Manuel Moteur ABC 6DZC [PDF]

Zitiervorschau

B24 Edition: 005 release date: 14-Jul.-2017

Maintenance manual for diesel engines ABC type 6/8DZC

Anglo Belgian Corporation Wiedauwkaai 43 9000 Ghent, Belgium T : +32 (0) 9 267 00 00 F : +32 (0) 9 267 00 67 E : [email protected]

File : B24_00_dd2017_07_14_Ed005_EN_FrontPage_Maintenance_manual_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC

B24 Edition: 005 release date: 14-Jul.-2017

Maintenance manual for diesel engines ABC type 6/8DZC

Disclaimer This document provides general information only and is not binding. The information included in the document may be subject to change or improvements by ABC at any time without notice. ABC makes no commitment to update the information in this manual between official releases. ABC (and its related bodies corporate) makes no representation or warranty, either implied or expressed, with respect to the accuracy, reliability or completeness of the information, but ABC has made every effort to ensure that the document is accurate; ABC disclaims liability for any inaccuracies or omissions that may have occurred. (If you find information in this manual that is incorrect, misleading, or incomplete, we would appreciate your comments and suggestions). This edition supersedes the previous edition of this document. All rights reserved. No part of this publication may be reproduced or copied in any form, without prior permission of ABC.

File : B24_00_dd2017_07_14_Ed005_EN_FrontPage_Maintenance_manual_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC

B24 Edition: 005 release date: 14-Jul.-2017

Maintenance manual for diesel engines ABC type 6/8DZC

CONTENTS GENERAL SAFETY GUIDELINES

Ed. 7

GENERAL 6-8 DZC

Ed. 10

Chapter 1

:

CYLINDER HEAD

Ed. 8

Chapter 2

:

DRIVE UNIT (PISTON/CONNECTING ROD)

Ed. 6

Chapter 3

:

CYLINDER BLOCK

Ed. 7

Chapter 4

:

INJECTION SYSTEM

Ed. 7

Chapter 5

:

GOVERNOR SYSTEM

Ed. 7

Chapter 6

:

CRANKCASE

Ed. 7

Chapter 7

:

CRANKSHAFT

Ed. 7

Chapter 8

:

TIMING GEAR

Ed. 7

Chapter 9

:

ENGINE DRIVEN PUMPS

Ed. 8

Chapter 10

:

STARTING SYSTEM

Ed. 7

Chapter 11

:

TURBOCHARGER

Ed. 8

Chapter 12

:

COOLERS

Ed. 7

Chapter 13

:

TECHNICAL SPECIFICATIONS PRODUCTS

Ed. 5

File : B24_00_dd2017_07_14_Ed005_EN_FrontPage_Maintenance_manual_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC

B24 Edition: 005 release date: 14-Jul.-2017

Maintenance manual for diesel engines ABC type 6/8DZC

File : B24_00_dd2017_07_14_Ed005_EN_FrontPage_Maintenance_manual_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC

GENERAL 6/8 DZC Chapter 0 – Page 1/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

CHAPTER 0 GENERAL 6/8 DZC

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 2/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

CONTENTS 1

2

3

4

5

File:

DEFINITIONS AND TERMINOLOGY ...................................................................................................... 3 1.1

Engine type indication .............................................................................................................. 3

1.2

Numbering of the cylinders ...................................................................................................... 4

1.3

Table of abbreviations .............................................................................................................. 4

TECHNICAL DATA ..........................................................................................................................6 2.1

Technical specifications according to engine type and application ........................................... 6

2.2

Consumption according to engine type and application ........................................................... 6

2.3

Nominal dimensions ................................................................................................................ 7

2.4

Valve timing: theoretical figures ............................................................................................... 8

2.5

Firing order ............................................................................................................................ 10

2.6

Critical speed ......................................................................................................................... 10

2.7

Temperatures (in°C) ............................................................................................................... 10

2.8

Pressures ................................................................................................................................11

2.9

Lubricating and cooling systems capacities (liters) ..................................................................13

2.10

Test-bed measurements ........................................................................................................ 20

GENERAL MAINTENANCE RECOMMENDATIONS ................................................................................... 21 3.1

Warnings ................................................................................................................................ 21

3.2

Tooling ................................................................................................................................... 21

3.3

Masses of the major components ........................................................................................... 22

3.4

Handling of components ........................................................................................................ 25

3.5

Precautions for mounting and dismantling ............................................................................. 25

3.6

Assembly dimensions and wear limits .................................................................................... 26

3.7

Standardized dimensions for reconditioning .......................................................................... 26

MAINTENANCE PROGRAM.............................................................................................................. 27 4.1

Maintenance (M) and overhaul (O) ......................................................................................... 27

4.2

Maintenance intervals and overhaul order .............................................................................. 42

TIGHTENING TORQUES ................................................................................................................. 43

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 3/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

1

DEFINITIONS AND TERMINOLOGY

1.1

ENGINE TYPE INDICATION Engine type: 6/8 DZC 1000 166 A/K C… Reference 6/8

Number of cylinders in line configuration

DZC

Type of engine, 4 stroke, in line, supercharged engine with intercooler

1000

Engine speed in rpm

166

Code number for the main effective pressure (Pme), i.e. the Pme (bar) is multiplied by 10. Code Number

Pme (bar)

120

12

135

13,5

150

15

166

16,6

179

17,9

A

Direction of rotation counter-clockwise as seen by an observer looking at the flywheel.

K

Direction of rotation clockwise as seen by an observer looking at the flywheel.

C

File:

Explanation

•

C0:

Standard

•

C1:

CCR I / IMO I

•

C2:

CCR II / IMO II

•

C3:

UIC I

•

C4:

UIC II

•

C5:

EU IIIA loc

•

C6:

DF Genset

•

C7:

DF Marine / IMO II

•

C8:

Bio fuel

•

C9:

IMO II

Pme up to 18,8 bar

•

C10:

IMO II

Pme ≤ 16,6 bar

•

C11:

EPA Tier III

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

Pme = max. 18,3 bar

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 4/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

1.2

NUMBERING OF THE CYLINDERS The numbering of the cylinders begins with the cylinder closest to the flywheel:

Ref.

Fig. 0.1

1.3

A

Counter-clockwise

K

Clockwise

Numbering of the cylinders

TABLE OF ABBREVIATIONS Abbreviation

File:

Sense of rotation

Explanation

°CA

Degrees crank angle

BDC

Bottom dead center

BI

Beginning of injection

CCW

Counter-clockwise

Con rod

Connecting rod

CW

Clockwise

EC

Exhaust closes

EO

Exhaust opens

FO

Fuel oil

FW

Fresh water

HT

High temperature

IC

Inlet closes

IO

Inlet opens

LT

Low temperature

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 5/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Abbreviation

File:

Explanation

LW

Limit of wear

MM

Maintenance manual

OD

Original dimension

OM

Operating manual

PPE

Personal protective equipment

R1

First undersize/oversize

R2

Second undersize/oversize

RL

Reworking limit

rpm

Revolutions per minute (rev/min)

SW

Sea water

TC

Turbo compressor

TDC

Top dead center

TKP

Turbo side pump-side

TKV

Turbo side flywheel

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 6/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

2

TECHNICAL DATA

2.1

TECHNICAL SPECIFICATIONS ACCORDING TO ENGINE TYPE AND APPLICATION Parameter

2.2

File:

Abbreviation

Unit

Continuous rating power ISO3046/1

Ne

kW

Nominal revolutions/minute

N

Rpm

Mean effective pressure

Pme

Bar

Maximum combustion pressure

Pmax

Bar

Mean piston speed at nominal engine speed

Cm

m/s

CONSUMPTION ACCORDING TO ENGINE TYPE AND APPLICATION •

Fuel consumption at nominal power with fuel according to ISO3046/1 and a lower calorific value of Hu 42,7 MJ/kg is expressed in g/kWh (tol +5 %). Specific for each engine type on demand.

•

Consumption of lube-oil at nominal power: g/kWh

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 7/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

2.3

NOMINAL DIMENSIONS Parameter Number of cylinders Swept volume per cylinder Compression ratio

Value 6 or 8 in line 15,95 dm³ 12,1 : 1

Total swept volume:

•

6 cyl.

95,7 dm³

•

8 cyl.

127,6 dm³

Bore

256 mm

Stroke

310 mm

Diameter:

•

Main bearing shell

184 mm

•

Connecting rod bearing shell

178 mm

•

Piston pin

110 mm

•

Camshaft bearing

82 mm

•

Injection pump piston

20 mm

Thread cylinder head stud:

•

Cylinder block stud

M27 x 2

•

Cylinder head stud

M24 x 2

•

Push rods

738 mm

•

Cylinder block studs

376 mm

Length:

Height:

•

Chrome-plated fire ring

5 mm

•

Compression ring

4 mm

•

Oil scraper ring

8 mm

•

Inlet valve

20,40 mm

•

Exhaust valve

20,40 mm

Lift:

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 8/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Parameter

Value

•

Injector nozzle needle

0,6 mm

•

Inlet cam

18,3 mm

•

Exhaust cam

18,3 mm

•

Injection cam

18 mm

Distance between cylinders

380 mm

Spacing of the center cylinder

400 mm

Number per cylinder:

2.4

•

Inlet valve

2

•

Exhaust valve

2

•

Top piston ring

1

•

Compression ring

2

•

Oil scraper ring

1

VALVE TIMING: THEORETICAL FIGURES Real opening and closing times in°CA. 6DZC

8DZC

Opens before TDC

60°

70°

Closes after BDC

40°

40°

Opens before BDC

62°

62°

Closes after TDC

55°

65°

115°

135°

Inlet

Exhaust

Valve overlap

For these angles, the valve clearances in cold conditions have been taken into account. These are:

File:

•

Exhaust: 0,20 mm

•

Inlet: 0,20 mm

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 9/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Exhaust

Expansion

Inlet

Compression

Fig. 0.2

The meaning of the abbreviations used in the above diagram are listed in “1.3 Table of abbreviations” (page 4).

