5. Turn the crankshaft carefully until the bearing shell hTurn the crankshaft carefully until the bearing shell has turned 180°as turned 180° and can be and can be removed. Removeremoved. Remove turning tool.

turning tool.

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 Clean the bearing shells and check for wear, scoring and other damages.Clean the bearing shells and check for wear, scoring and other damages.

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 The main bearing journals should be inspected for surface finish. Damaged journals, i.e. roughThe main bearing journals should be inspected for surface finish. Damaged journals, i.e. rough surface, scratches, marks of shocks etc., should be polished.

surface, scratches, marks of shocks etc., should be polished.

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 No scraping or other damage of bearing shells, caps and saddles is allowed. Burrs should beNo scraping or other damage of bearing shells, caps and saddles is allowed. Burrs should be locally removed, only.

locally removed, only.

WARNING!

WARNING!

Never re-install a bearing with the nickel-barrier exposed in any part of the bearing shell.

Never re-install a bearing with the nickel-barrier exposed in any part of the bearing shell.

WARNING!

WARNING!

Mark the new bearings with the bearing numbers.

Mark the new bearings with the bearing numbers.

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 Spare paSpare part rt setssets

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 Sealing set for cylinder head replacementSealing set for cylinder head replacement

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 Sealing set for cylinder head overhaulSealing set for cylinder head overhaul

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 Overhaul of cylOverhaul of cyl inder headinder head

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 Pressure test cylinder head water side.Pressure test cylinder head water side.

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 Dismantle and clean the underside,Dismantle and clean the underside,

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 Dismantle, clean and check condition of inlet and exhaust valves and ports.Dismantle, clean and check condition of inlet and exhaust valves and ports.

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 Inspect cooling spaces and clean, if necessary.Inspect cooling spaces and clean, if necessary.

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 Grind the valves and seat rings.Grind the valves and seat rings.

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 Inspect the valve rotators.Inspect the valve rotators.

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 Check rocker arms.Check rocker arms.

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 Pressure test cylinder head water side.Pressure test cylinder head water side.

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 Replace the O-rings in the valve guides.Replace the O-rings in the valve guides.

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 Replace the O-rings at bottom of cylinder head screws at every overhaul.Replace the O-rings at bottom of cylinder head screws at every overhaul.

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 Fill cylinder head screw pocket with engine oil.Fill cylinder head screw pocket with engine oil.

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 ReReplaceplacement coment co mponmpon entsents

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  Anti-polishin Anti-polishing g ringring

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 InspeInspect tct t he cylinder linhe cylinder lin ersers  Always

 Always hone hone the cylinthe cylinder lineder liner when r when new piston new piston rings arings are mountre mounted.ed.

Normally a light honing is sufficient.

Normally a light honing is sufficient.

If the honing is done when the cylinder liner is on its place in the engine block, the crankshaft under the If the honing is done when the cylinder liner is on its place in the engine block, the crankshaft under the cylinde

cylinder liner concerned must be r liner concerned must be covered by plastic filmcovered by plastic film..

Honing rests must be prevented from falling into the oil sump of the engine.

Honing rests must be prevented from falling into the oil sump of the engine.

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 InspeInspect tct t he cylinder linhe cylinder lin ersers 1.

1. Measure the cylinder liner diameter using measurement record.Measure the cylinder liner diameter using measurement record.

2.

2. Replace liner if wear limits are exceeded.Replace liner if wear limits are exceeded.

3.

3. Hone the liners.Hone the liners.

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 The honing is to be carried out by means of Plateau honing.The honing is to be carried out by means of Plateau honing.

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 Only ceramic hones wOnly ceramic hones with a coarseness of 80 and 400 shoulith a coarseness of 80 and 400 should be used.d be used.

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 The pitch angle of the honing lines in the cross hatch pattern should be about 30°.The pitch angle of the honing lines in the cross hatch pattern should be about 30°.

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  As coo As coolant a lant a honinhoning oil is preferredg oil is preferred..

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 When honing the liner fitted to the engine the used honing oil must be directed from the engineWhen honing the liner fitted to the engine the used honing oil must be directed from the engine with e.g. a tarpaulin or similar.

with e.g. a tarpaulin or similar.

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 The honing time depends on the condition of the bore surface. Usually only a few minutes'The honing time depends on the condition of the bore surface. Usually only a few minutes' honing is required.

honing is required.

4.

4.  After  After honinhoning, clean g, clean bore cbore carefully.arefully.

5.

5. Check the cylinder liner diameter.Check the cylinder liner diameter.

6.

6. Clean the cylinder liner cooling bores.Clean the cylinder liner cooling bores.

7.

7. Renew the anti-polishing ring after piston mounting.Renew the anti-polishing ring after piston mounting.

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 Replace Replace the main gas admisthe main gas admis siosio n valvesn valves

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 Check that the gas supply valves are closed, the gas ventilation valve is in open position and gasCheck that the gas supply valves are closed, the gas ventilation valve is in open position and gas pressure is drained out from the gas lines.

pressure is drained out from the gas lines.

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 Dismantle flexible pipe Dismantle flexible pipe connecconnection.tion.

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 DisconneDisconnect the cable of ct the cable of admission valve and remove the gas admission valve.admission valve and remove the gas admission valve.

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 Replace the main gas admission valve with new one.Replace the main gas admission valve with new one.