Setting value of BI: According to the required emission demands (see maintenance manual, chapter “Injection system”).

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 abovementioned opening and closing times. The control can be limited to the measurement of the crank position in regard to the TDC, when both valve bridges are at the same height, this is the theoretical crank angle measured at the crankshaft for: 6DZC: 2°30’ before TDC – lifting ca. 12 mm 8DZC: 2°30’ before TDC – lifting ca. 16 mm

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 10/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

2.5

FIRING ORDER •

6 cyl.:

•

2.6



A: 1-2-4-6-5-3-1



K: 1-3-5-6-4-2-1

8 cyl.:



A: 1-4-7-3-8-5-2-6-1



K: 1-6-2-5-8-3-7-4-1

CRITICAL SPEED Every installation is checked for critical engine speeds. These calculations indicate if, at particular speeds, dangerous torsional vibrations occur. This is important as these vibrations can lead to catastrophic failure of the crankshaft, coupling, propeller shaft or generator shaft, damage to gears and bearings, overheating of the vibration damper or inadmissible irregularity of the driven electric machines. Continuous running at those speeds is very dangerous and those speeds must be marked on the engine speed indicator as forbidden areas. ABC cannot be responsible for failures arising from the nonobservance of those forbidden areas.

IN CASE OF MODIFICATIONS EFFECTED AFTER THE INSTALLATION (FOR EXAMPLE, ALTERATION OF THE PROPELLER OF GEARS) THE COMPLETE INSTALLATION HAS TO BE RECALCULATED FOR CRITICAL SPEEDS. FOR THIS PURPOSE, IT IS NECESSARY TO CONTACT ABC.

2.7

TEMPERATURES (IN°C) Parameters

Value

Exhaust gases:

•

Cylinder heads

°C (See test sheet)

•

Before turbine

°C (See test sheet)

•

After turbine

°C (See test sheet)

Supercharging air:

File:

•

Before air cooler

°C (See test sheet)

•

After air cooler

°C (See test sheet)

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 11/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Cooling system (engine outlet)

Double cooling circuit (HT +LT)

Split cooling circuit

Normal working

80°C (75-87) – 85°C (80-89)

80°C (75-87) – 85°C (80-89)

Warning signal

90°C

90°C

Stop signal

95°C

95°C

Preheating

40°C – 45°C

40°C – 45°C

Lubrication circuit (engine inlet)

2.8

Double cooling circuit (HT +LT)

Split cooling circuit

Normal working

71 – 79°C

71 – 79°C

Warning signal

80°C

80°C

Stop signal

85°C

85°C

Preheating

35°C – 40°C

35°C – 40°C

PRESSURES Description

Opening pressure (gauge pressure)

Working pressure (gauge pressure)

Proof pressure (gauge pressure)

Cylinder head:

•

Combustion space

-

Max. 130

150

•

Cooling water space

-

Max. 3,5

5

-

Max. 3,5

5

Cylinder block:

•

Cooling water space

Air cooler:

•

Water space

-

Max. 2,5

5

•

Air space

-

Max. 3

5

Oil cooler:

File:

Plate cooler

Pipe cooler

•

Water side

-

Max. 2,5

7

8

•

Oil side

-

Max. 5

7

10

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 12/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Description

Opening pressure (gauge pressure)

Working pressure (gauge pressure)

Proof pressure (gauge pressure)

Fuel injection pump:

•

Plunger and liner

-

Max. 1200

-

•

Body

-

-

7

-

Gasoil max. 2,5

-

Fuel supply

HFO max. 3,5 Injection pipes Opening injection needle Safety valve (cylinder head) Safety valve (crankcase)

-

Max. 1200/1500

275

-

-

150 ± 2

-

-

0,1

-

-

Lube-oil pressure (entrance engine) at normal engine working temperatures:

6 cyl.

8 cyl.

•

330 rev/min

-

2-2,5

1,75

-

•

500 rev/min

-

2,5-3

2

-

•

720 and 750 rev/min

-

4,85

4,85

-

•

900 and 1 000 rev/min

-

5

5

-

Starting air

-

Max. 30

-

Cooling circuit: in order to obtain the minimal hydrostatic pressure for the soft-water pump inlet, the underside of the expansion tank must be at least 2 m above the engine’s center line but no more than 10 m (see operating manual, chapter “Description and supervision of the cooling water circuits”).

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 13/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

2.9

LUBRICATING AND COOLING SYSTEMS CAPACITIES (LITERS)

2.9.1

Lubrication system Oil sump

6 cyl. (l)

8 cyl. (l)

Min.

180

230

Max.

450

510

Min.

180

230

Max.

615

675

Min.

275

350

Max.

500

650

Min.

450

580

Max.

1000

1200

6 cyl. (l)

8 cyl. (l)

According to engine type and/or application

According to engine type and/or application

UG8

1,4

1,4

UG25+

2,1

2,1

-

-

Type 1 (standard wet sump) (h = 264 mm)

Type 2 (extra deep wet sump) (h = 364 mm)

Type 3 (oil sump in frame for propulsion)

Type 4 (Oil sump in frame for generator sets)

Property Standard oil pipes on engine Governor:

Heinzmann

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 14/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

2.9.2

2.9.3

Cooling systems Property

6 cyl. (l)

8 cyl. (l)

Engine capacity (basic engine)

205

275

Air cooler

11,7

11,7

Information concerning the fabrication of important components Component Crankcase

Cylinder block

Cylinder head

Pump carter

Connecting rod

Crankshaft

Property

Information

Fabrication

Sand-cast

Material

GGG 40 – 50

Finishing

ABC

Fabrication

Sand-cast

Material

GGG 40 – 50

Finishing

ABC

Fabrication

Sand-cast

Material

Lamellar cast iron

Finishing

ABC

Fabrication

Sand-cast

Material

Lamellar cast iron

Finishing

ABC

Fabrication

Forged in a matrix

Material

Steel 42CrMo4V

Finishing

ABC

Fabrication

Forged in a matrix

Material

6 cyl.: Steel 42CrMo4 8 cyl.: Steel 42CrMo4V

Cylinder liner

Cylinder head gasket File:

Finishing

By supplier

Fabrication

Centrifugal cast

Material

Perlitic cast iron with P and Mo

Finishing

Machined & plateau honed at ABC

Material

Brass

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 15/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Component Piston

Piston rings

Property

Information

Fabrication

Cast

Material

Nodular cast iron

Finishing

By supplier (+ hardened grooves)

Fabrication

Cast: top ring with chrome ceramic coating 1st tapered compr. Ring chrome coated 2nd tapered compr. Ring Oil scraper ring chrome coated with spiral spring

Valves

Material

Lamellar cast iron

Finishing

By supplier

Material

Intake X45CrSi9V Exhaust X45CrSi9V (MDO/Gasoil) Exhaust X45CrSi9V + Nimonic 80A (HFO)

Inserts

Valve guide

Gear wheels

Camshaft

File:

Finishing

By supplier

Fabrication

Centrifugal cast

Material

Centrifugal cast iron

Finishing

By supplier

Fabrication

Centrifugal cast

Material

Special cast iron (Metal Roger)

Finishing

ABC

Fabrication

Forged in a matrix

Material

Steel 17CrNiMo6MQ, 14NiCr18 & GGG

Finishing

ABC and/or supplier hardening & grinding

Fabrication

Forged in a matrix

Material

15CrNi6

Finishing

By supplier

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 16/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

2.9.4

3D illustration with identification of important components A

B

C

H

D

I

E

J

G

F

K

L

M

N

O

Fig. 0.3

Ref.

File:

Description

A

Speed governor

B

Crankcase breather

C

Turbocharger

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 17/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Ref.

File:

Description

D

Cylinder head

E

Water return pipe

F

Box engine control unit

G

Oil filter

H

Flywheel

I

Integrated camshaft

J

Crankcase

K

Injection pump

L

Fuel filter

M

Pump drive gear case

N

Oil pump

O

Water pump

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 18/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

A

C

B

Fig. 0.4

Ref.

File:

Description

A

Oil cooler

B

Exhaust manifold

C

Charge air cooler

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 19/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

2.9.5

Cross-section ABC 6/8 DZC engine

A

B

G

C D

H E

F

Fig. 0.5

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 20/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Ref.

2.10

Description

A

Exhaust manifold

B

Charge air manifold

C

Water inlet manifold

D

Oil cooler

E

Crankcase

F

Oil pan

G

Camshaft tunnel

H

Con rod bolts tightened by elongated stretch

TEST-BED MEASUREMENTS The measurements made on the test-bed are given on the sheet of the engine reception test.

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 21/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

3

GENERAL MAINTENANCE RECOMMENDATIONS

3.1

WARNINGS •

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.).

REMEMBER THAT THE REMOVAL OF OBJECTS (PISTON/CONNECTING-ROD ASSEMBLIES) CAN UNBALANCE THE CRANKSHAFT, CAUSING IT TO ROTATE UNEXPECTEDLY.

3.2

•

Inspect the nuts and bolts and their attachments as well as the air, water and oil pipework before starting the engine.

•

When rotating the engine with a bar, make sure all moving parts can move freely.

•

Speed governors: It is forbidden to disassemble or re-adjust speed governors overspeed devices or any other component which controls or limits the dynamic conditions of the engine unless this is expressly allowed and approved by ABC and this may only be done by authorized personnel.

•

Injection nozzles: When testing the nozzles outside the engine with the nozzle tester, observe the following precautionary measures:

•

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 TISSUE. FUEL OIL ENTERING THE BLOOD STREAM CAN CAUSE BLOOD POISONING.

•

USE ONLY CLEAN GASOIL OR TEST OIL FOR TESTING.

•

DO NOT TEST THE NOZZLE NEAR A FLAME OR 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

•

Special tools designed by ABC and to be ordered separately

•

Lifting equipment: hoisting tackle, slings, etc.

The tools needed for the mounting, dismantling or maintenance of the several engine components, can be ordered with numbers from the maintenance book.

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 22/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

3.3

MASSES OF THE MAJOR COMPONENTS Section 01

Description Crankcase:

•

04

08

09

10

Main bearing cap



Normal

14,6



Wide

18,25



Guide

16,90

•

Main bearing stud

0,52

•

Cylinder block stud

1,52

Main bearing:

•

Upper half bearing shell

0,72

•

Lower half bearing shell

0,84

•

Axial half thrust bearing ring

0,46

Cylinder block:

•

Liner

67,50

•

Cylinder head stud

1,68

•

Cylinder head stud (extended)

1,76

Piston:

•

Piston in nodular cast iron (GGG)

•

Piston pin

12,55

•

Set piston rings

0,75

30 – 32

Connecting rod:

•

Connecting rod with bush, bearings bolts and nuts

•

Big end bearing shells (upper and lower together) of the connecting rod

1,25

•

Bush small end

1,60

09/10

Drive work with piston, piston pin, piston rings, piston circlips, con rod with bush, bearings, cap and bolts

11

Cylinder head:

•

File:

Mass (kg)

Cylinder head with valves, bridges, rockers and support with shaft

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

40 – 45

83 – 91

134,5

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 23/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Section

12

Cylinder head with inserts and valve guides

105

•

Inlet valve

1,10

•

Exhaust valve

1,25

•

Bridge rocker with pad and adjusting screw

1,3

•

Rockers with shaft and support

15,15

•

Valve guides

0,27

•

Rocker with bush and pad

2,52

Governor:

•

Woodward (UG8-L/UG8-D/UG25+)

•

Assembly gear wheel driving Woodward governor

•

Heinzmann actuator

14

Fuel circuit:

17

22 – 26 12 15,3

Assembly lever adjustment injection pump

16

Mass (kg)

•

13

15

File:

Description

0,53

•

Injection pump

9,08

•

Nozzle and nozzle holder

2,3

Pump driving:

•

Gearwheel case engine driven pumps with intermediate shafts and shaft drive fuel pump

181

•

Intermediate plate

22,5

•

Intermediate shaft with gear wheel drive water pump

4,8

•

Intermediate shaft with gear wheel drive oil pumps

10,3

Distribution:

•

Two-parts distribution gear wheel on crankshaft

•

Gear wheel on camshaft

•

Intermediate support bearing with gears

•

Gear case

10,35 21 33,25 47

Camshaft:

•

Guide bearing

•

Bearing

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

4 3,8

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 24/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Section

Description

•

18

Camshaft



Cylinder stud



Begin stud



End stud

15,3



Intermediate flange

1,7

18,6 8

Tappet mechanism:

•

Tappet bracket

11,3

•

Tappet with roll (valves)

0,94

•

Tappet with roll (injection pump)

1,46

•

Assembly valve push-rod

1,4

20

Turbo-compressor KBB type M40

260

21

Exhaust system:

•

4,19

Expansion compensator

23

Air cooler

27

Standard flywheel with starting gear wheel

29

Vibration damper type:

30

31

File:

Mass (kg)

232 935,5

•

ASK 2204A (H&W)

304

•

D50/1/1 + C 41/2/58U

171

•

D50/2 + C41/2/58U

171

•

D63/62 + C44/2/98U

296

•

D72/66/1 + C 44/2/98U

449

Oil circuit:

•

Lubricating pump and gear wheel

37,20

•

Scavenge pump and gear wheel

36,50

•

Oil pressure regulating valve

9

Oil filter:

•

Support oil filter

50

•

Duplex oil filter

112

•

Centrifugal oil filter

3,87

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 25/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Section 40/45

41

Description Soft-water circuit:

•

Water pump and gear wheel

33,60

•

Thermostatic regulating valve (nominal temp. 43°C)

19,4

•

Thermostatic regulating valve (nominal temp. 80 – 85°C)

19,9

Seawater circuit (if applicable)

• 50/51

66

Self-priming seawater pump and gear wheel

70,40

Fuel feeding:

•

Fuel pump and half coupling

7,15

•

Duplex fuel filter (dry weight)

16

Control system:

133

3.4

Mass (kg)

•

DMU (diesel monitoring unit), separate from engine

22,3

•

Monitoring panel on engine

15,0

Service oil tank (440 l) – dry weight

203

Service oil tank (1020 l) – dry weight

512

HANDLING OF COMPONENTS Always use a lifting apparatus for handling important pieces, such as cylinder heads, piston and connecting rods, and cylinders. For specific guidelines for handling the engine, see the installation prescription manual.

3.5

PRECAUTIONS FOR MOUNTING AND DISMANTLING During the life of the engine it is possible that it, or some parts of it, must be dismantled. Dismantling, mounting or replacing should all be performed in a prescribed order. The executers should be familiar with the topic and with the characteristics of the engine and its components as described in the relevant documentation. There, you will find the procedures for the dismantling, replacing and mounting of the important parts of the engine. Keep in mind the following basics:

File:

•

Some parts are marked to show their position or place as mounted. Before dismantling such a part, make sure that the marks are attached correctly. This makes it possible to re-assemble the parts in an identical way, preventing a malfunction. Provide the unmarked parts with a label (piston rings, bearing shells…).

•

Empty the oil, water and fuel circuit according to the mounting task.

•

Close the pipes and openings of the parts when dismantling them.

•

Protect the components which are not immediately re-used with an anti-rust agent and clean them before mounting.

•

Renew all joints if necessary. After starting the engine again, check all joints for leakages.

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 26/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

3.6

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 values are the result of long experience, they represent the point at which the safety and proper functioning become endangered. Those values are given in the OD (original dimensions) and LW (limit of wear) columns.

3.7

STANDARDIZED DIMENSIONS FOR RECONDITIONING Parts which can be reconditioned (e.g. crankshaft, guide bearing cap, etc.) have standardized dimensions and tolerances. If the parts are reworked to those dimensions, parts to be fit (bearing shells for reconditioned crankshaft, oversize half thrust rings, etc.) can be supplied from stock. The dimensions for the first reworking are marked R1, those for the second R2, and so on.

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 27/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

4

MAINTENANCE PROGRAM The maintenance schedule and periodicity intervals were established by the manufacturer in order to achieve best efficiency and reliability of the engine and lifetime of components. Periodicity intervals are based on manufacturer’s experience. All the maintenance jobs set out in this program are of a periodical nature. They should be repeated at regular intervals, usually expressed in hours of service of the engine. In order to facilitate the maintenance and to limit 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 each other. The maintenance jobs of the same frequency in each group are set out in the following pages. For each maintenance job, the basic frequency level is mentioned in running hours. Although this is not explicitly mentioned in the table, these maintenance jobs have to be repeated each time a multiple of the indicated running hours are passed.

4.1

MAINTENANCE (M) AND OVERHAUL (O) The different groups of maintenance jobs are classified under one or the other of the two classes below:

•

Normal maintenance jobs

•

Partial and complete overhauls

For each maintenance job is indicated if the job is applicable for an engine execution based on the fuel type. The three main fuel types are:

•

All diesel oils – DO

•

Heavy fuel oil or biofuel – HFO-BIO

•

Dual fuel (gas/ diesel oil) – DF

ABC reserves the right to change these service intervals depending on the operating condition load profile, quality and/or type of fuel and lubricating oil, and the cooling water conditions. The stated frequency is only to be used as a guidance, but should NOT be exceeded during the guarantee period. The frequency can strongly be influenced by the service conditions, quality of the fuel oil, quality of the lubricating oil, treatment of the cooling water etc.

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 28/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

4.1.1

Normal maintenance jobs Normal maintenance jobs involve partial dismantling, which can be carried out by the operation staff. We identify eight types of maintenance operations for the 6/8DZC-engines: Period

4.1.2

Mark

Every week or every 100 hours

M1

Every half month or every 250 hours

M1a

Every month or every 500 hours

M2

Every 1000 hours

M3

Every 1500 hours

M4

Every ±3000 hours

M5

Every ±6000 hours

M6

Every year

M7

Partial and complete overhauls This involves substantial dismantling and more specialized work, which usually entails taking the engine temporarily out of service. We identify three overhaul periods: Period

Mark

Condition check and partial overhaul at periods of 12 000 hours

O1

The complete overhaul at periods of 24 000 hours

O2

The partial overhaul at periods of 48 000 hours

O3

Under normal operational conditions, ABC permits a maximum tolerance of approximately 20 % on the periodicity of maintenance, and a maximum tolerance of 3000 hours on the periodicity of overhauls.

The hours of running indicated on the counter or stated in the log book may in some cases be replaced by equivalent units that vary more or less linearly (kilometers travelled by traction units, energy produced by pumping installations or by electricity generating sets).

4.1.3

References For each maintenance job, a reference to the manual that contains the maintenance procedure is added. The following manuals are referenced:

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 29/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Manual code

4.1.4

Manual title

B33

Operating manual for diesel engines ABC type 6/8/12/16DZC

B24

Maintenance manual for diesel engines ABC type 6/8DZC

B82

Manual for dual fuel engines ABC type 6/8/12/16DZD

B83

Manual for HFO engines type 6/8/12/16DZC

Table of maintenance jobs C1 – Before every start or every 24 hours

File:

DO

HFOBIO

DF

See B33 chapter “General directives” §4.1.2

X

X

X

Check oil level in hydraulic governor.

See B33 chapter “General directives” §4.1.3

X

X

X

C1 – 03

Check starting air pressure.