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 Replace O-rings with new ones.Replace O-rings with new ones.

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 CleClean the main gas admission an the main gas admission valve filter insertvalve filter insert

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 Clean the main gas admission valve filter insert.Clean the main gas admission valve filter insert.

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 Replace if needed.Replace if needed.

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 Replace O-ring with new ones.Replace O-ring with new ones.

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 System System compocompo nents:nents: 01 01 Main Main gas filter, gas filter, 02 02 Main Main gas piping, gas piping, 03 03 PCC PCC gas piping, gas piping, 04 04 Gas Gas manifold,manifold, 05

05 Main gas Main gas admission valve, admission valve, 06 06 PCC gas PCC gas channels channels in Hot-box, in Hot-box, 07 07 PCC gas PCC gas delivery piping,delivery piping, 08

08 Main gas Main gas venting valve, venting valve, 09 09 Actuator for Actuator for main gas main gas venting valve, venting valve, 10 10 PCC PCC gas venting gas venting valvvalve,e, 11

11 Non-return Non-return valve, valve, 12 12 Gas ventiGas venting png piping.iping.

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 Pipe Pipe connectionsconnections :: A  A 108 G108 Gas inleas inlet, B t, B 110 PCC 110 PCC gas inlet, gas inlet, C C 727 727 Gas systeGas system vent, m vent, D D PCC ventinPCC ventingg gas, E

gas, E 311 Control 311 Control air to main gas air to main gas venting valveventing valve

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 TeTestst ing the gas systing the gas syst em for leakem for leak

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 Connect compressed air/nitrogen, of 3 bar to the inlet flange of the gas system on the engine.Connect compressed air/nitrogen, of 3 bar to the inlet flange of the gas system on the engine.

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 Check all connections with soap water or leakage spray, beginning from the inlet flange andCheck all connections with soap water or leakage spray, beginning from the inlet flange and continuing through the gas line.

continuing through the gas line.

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 Growing bubbles on the connection indicates leakage.Growing bubbles on the connection indicates leakage.

NOTE!

NOTE!

Release the air pressure in the system before disassembling.

Release the air pressure in the system before disassembling.

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 Disassemble the leaking connection, examine the O-rings and sealing faces. Replace wornDisassemble the leaking connection, examine the O-rings and sealing faces. Replace worn parts.

parts.

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 Repeat the leak test for the repaired connection(s).Repeat the leak test for the repaired connection(s).

NOTE!

NOTE!

When the engine is running a portable gas leak detector can be used.

When the engine is running a portable gas leak detector can be used.

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Inspe

Inspection of tction of t he piston crownhe piston crown

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 Clean all the parts and all spaces carefully.Clean all the parts and all spaces carefully.

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 Inspect combustion space for corrosion and/or bInspect combustion space for corrosion and/or b urning marks.urning marks.

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 Check a deposit layers thickness in the cooling spaces.Check a deposit layers thickness in the cooling spaces.

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 Inspect all surfaces by crack detection test.Inspect all surfaces by crack detection test.

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 No cracks are allowed.No cracks are allowed.

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 Measure the distance between the inner and outer support surfaces, see measurement record.Measure the distance between the inner and outer support surfaces, see measurement record.

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 Check the height of the ring grooves, use measuring record.Check the height of the ring grooves, use measuring record.

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 Replace complete set of piston rings. Note the running-in programme.Replace complete set of piston rings. Note the running-in programme.

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 The piston assembly must be dismantled for inspection of mating surfaces between piston skirt andThe piston assembly must be dismantled for inspection of mating surfaces between piston skirt and piston crown and for inspection and cleaning of cooling oil spaces.

piston crown and for inspection and cleaning of cooling oil spaces.

Visua

Visual inspectiol inspectio nn

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 The combustion space must be checked for corrosion and/or burning marks.The combustion space must be checked for corrosion and/or burning marks.

If marks deeper than 2 mm are found the piston crown should be replaced.

If marks deeper than 2 mm are found the piston crown should be replaced.

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 Check a deposit layers thickness in the cooling spaces.Check a deposit layers thickness in the cooling spaces.

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 Deposits in the cooling oil space thicker than 0.5 mm is an indication of contaminated lubricatingDeposits in the cooling oil space thicker than 0.5 mm is an indication of contaminated lubricating oil. Such extensive deposit layers can cause overheating of the piston crown.

oil. Such extensive deposit layers can cause overheating of the piston crown.

Cra

Crack dck d eteetection ction testtest

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  A crack  A crack detection detection test by ustest by use of liquie of liquid pend penetrant etrant or, or, preferably, preferably, magnetic magnetic particle particle detection detection methodmethod should be performed, comprising all

should be performed, comprising all surfaces.surfaces.

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 No cracks are allowed.No cracks are allowed.

Measurements Measurements

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  Assessment  Assessment of wear of wear of the of the support support surfaces surfaces to be to be made by made by measurement measurement of the dof the distance istance between between thethe inner and outer support surfaces, see measurement record.

inner and outer support surfaces, see measurement record.

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 Check the height of the ring grooves, use measuring record.Check the height of the ring grooves, use measuring record.

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 Replace complete set of piston rings. Note the running-in programme.Replace complete set of piston rings. Note the running-in programme.

NOTE!

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In document Núm. 16 (2018) (página 142-145)