See B33 chapter “General directives” §4.1.4

X

X

X

C1 – 04

Drain off any water from the daily fuel tank and the water separator (in fuel line).

See B33 chapter “General directives” §4.1.5

X

X

X

C1 – 05

Check fuel level in the daily tank.

See B33 chapter “General directives” §4.1.6

X

X

X

C1 – 06

Check for cooling water, lubricating oil, fuel oil, exhaust and air leaks.

See B33 chapter “General directives” §4.1.7

X

X

X

C1 – 07 (*)

Clean the compressor (air intake side) of the turbocharger by water injection.

See B33 chapter “General directives” §4.1.8

X

X

X

Mark

Part to be maintained or checked

C1 – 01

Check water level in expansion tank and oil level engine.

C1 – 02

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

Reference

See B24 chapter “Engine driven pumps” – “Fuel filtration”

See B24 chapter “Turbocharger”

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 30/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

M1 – Every week or every 100 hours Mark

Reference

DO

HFOBIO

DF

M1 – 01

Fill up the automatic lubricator on the starting air pipe.

See B33 chapter “General directives” §4.2.2

X

X

X

M1 – 02

Drain off water from:

See B33 chapter “General directives” §4.2.3

X

X

X

•

Compressed air receivers

•

Water separator (starting airline)

M1 – 03

Clean water filters, if provided.

See B33 chapter “General directives” §4.2.4

X

X

X

M1 – 04

1

Check position of contamination indicator on oil filter at operating temperature and nominal speed.

See B33 chapter “General directives” §4.2.5

X

X

X

2

Replace filter elements, if necessary.

M1 - 05

Check free passage of blow off hole on air cooler, if provided.

See B33 chapter “General directives” §4.2.6

X

X

_

M1 - 06

Clean centrifugal filter.

See B33 chapter “General directives” §4.2.7

_

X

_

M1 - 07

1

Lubricate the control levers, injection pump control rod and link of the governor and control spindle bearing bushings.

See B33 chapter “General directives” §4.2.8

_

X

_

2

Check if each injection pump control rod can be moved freely. See B82 chapter “Maintenance instructions” §3.1.1.

_

_

X

M1 - 08

File:

Part to be maintained or checked

Check the drain system of the air cooler, if provided.

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 31/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

M1a – Every half month or every 250 hours Mark M1a – 01

Part to be maintained or checked Clean the turbine (exhaust gas side) of the turbocharger by water injection.

Reference

DO

HFOBIO

DF

See B83 chapter “Maintenance instructions”.

_

X

_

Reference

DO

HFOBIO

DF

M2 – Every month or every 500 hours Mark

Part to be maintained or checked

M2 – 01 (*)

Replace air intake filter element.

See B33 chapter “General directives” §4.4.2

X

X

X

M2 – 02

Clean centrifugal filter. (Frequency depends on the level of contamination.)

See B33 chapter “General directives” §4.4.3

X

See M1 - 06

X

M2 – 03

Check if renewal of the fuel filter elements is necessary. (Frequency depends on fuel quality and possible contamination of the filter elements.)

See B33 chapter “General directives” §4.4.4

X

X

X

M2 – 04

1

Lubricate the control levers, injection pump control rod and link of the governor and control spindle bearing bushings.

See B33 chapter “General directives” §4.4.5

X

See M1 - 07

X

2

Check if each injection pump control rod can be moved freely. See B33 chapter “General directives” §4.4.6

X

X

X

DO

HFOBIO

DF

M2 – 05

Clean the magnetic filter of the turbocharger.

M3 – Every 1000 hours Mark

File:

Part to be maintained or checked

Reference

M3 – 01

Renew fuel filter elements.

See B33 chapter “General directives” §4.5.2

X

X

X

M3 – 02

Replace filter element of closed crankcase ventilation breather.

See B24 chapter “Crankcase” – “Closed Crankcase ventilation”

X

X

X

M3 – 03

Check the proper functioning of the automatic lubricator for the starting air system.

See B24 chapter “Starting system” – “Pneumatic starting on cylinders”

X

X

X

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 32/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Mark

Part to be maintained or checked

M3 – 04

Take a sample of the lubrication oil and make an oil analysis.

M3 – 05

Check rotation of exhaust valve rotocaps.

Reference

DO

HFOBIO

DF

See B33 chapter “General directives” §4.5.5

X

X

X

See B83 chapter “Maintenance instructions”

_

X

_

Reference

DO

HFOBIO

DF

M4 – Every ±1500 hours Mark M4 – 01

Replace oil filter elements.

See B33 chapter “General directives” §4.6.2

X

X

X

M4 – 02

1

Check cooling water quality.

X

X

X

2

Adjust the water treatment if necessary.

See B33 chapter “General directives” §4.6.3

1

Check intake and exhaust valve clearances.

See B33 chapter “General directives” §4.6.4

X

X

X

2

Adjust if necessary.

1

Check nozzles and opening pressure of nozzles and their spray pattern.

See B33 chapter “General directives” §4.6.5

_

X

_

2

Replace nozzles if necessary.

M4 – 03

M4 – 04

File:

Part to be maintained or checked

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 33/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

M5 – Every ±3000 hours Mark M5 – 01

Part to be maintained or checked 1

Change engine oil.

2

Replace or clean the crankcase and crankcase breather element.

Reference

DO

HFOBIO

DF

See B33 chapter “General directives” §4.7.2

X

X

X

See B33 chapter “General directives” §4.7.3

X

X

X

Frequency depends on application/working conditions/regular oil analysis (see M3 – 04). M5 – 02

•

Overspeed

•

Thermostats

•

Pressostats

•

Microswitch for load/overload indication

M5 – 03

Change oil of hydraulic governor.

See B33 chapter “General directives” §4.7.4

X

X

_

M5 – 04

1

Check combustion pressures and full load at idling speed.

See B33 chapter “General directives” §4.7.5

X

X

X

2

Adjust if necessary.

See B24 chapter “Injection system” – “Injection mechanism driving the fuel pump”

1

Check nozzles and opening pressure of nozzles and their spray pattern.

See B33 chapter “General directives” §4.7.6

X

See M4 - 04

X

2

Replace nozzles if necessary.

1

Check the condition of injection pump cavitation plugs.

See B24 chapter “Injection system” – “Injection pump”

_

X

_

2

Renew them if necessary.

M5 - 05

M5 - 06

File:

Check the alarm and security devices for correct function and operation:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 34/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

M6 – Every ±6000 hours Mark M6 – 01

M6 – 02

M6 – 03

M6 – 04 (*) M6 – 05 (*)

File:

Part to be maintained or checked 1

Thoroughly examine the nozzles and their holders.

2

Replace nozzles if necessary.

1

Check gear wheel of the governor, if a mechanically driven governor is installed.

2

Measure backlash.

Check tappet mechanisms:

•

Tappets

•

Shafts

•

Rolls

1

Check the air intake circuit and compressor wheel.

2

Clean if necessary.

1

Check the exhaust gas circuit.

2

Clean if necessary.

Reference

DO

HFOBIO

DF

See B33 chapter “General directives” §4.8.2

X

X

X

See B24 chapter “Governor” – “The governor drive mechanism”

X

X

_

See B24 chapter “Cylinder head” – “Tappet mechanism”

X

X

X

See B24 chapter “Turbocharger”

X

X

X

See B24 chapter “Turbocharger”

X

X

X

M6 – 06

Measure complete crankshaft deflection (all cylinders) and the crankshaft axial clearance.

See B24 chapter “Crankshaft.” – “Crankshaft”

X

X

X

M6 – 07 (*)

Check the differential pressure of the air cooler and clean if necessary.

See B24 chapter “Coolers” – “Charge air cooler”

X

X

X

M6 – 08

1

Check the condition of injection pump cavitation plugs.

See B24 chapter “Injection system” – “Injection pump”

X

See M5 - 06

X

2

Renew them if necessary.

M6 - 09

Check the valve wear (measure).

See B24 chapter “Cylinder head” – “Inlet and exhaust valves”

X

X

X

M6 - 10

Check the condition the elastic couplings on the flywheel and (if present) on the PTO coupling.

See B33 chapter “General directives” §4.8.11

X

X

X

M6 - 11

Check the oil mist detection unit.

See B33 chapter “General directives” §4.8.12

X

X

X

M6 - 12

Check the preheating module.

See B33 chapter “General directives” §4.8.13

X

X

X

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 35/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Mark

Part to be maintained or checked

Reference

DO

HFOBIO

DF

M6 - 13

Check the gas actuator.

See B82 chapter “Maintenance instructions”

_

_

X

M6 - 14

Check the status of the fuel cooler.

See B82 chapter “Maintenance instructions”

_

_

X

Reference

DO

HFOBIO

DF

_

_

X

_

_

X

M7 – Every year Mark

•

See specific manual(s)

•

See B82 chapter “Maintenance instructions”

Check the gas detection components.

•

See specific manual(s)

•

See B82 chapter “Maintenance instructions”

M7 - 03

Check the explosion relieve valves on the air collector and on the exhaust collectors.

See B82 chapter “Maintenance instructions”

_

_

X

M7 - 04

Check the knocking sensors and have them calibrated.

See B82 chapter “Maintenance instructions”

_

_

X

M7 - 05

If the engine is mounted on flexible supports, check the condition of the supports.

See B33 chapter “General directives” §4.9.6

X

X

X

M7 – 01

M7 - 02

File:

Part to be maintained or checked Check the gas train.

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 36/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Every 12 000 hours Mark

Part to be maintained or checked

O1 – 01

Check the condition of the cylinderheads to determine if a top overhaul is necessary. If required, see below. Perform a complete overhaul of cylinder heads. 1

O1 – 02

File:

Remove the valves, if necessary grind or renew the valves and/or seats.

2

Check the valve guides and renew them if necessary.

3

Check the valve springs and collars.

4

Check valve dimensions and renew if necessary.

5

Perform a complete overhaul of the valve mechanism on the cylinder heads (bridges rockers, bushes and shaft).

6

Replace all joints (water, oil, air and exhaust gases).

7

Check the opening pressure on the relief valves on the cylinder heads.

8

Clean the oil ducts.

9

Renew the rocker bushes and check shaft for dimensions.

10

Renew the rotocaps.

11

Perform an overhaul of the cylinder head starting air valve.

1

Check the injection timing (BI).

2

Check tightness of injection pump plungers and of the relief valves.

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

Reference See B24 chapter “Cylinder head”, sections:

•

“Cylinder head”

•

“Rocker lever mechanism”

•

“Inlet and exhaust valves”

DO

HFOBIO

DF

X

_

X

X

See B24 chapter “Starting system”, section “Cylinder head starting valve”

See B24 chapter “Injection system” – “Injection mechanism driving the fuel pump”

X

X

X

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 37/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Mark O1 – 03

File:

Reference

DO

HFOBIO

DF

See B24 chapter “Engine driven pumps” – “Fresh water pump (HT water pump)” and “Sea water pump

X

X

X

Part to be maintained or checked 1

Perform an overhaul of the seawater pump, soft-water pump.

2

Check the anodes in the cooling water circuit and renew if necessary.

O1 - 04

For viscous damper, take a sample of the damper’s silicon oil for analysis.

See B24 chapter “Crankshaft” – “Torsional vibration dampers”

X

X

X

O1 – 05

Visually inspect the distribution:

See B24 chapter “Timing gear”, sections:

X

X

X

•

Gear wheels

•

Cams

•

Camshaft bearing taps

•

Bearings

•

Camshaft

•

Timing gear wheels

O1 – 06

Visually inspect the pump driving gear wheels in the gear case.

See B24 chapter “Engine driven pumps” – “Pump gear case”

X

X

X

O1 – 07(*)

Visually inspect the pipe oil cooler and clean if necessary.

See B24 chapter “Coolers” – “Pipe cooler”

X

X

X

O1 – 08

Perform a complete overhaul of the turbocharger (including bearings).

See B24 chapter “Turbocharger”

_

X

_

O1 – 09

Renew the water separator filter.

See B24 chapter “Starting system” – “Water separator”

X

X

X

O1 – 10

Perform an overhaul of the hydraulic stop cylinder.

See B24 chapter “Starting system”– “Automatic stop device”

X

X

X

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 38/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Every 24 000 hours Mark

Part to be maintained or checked

O2 – 01

Perform a complete overhaul of the cylinder heads.

O2 – 03

File:

DO

HFOBIO

DF

X

See O1 01

X

See B24 chapter “Drive unit (piston and conrod)

X

X

X

See B24 chapter “Cylinder block”

X

X

X

See B24 chapter “Cylinder head”, sections:

Remove the valves, if necessary grind or renew the valves and/or seats.

•

“Cylinder head”

•

2

Check the valve guides and renew them if necessary.

“Rocker lever mechanism”

•

3

Check the valve springs and collars.

“Inlet and exhaust valves”

4

Check valve dimensions and renew if necessary.

5

Perform a complete overhaul of the valve mechanism on the cylinder heads (bridges rockers, bushes and shaft).

6

Replace all joints (water, oil, air and exhaust gases).

7

Check the opening pressure on the relief valves on the cylinder heads.

8

Clean the oil ducts.

9

Renew the rocker bushes and check shaft for dimensions.

10

Perform an overhaul of the cylinder head starting air valve.

1

Take out the pistons.

2

Measure the clearance and wear of the piston ring grooves.

3

Renew the piston rings.

1

Measure the wear (ovality and conicity) of the liners.

2

Remove and hone the liners, renew them if necessary.

3

Replace seal O-rings.

4

Replace anti-polishing rings.

1

O2 – 02

Reference

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

See B24 chapter “Starting system”, section “Cylinder head starting valve”

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 39/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Mark O2 – 04

O2 – 05

O2 – 06

DO

HFOBIO

DF

1

Replace the con rod big end bearing shells.

See B24 chapter “Drive unit (piston and conrod), sections:

X

X

X

2

Check the condition of the con rod small end bush, replace if necessary.

1

Check the condition of the main bearings, including axial bearings.

See B24 chapter “Crankcase” – “The main bearings”

X

X

X

2

Renew if necessary.

1

Check the hydraulic or electronic governor.

See B24 chapter “Governor system” – “Speed governor - UG”

X

X

X

2

Return it to the manufacturer, if necessary.

•

“Dismounting procedures

•

”Maintenance procedures conrod”

O2 – 07

Perform a complete overhaul of the fuel injection pumps.

See B24 chapter “Injection system” – “Injection pump”

X

X

X

O2 – 08

1

Check the gear wheel pump casing.

X

X

X

2

Renew the bearings.

See B24 chapter “Engine driven pumps” – “Pump gear case”

3

Visually check the gearwheels and measure the gearwheel clearances. See B24 chapter “Crankshaft”, sections:

X

X

X

O2 – 09

File:

Reference

Part to be maintained or checked

Perform a complete overhaul of a viscous vibration damper.

•

“Torsional vibration dampers”

•

“Secondary PTO”

O2 – 10 (**)

Perform a complete overhaul of the turbocharger (including bearings).

See B24chapter “Turbocharger”

X

See 01 - 08

X

O2 – 11

1

Perform an overhaul of the oil and fuel feed pump.

See B24 chapter “Engine Driven pumps”, sections:

X

X

X

2

Replace the fuel feed pump connection and sealings.

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

•

“Lubricating oil pump and pressure valves”

•

“Fuel feed pump”

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 40/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Mark

Part to be maintained or checked

O2 – 12

Perform a complete overhaul of the flexible pump drive on a viscous damper.

Reference

DO

HFOBIO

DF

See B24 chapter “Crankshaft” – “Flexible pump drive”

X

X

X

If the flexible pump drive is connected to a spring type damper, see O2 – 16. O2 – 13

Perform an overhaul of the main starting air valve.

See B24 chapter “Starting system” – “Main starting valve”

X

X

X

O2 – 14

1

Wash out the cylinder block, remove the deposits.

See B24 chapter “Cylinder block”

X

X

X

2

Repaint the interior if necessary.

1

Perform an overhaul of the HT, LT and oil thermostatic valve.

See B24 chapter “Engine driven pumps”, section:

X

X

X

2

Renew the thermostatic elements.

X

X

X

O2 – 15

O2 – 16

File:

1

Check the condition of the spring blade type flexible pump drive.

2

Renew if necessary.

•

Thermostatic valve oil circuit”

•

“Thermostatic valve water circuit”

See B24 chapter “Crankshaft”, sections:

•

“Spring coupled damper”

•

“Flexible pump drive”

O2 – 17

Perform an overhaul of the governor gear drive.

See B24 chapter “Governor” – “The governor drive mechanism”

X

X

X

O2 – 18(*)

Completely clean the oil plate cooler.

See B24 chapter “Coolers” – “Plate cooler”

X

X

X

O2 – 19

Perform an overhaul of the oil bypass valve.

See B24 chapter “Engine driven pumps” – “Lubricating oil pumps and pressure valves”

X

X

X

O2 – 20

Renew the camshaft bearings, if present.

See B24 chapter “Timing gear” – “Camshaft”

X

X

X

O2 – 21

Perform an overhaul of the crankcase safety valves.

See B24 chapter “Crankcase” – “Crankcase”

X

X

X

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 41/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Mark

Reference

Part to be maintained or checked

DO

HFOBIO

DF

O2 – 22

Perform an overhaul of the PTO bearing, if present

See B24 chapter “Crankshaft” – “Secondary PTO”

X

X

X

02 - 23

Completely clean the air cooler.

See B24 chapter “Coolers” – “Charge air cooler”

X

X

X

02 - 24

Clean the expansion tank.

See B33 chapter “General directives” §4.10

X

X

X

DO

HFOBIO

DF

Every 48 000 hours

File:

Reference

Mark

Part to be maintained or checked

O3 – 01

Replace the main bearings and axial bearing.

See B24 chapter “Crankcase” – “The main bearings”

X

X

X

O3 – 02 (***)

Replace con rod bolts and nuts.

See B24 chapter “Drive unit (piston and conrod)

X

X

X

•

“Dismounting procedures

•

”Maintenance procedures conrod”

O3 – 03

Perform a complete overhaul of a spring blade type torsional vibrations damper.

See B24 chapter “Crankshaft” – “Spring coupled damper”

X

X

X

O3 – 04

Renew the cylinder liners.

See B24 chapter “Cylinder block”

X

X

X

O3 – 05

Renew the insulation on the exhaust pipe, if necessary.

See B24 chapter “Turbocharger”

X

X

X

O3 – 06

Renew all bearings of the fuel control spindle.

See B24 chapter “Injection system” – “Fuel pump control spindle”

X

X

X

O3 – 07

Renew the pressure and thermal switches (alarm & safety).

/

X

X

X

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 42/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Ref.

4.2

Description

*

Depends on the environment (air pollution, engine room ventilation, water quality...)

**

For applications with frequent load changes, the complete overhaul is recommended at 12 000 hours.

***

Con rod bolts and nuts must be replaced, after loosening if they already have been tightened 3 times before, or every 48 000 hours, whichever comes first.

MAINTENANCE INTERVALS AND OVERHAUL ORDER Mark (C = Check, M = Maintenance, O = Overhaul)

Service hours

File:

Every week or every 100 hours

M1

Every half month or every 250 hours

M1a

Every month or every 500 hours

M1 + M1a + M2

Every 1000 hours

M1 + M1a + M2 + M3

Every ±1500 hours

M1 + M1a + M2 + M4

Every ±3000 hours

M1 + M1a + M2 + M3 + M4 + M5

Every ±6000 hours

M1 + M1a + M2 + M3 + M4 + M5 + M6

Every year

M7

Every 12 000 hours

M1 + M1a + M2 + M3 + M4 + M5 + M6 + O1

Every 24 000 hours

M1 + M1a + M2 + M3 + M4 + M5 + M6 + O1 + O2

Every 48 000 hours

M1 + M1a + M2 + M3 + M4 + M5 + M6 + O1 + O2 + O3

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 43/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

5

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. 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 maintenance manual.

Table 0.1

Tightening torque table

Component to be tightened or inserted

Tightening torque Nm kg

Type of thread

Bolt material

Crankcase (sec. 1) Bearing studs (implantation)

M20 x 1,5

~50

~5

42CrMo4V

(Loctite no. 245) Bearing stud nuts

M20 x 1,5

390-410

40-42

42CrMo4V+K

(Molykote G-N plus only on thread of stud) Crankshaft (sec. 6) Bolts fixing balance weights on crankshaft

M27 x 2

Distribution gear wheel bolts

M10 x 1,25

570

58

34CrMo4V

(Molykote G-N plus)

42CrMo4V

40

4

42CrMo4V

~100

~10

Cylinder block (sec. 8) Cylinder block studs (implantation)

M27 x 2

Cylinder block stud nuts (*)

M27 x 2

34CrNiMo6V+K

(Loctite no. 245) 295

30

+60°+60°

+60°+60°

42CrMo4V+K

(Molykote G-N plus) Carefully follow mounting instructions in maintenance manual, chapter “Cylinder block” Cylinder block bolts

M20

365

37

DIN931-8.8

Connecting rod (sec. 10)

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 44/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Component to be tightened or inserted

Type of thread

Big end stud nuts (type 1 con rod) (**)

M20 x 1,5

Tightening torque Nm kg 0,6 ± 0,02 mm

0,6 ± 0,02 mm

Bolt material 45CrMo4V+K

(Molykote G-N plus on thread of stud) Big end stud nuts (type 2 con rod) (**)

M22 x 1,5

0,7 ± 0,02 mm

0,7 ± 0,02 mm

42CrMo4V+K

(Molykote G-N plus only on thread of stud) Cylinder head (sec. 11) Cylinder head studs (implantation)

M24 x 2

~100

~10

X5CrNiCuNb17.4

(Loctite no. 222) Cylinder head nuts for “X” marked cylinder head studs(*)

M24 x 2

245

25

+85°+85°

+85°+85°

42CrMo4V+K

(Molykote G-N plus) Carefully follow instructions in maintenance manual, chapter “Cylinder head” Cylinder head nuts for unmarked cylinder head studs(*)

M24 x 2

245

25

+75°+75°

+75°+75°

42CrMo4V+K

(Molykote G-N plus) Carefully follow mounting instructions in maintenance manual, chapter “Cylinder head” Studs for rocker brackets (implantation)

M16

~50

~5

42CrMo4V

Nuts for fixation rocker bracket studs

M16

155

16

10 DIN982

Central bolt for fixation rocker bracket

M16

155

16

42CrMo4V+K

Rocker shaft locking bolts

M12

85

8,6

8.8 DIN912

Nut nozzle holder

M56 x 2

195

20

Ck55

(Loctite no. 245)

(Loctite no. 542)

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 45/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Component to be tightened or inserted Safety valve in cylinder head

Type of thread

Tightening torque Nm kg

M39 x 1,5

137

14 – 15

25

2,5

Bolt material /

Governor drive (Woodward) (sec. 12) Bolts driving gearwheel on camshaft gearwheel 54T

M8

Bolts gear 27T

M8

8.8 DIN912

(Loctite no. 243) 25

2,5

8.8 DIN912

(Loctite no. 243) Self-locking nuts fixing conical gears UG8, UG25+

M10

30

3

8 DIN985

M12

50

5

36NiCr6 V+K / 42CrMo4+QT+C

Cap nut fixing nozzle holder in cylinder head

M76 x 2

540

55

42CrMo4V

Nozzle nut

/

Fuel feeding (sec. 14, 18, 59) Injection pump bolts (Section 018)

(Molykote G-N plus) Mount following instructions in maintenance manual, chapter “Injection system” 217

21,7

Coupling nuts injection pipe

/ /

(thread lubricated with oil)

File:

•

Type 1: 620.058.1100.04

M22 x 1,5

60 ± 5

6,1 ± 0,5

•

Type 2: 620.058.1100.05

M22 x 1,5

60 ± 5

6,1 ± 0,5

•

Type 3: 620.058.1100.06

M22 x 1,5

105 ± 5

10,5 ± 0,5

High pressure fixation nut injection pump

/

Screws flange fixation extended coupling piece

M10

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

868-895

88,5 – 91

/

(Molykote G-N plus) 34,5

3,5

8.8 DIN912

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 46/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Component to be tightened or inserted

Tightening torque Nm kg

Type of thread

Bolt material

Pump driving gear casing (sec. 15, 29, 30, 40, 41, 93) Casing bolts

M12

85

8,6

8.8 DIN912

Bolts driving gear on damper flange – only for Geislinger dampers

M10

50

4,8

8.8 DIN933

Nuts & bolts fixing intermediate shafts on gear casing

M10

50

4,8

8 DIN982

M8

25

2,5

8.8 DIN7984

Lock nuts intermediate shafts

M20

150

15

6 DIN985

M30 x 1,5

120

12

/

M10

50

4,8

8.8 DIN933

Coupling bolts intermediate gears

(Loctite no. 542)

(Loctite no. 542) Lock nut(s) driving gearwheel oil pump

M20

150

15

6 DIN985

M30 x 1,5

250

25

/

Locking nut fixing driving gearwheel water pump

M20

150

15

6 DIN 985

M12 x 1,5

147 (Loctite 270)

15 (Molykote)

/

M24 x 2

147 (Loctite 270)

15 (Molykote)

8.8 DIN439-B

147

15

DIN934-A2 (left)

1,7

12.9 DIN912

Nut fixing impeller of water pump

M20

(Loctite 270) Bolts clamping assembly of driving gear on seawater pump

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

M6

17

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 47/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Component to be tightened or inserted Bolts cover vibration damper:

•

Hasse & Wrede

•

Geislinger

Type of thread M12

Tightening torque Nm kg 85

8,6

Bolt material 8.8 DIN933

(Loctite no. 243) M16

266

23

8.8 DIN 912

(Loctite no. 242, disc spring with Molykote 1000) M10

45

4,5

8.8 DIN912

(Loctite no. 242, disc spring with Molykote 1000) M8

20

2

8.8 DIN912

Coupling bolts PTO shaft on damper

M16

343

35

12.9 DIN19

M12

100

10

10.9 DIN933

Bolts fastening soft water pump on gear casing.

M10

39

4

8.8 DIN931

Bolts fastening sea water pump on gear case.

M10

39

4

8.8 DIN933

Bots fixing guide-bearing camshaft to cylinder block

M12

120

12

10.9 DIN933

Camshaft connecting bolts

M12 x 35

120

12

10.9 DIN933

Coupling bolts camshaft intermediate flange

M12 x 30

85

8,6

8.8 DIN7984

Camshaft-bearing bolts

M12

120

12

10.9 DIN912

M8

25

2,5

8.8 DIN912

Tappet bracket fixing bolts

M12

120

12

10.9 DIN912

Bolts clamping assembly camshaft gearwheel adapter

M10

70

7

10.9 DIN912

M12

170

11,2

12.9 DIN912

Fixing bolts camshaft gearwheel on adapter

M12

85

8,6

DIN7984

Camshaft – distribution (sec. 16, 17)

File:

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

(Loctite no. 270)

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

GENERAL 6/8 DZC Chapter 0 – Page 48/48 Ed. 10 – 14/07/2017 – EN General 6/8 DZC

Component to be tightened or inserted Coupling bolts intermediate gear

Tightening torque Nm kg

Type of thread M12

85

8,6

Bolt material 8.8 DIN933

(Loctite no. 245) Bolts fixing cap on bearing support intermediate gear

M10

Bolts fixing bearing support intermediate gears on crankcase

M16

45

4,5

8.8 DIN931

(Loctite no. 245) 205

21

8.8 DIN931

Turbochargers and exhaust manifolds (sec. 20, 21, 22) Bolts fixing turbo M40

M16

200

21

8.8 DIN931

Nuts fixing turbo support

M16

350

35

12.9 DIN934

Bolts fixing turbo support

M16

350

35

12.9 DIN933

Bolts expansion bellows

M16

140

14

Heat resistant

(Molykote HSC) Exhaust manifold flanges

M16

200

Elastic bolts (620.021.9012.09) Intake air manifold flanges

20

34CrNiMo6V+K

(Molykote HSC) M16

140

14

8.8 DIN933

(Molykote HSC) Flywheel (sec. 27) Flywheel bolts

M30 x 2

1380

141

10.9 DIN960

(Molykote G-N plus) Thermostatic valves (sec. 35) Nuts assembling thermostatic oil valve

Ref.

File:

/

54

5,5

/

Description

*

Tightening by a specific rotation angle of the nut

**

Tightening up to a specific elongation of the stud

B21_001_dd2017_07_14_Ed010_EN_General_6_8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 1/44 Ed. 08- 14/07/2017 – EN Cylinder head

CHAPTER 1 CYLINDER HEAD (Assembly 11-18)

File:

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 2/44 Ed. 08- 14/07/2017 – EN Cylinder head

CONTENTS 1

2

3

4

File:

CYLINDER HEAD ............................................................................................................................4 1.1

Description............................................................................................................................... 4

1.2

Mass ........................................................................................................................................ 4

1.3

Illustrations .............................................................................................................................. 5

1.4

Recapitulation of maintenance jobs ......................................................................................... 8

1.5

Spare parts ............................................................................................................................... 8

1.6

Tools ........................................................................................................................................ 9

1.7

Dismounting the cylinder head............................................................................................... 10

1.8

Maintaining the cylinder head .................................................................................................11

ROCKER LEVER MECHANISM ........................................................................................................... 19 2.1

Description............................................................................................................................. 19

2.2

Mass ...................................................................................................................................... 19

2.3

Recapitulation of maintenance jobs ....................................................................................... 19

2.4

Spare parts ............................................................................................................................. 19

2.5

Tools ...................................................................................................................................... 19

2.6

Dismantling and cleaning the rocker lever mechanism ........................................................... 20

2.7

Checking and replacing the rocker lever bushes ..................................................................... 20

2.8

Re-assembling the rocker lever mechanism ........................................................................... 21

INLET AND EXHAUST VALVES .......................................................................................................... 24 3.1

Description............................................................................................................................. 24

3.2

Mass ...................................................................................................................................... 24

3.3

Recapitulation of maintenance jobs ....................................................................................... 24

3.4

Spare parts ............................................................................................................................. 24

3.5

Tools ...................................................................................................................................... 25

3.6

Removing the valves from the cylinder head .......................................................................... 25

3.7

Maintaining the valves ........................................................................................................... 26

3.8

Re-assembling the valves ....................................................................................................... 30

3.9

Renewing the rotocaps........................................................................................................... 30

3.10

Remounting the cylinder head ................................................................................................31

TAPPET MECHANISM .................................................................................................................... 36 4.1

Description............................................................................................................................. 36

4.2

Mass ...................................................................................................................................... 36

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 3/44 Ed. 08- 14/07/2017 – EN Cylinder head

File:

4.3

Illustration ............................................................................................................................... 37

4.4

Recapitulation of maintenance jobs ....................................................................................... 38

4.5

Spare parts ............................................................................................................................. 38

4.6

Tools ...................................................................................................................................... 38

4.7

Dismounting the tappet mechanism ...................................................................................... 38

4.8

Maintaining the tappet mechanism ........................................................................................ 39

4.9

Remounting the tappet mechanism ....................................................................................... 41

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 4/44 Ed. 08- 14/07/2017 – EN Cylinder head

1

CYLINDER HEAD

1.1

DESCRIPTION The cylinder head (1, Fig. 1.1) is made of lamellar cast iron. It is fitted with:

•

Two inlet valves (48, Fig. 1.1) and two exhaust valves (49, Fig. 1.1). The valves slide in the valve guides (4, Fig. 1.1), which are placed around the central nozzle.

•

Two inlet inserts (2, Fig. 1.1) and two exhaust inserts (3, Fig. 1.1). The inserts are made of special cast iron and are shrink-fitted into the cylinder head with liquid nitrogen.

The cylinder head is mounted on the cylinder block with six dynamic elastic studs. The flat brass gasket (65, Fig. 1.1) ensures the tightness of the combustion room.

1.2

MASS Component

File:

Mass (kg)

Disassembled, bare cylinder head

98

Complete cylinder head, with rockers

134,5

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 5/44 Ed. 08- 14/07/2017 – EN Cylinder head

1.3

ILLUSTRATIONS

Fig. 1.1

File:

Exploded view cylinder head (MDO)

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 6/44 Ed. 08- 14/07/2017 – EN Cylinder head

Fig. 1.2

File:

Exploded view cylinder head (HFO)

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 7/44 Ed. 08- 14/07/2017 – EN Cylinder head

File:

Fig. 1.3

Exploded view safety valve

Fig. 1.4

Exploded view inlet and exhaust joints

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 8/44 Ed. 08- 14/07/2017 – EN Cylinder head

1.4

RECAPITULATION OF MAINTENANCE JOBS Code

1.5

Description

O1-01

•

Complete overhaul of the cylinder heads

O2-01

•

Removing and, if necessary, grinding or replacing valves and valve seats

•

Checking and, if necessary, replacing valve guides

•

Checking valve springs and collars

•

Measuring and, if necessary, replacing valves

•

Complete overhaul of the valve mechanism (bridges, rockers, bushes, shaft)

•

Replacing all joints (water, oil, exhaust gasses)

•

Checking opening pressure of relief valves

•

Cleaning oil conducts

•

Replacing bushes and measuring shaft

•

Renewing the rotocaps

SPARE PARTS Fig.

File:

Ref. No.

Description

Number/Cyl.

Fig. 1.1

4

Valve guide

4

Fig. 1.1

2

Inlet valve insert

2

Fig. 1.1

3

Exhaust valve insert

2

Fig. 1.1

65

Cylinder head gasket

1

Fig. 1.1

60

Joint

1

Fig. 1.1

71

Joint

1

Fig. 1.1

72

Joint

1

Fig. 1.1

16

Joint

1

Fig. 1.1

17

Joint

8

Fig. 1.1

18

Joint

1

Fig. 1.1

19

Joint

2

Fig. 1.1

62

Seal O-ring cylinder head cover

1

Fig. 1.1

15

Seal O-ring nozzle holder sleeve

2

Fig. 1.4

80

Joint air intake cylinder head

1

Fig. 1.4

81

Joint exhaust flange cylinder

1

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 9/44 Ed. 08- 14/07/2017 – EN Cylinder head

This table only lists the spare parts of the cylinder head itself. Joints and washers for the pipes that are connected to the cylinder head are listed in the spare parts list of the 6/8DZC or the 12/16DZC engine.

The 12/16DZC engine is equipped with a special inlet valve rocker (77, Fig. 1.1 – 630.011.8204.01). It has an extra nozzle to enhance the lubrication of the inlet valves.

1.6

TOOLS Code

File:

Description

620.083.1200.02

Tool for mounting and dismounting valve springs

620.083.1300.01

Tool for extracting nozzle holder

100.933.012.000

Eye bolt for lifting cylinder head

620.083.1600.03

Torque wrenches with sockets and accessories

620.083.9007.01

Magnetic base

620.084.2100.01

Tool for hydraulic test cylinder head

620.084.2200.01

Tool for remilling inlet and exhaust inserts

620.084.2300.02

Tool for mounting, dismounting and lapping the nozzle holder sleeve in the cylinder head

620.084.2400.01

Tool for mounting and dismounting valve guides

620.084.9010.01

Tool for lapping of cylinder liner collar and cylinder head

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 10/44 Ed. 08- 14/07/2017 – EN Cylinder head

1.7

DISMOUNTING THE CYLINDER HEAD Required staff One service man Procedure

File:

1

Drain the water circuit until all water is removed from the cylinder head.

2

Unscrew the handle (63, Fig. 1.1) and remove the cylinder head cover (61, Fig. 1.1).

3

Disconnect all pipes from the cylinder head. This includes:

•

The fuel injection pipes

•

The fuel drain pipes

•

The lube oil pipe for the valve gear

4

Remove the water outlet elbow and the complete rocker levers (20-24, Fig. 1.1), including the bracket (27, Fig. 1.1), the bridges (33, Fig. 1.1) and the push rods.

5

Remove the nozzle holder. Proceed as follows: a

Remove the injection pipe coupling and the hexagon cap nut.

b

Remove the nozzle holder, using tool 620.083.1300.01.

c

Screw the hexagon cap nut back on.

6

Disconnect the cylinder head from the gas outlet manifold and the air intake manifold.

7

Remove the fixing nuts from the cylinder head. You have to do this in two steps: a

Turn each nut 90° to loosen the nuts.

b

Further unscrew each nut and remove them from the cylinder head.

8

Mount the eye bolt in the cylinder head.

9

Lift the cylinder head and place it on a wooden surface (e.g. on a wooden pallet). This avoids damage to the sealing surface at the side of the cylinder head gasket.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 11/44 Ed. 08- 14/07/2017 – EN Cylinder head

1.8

MAINTAINING THE CYLINDER HEAD

1.8.1

Overview Maintaining the cylinder head includes:

1.8.2

1

Cleaning the cylinder head (page 11)

2

Testing the cylinder head (hydraulic test) (page 12)

3

Checking the sealing surface (page 13)

4

Checking and replacing the valve guides (page 13)

5

Checking, remilling and replacing the inserts (page 15)

6

Removing and lapping the nozzle holder sleeve (page 15)

Cleaning the cylinder head YOU USE HAZARDOUS LIQUIDS (PETROL, WHITE SPIRIT…) TO CLEAN THE CYLINDER HEAD. REFER TO THE SAFETY PRESCRIPTION CARD FOR INSTRUCTIONS ON SAFE AND PROPER USE OF THESE LIQUIDS. Required staff One service man Procedure 1

Completely disassemble the cylinder head. Only leave the valve guides (4, Fig. 1.1), the valve inserts (2 and 3, Fig. 1.1) and the nozzle holder sleeve (6, Fig. 1.1) in place.

2

Clean the cylinder head with petrol or white spirit and remove the deposit in the exhaust ducts with a blunt scraper.

3

Check the deposit on the inner walls of the water jacket. You can do this through the water inlet ports, the water exhaust ports and the plug holes. If the deposit is thicker than 0,4 mm you have to remove it with Oltec Clean 9100 (IAS) or an equivalent. Proceed as follows: a

Close all holes in the water jackets with wooden or plastic plugs. Leave one hole open.

b

Make sure there are no open flames in the vicinity of the cylinder head and pour the cleaning liquid (water and cleaning agent) in the cylinder head. Result:

The cleaning agent starts working on the deposit and produces gasses. These gasses are highly flammable.

c

Wait until the gasification stops and drain the cleaning liquid from the cylinder head.

d

Recheck the inner walls of the water jackets and do one of the following: If the deposit…

File:

Do the following...

Not gone yet

Repeat steps a through c.

Is gone

Rinse the cylinder head with water and dry it with compressed air.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 12/44 Ed. 08- 14/07/2017 – EN Cylinder head

1.8.3

Testing the cylinder head (hydraulic test) Required staff One service man Procedure After you cleaned the water jackets, you have to execute a hydraulic test on the jackets (at 7 bar, for at least 2 hours). Proceed as follows: 1

Fill the cylinder head with water and put it under pressure (7 bar), using tool 620.084.2100.01. The exact arrangement of the tool is shown in Fig. 1.5.

2

While the cylinder head is under pressure, closely check the lower surface of the cylinder head, the inlet ducts, the outlet ducts and the plugs in the water jackets for leaks. Leaking water can damage the cylinder (water hammer) and the timing gear (oil contamination).

PAY SPECIAL ATTENTION TO THE PLUGS IN THE UPPER SURFACE OF THE CYLINDER HEAD AND AROUND THE NOZZLE HOLDER SLEEVE. IF WATER LEAKS IN THOSE PLACES, IT WILL CONTAMINATE THE OIL. IF YOU DETECT A LEAK AROUND THE NOZZLE HOLDER SLEEVE, YOU HAVE TO LAP THE NOZZLE HOLDER SLEEVE (SEE “1.8.7 REMOVING AND LAPPING THE NOZZLE HOLDER SLEEVE” ON PAGE 17).

A

B

Ref.

Description

A

Venting

B

Tool 620.084.2100.01

C

Water connection thread ½”G

C

Fig. 1.5

File:

Arrangement for hydraulic test

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 13/44 Ed. 08- 14/07/2017 – EN Cylinder head

1.8.4

Checking the sealing surface Required staff One service man Procedure 1

Check the flatness of the sealing surface at the gasket side of the cylinder head with Prussian blue and a surface plate. If the surface is uneven or damaged, it has to be reworked. Contact the ABC service department for further information.

2

Check the sealing surface of the cylinder liner with lapping ring (620.084.9010.01). If the sealing is not good, lap the surface lightly with the lapping ring. This allows you to obtain a perfect mating between the cylinder head gasket, the cylinder head and the cylinder liner.

1.8.5

Checking and replacing the valve guides Required staff One service man Procedure 1

Without removing the valve guides from the cylinder head, measure the inner diameter of the guides. You have to do this at three positions (A, Fig. 1.6).

Original Dimensions (mm) Min. 18,00 Max. 18,038

Fig. 1.6 2

File:

Wear Limit (mm) Max. 18,250

Measuring positions inner diameter valve guides and wear limits

Compare your results with the wear limits of the valve guide (Fig. 1.6). If the wear limit is exceeded at one or more positions, you have to replace the guide. Proceed as follows:

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 14/44 Ed. 08- 14/07/2017 – EN Cylinder head

a

Remove the valve guide from the cylinder head, using tool 620.084.2400.01 (Fig. 1.7).

b

Measure the diameter of the bore in the cylinder head (B, Fig. 1.7) and the outer diameter of the valve guide (C, Fig. 1.7) to make sure the normal measures are met: Diameter Diameter bore cylinder head Outer diameter valve guide

Normal measure 25H7

0 , 021  0 , 000

25p6

0 , 035  0 , 022

If these measures are not met, replace the part or contact the ABC service department. c

Fig. 1.7

File:

Mount the new valve guide in the cylinder head and measure the inner diameter of the valve guide (A, Fig. 1.6). It now has to correspond with the original measures in Fig. 1.6.

Extracting (left) and inserting (right) valve guides with tool 620.084.2400.01

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 15/44 Ed. 08- 14/07/2017 – EN Cylinder head

1.8.6

Checking, remilling and replacing the inserts Required staff One service man Procedure 1

Check if you have to remill the insert: You… Have to remill the insert

Do not have to remill the insert

If…

•

The insert displays major damages (burnings, mechanical shocks, gas leaks…)

•

You can insert a feeler gauge of 0,02 mm between the valve and the insert (when the valve is in good condition and is pressed in by hand).

The working surface of the insert has a marble aspect. This is caused by very small irregularities in the surface that do not require any reworking of the insert.

Continue with step 2 if you have to remill the insert. If not, you can stop this procedure. 2

Check if the valve guides are in good condition and if their inner diameter does not exceed the wear limit (Fig. 1.6). See “1.8.5 Checking and replacing the valve guides” (page 13). If the valve guides are not in good condition, remilling the insert will have no effect. You then have to replace the valve guides first.

3

4

File:

Remill the insert using tool 620.084.2200.01 (Fig. 1.8). Proceed as follows: a

Mount the correct mill cutter on the holder. Use cutter 620.084.8101.01 for inlet valve inserts and mill cutter 620.084.8201.01 for exhaust valve inserts.

b

Slide the holder with the mill cutter in the valve guide.

c

Place the thrust bearing and mount the high hexagon nut.

d

Place the tap wrench on the holder and gradually tighten the hexagon nut. When you feel resistance on the cutter, it starts to take away material.

e

Further tighten the hexagon nut to take away more and more material.

f

Stop after a few turns and recheck the insert (see step 1). Only stop remilling the insert when its working surface is completely clean and the feeler gauge does not fit anymore.

After remilling the insert, check if the rectification limit (Fig. 1.9 - Fig. 1.12) is not exceeded. If the limit is exceeded, replace the insert or contact the ABC service department.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 16/44 Ed. 08- 14/07/2017 – EN Cylinder head

A

B

Fig. 1.8

Mill cutter and thrust bearing

Ref.

File:

Description

A

Mill cutter. Use cutter 620.084.8101.01 for inlet valve inserts and cutter 620.084.8201.01 for exhaust valve inserts.

B

Thrust bearing

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 17/44 Ed. 08- 14/07/2017 – EN Cylinder head

Rectification limits

1.8.7

Fig. 1.9

Inlet insert – Original measures

Fig. 1.10

Fig. 1.11

Exhaust insert – Original measures

Fig. 1.12

Inlet insert – Rectification limit

Exhaust insert – Rectification limit

Removing and lapping the nozzle holder sleeve Required staff One service man Procedure If you detected leaks around the nozzle holder sleeve during the hydraulic test (see 1.8.3 on page 12), you have to replace the O-rings and lap the nozzle holder sleeve. Proceed as follows:

File:

1

Remove the special nut from the nozzle holder sleeve, using tool 620.084.2301.02.

2

Remove the nozzle holder sleeve from the cylinder head, using tool 620.084.2300.02.

3

Remove the O-rings from the nozzle holder sleeve and put the nozzle holder sleeve back in the cylinder head.

4

Lap the nozzle holder sleeve in the cylinder head to obtain a perfect sealing. To do so, use tool 620.084.2300.02 (without the bridge), lapping paste and a crank handle (socket S19).

5

Remove the nozzle holder sleeve from the cylinder head and clean it.

6

Put new O-rings on the nozzle holder sleeve and put the sleeve back in the cylinder head.

7

Fix the sleeve with the special nut and tighten the nut with a torque wrench to 195 Nm.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 18/44 Ed. 08- 14/07/2017 – EN Cylinder head

A

C

Ref.

Description

A

Lapping

B

Tool 620.084.2301.02

C

Tool 620.084.2300.02

B

Fig. 1.13

File:

Tools for removing and lapping nozzle holder sleeve

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 19/44 Ed. 08- 14/07/2017 – EN Cylinder head

2

ROCKER LEVER MECHANISM

2.1

DESCRIPTION The simple rocker levers (20-24, Fig. 1.1) are provided with bushes (21, Fig. 1.1) and mounted on a shaft (26, Fig. 1.1). The shaft is clamped in the support (27, Fig. 1.1) with two screws (31, Fig. 1.1). The support is aligned by the slotted spring pin (59, Fig. 1.1) and fastened on the cylinder head with the central screw (56, Fig. 1.1) and two studs with nuts (55 and 57, Fig. 1.1). The rocker levers are pressure lubricated through the shaft, the oil is drained via the push-rod sheaths. Via the bridge, the rocker levers act on the inlet and exhaust valves (48 and 49, Fig. 1.1).

2.2

MASS Component

Mass (kg)

Rocker levers and support

2.3

15

RECAPITULATION OF MAINTENANCE JOBS Code

2.4

Description

O1-01

•

Cleaning oil conducts

O2-01

•

Replacing bushes and measuring shaft

SPARE PARTS Fig.

Ref. No.

Fig. 1.1

2.5

21

Description Bush

Number/Cyl. 2

TOOLS Code

Description

620.084.2500.01*

Tool for mounting and dismounting valve rocker bush

/

Straight jaw external circlip plier 25-60 mm

*Special tool, does not come with the engine. Only supplied on request.

File:

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 20/44 Ed. 08- 14/07/2017 – EN Cylinder head

2.6

DISMANTLING AND CLEANING THE ROCKER LEVER MECHANISM Required staff One service man Procedure

2.7

1

Loosen the two nuts (57, Fig. 1.1) and the central screw (56, Fig. 1.1).

2

Remove the rocker lever assembly.

3

Remove the circlip (30).

4

Remove the rocker levers.

5

Remove the shaft from the support.

6

Clean the oil conducts in the support, the shaft and the rocker levers.

CHECKING AND REPLACING THE ROCKER LEVER BUSHES Required staff One service man Procedure 1

Measure the outside diameter of the shaft and the inner diameter of the bearing bush (A, Fig. 1.14). Do not remove the bushes from the rocker levers to do so.

Diameter

Fig. 1.14

2

File:

OD (Original Dimension)

WL (Wear Limit)

Outside diameter shaft

Min. 49,975 Max. 49,959

Max. 49,90

Diameter bearing bush

Min. 50,045 Max. 50,008

Max. 50,15

Wear limits rocker lever bushes and shaft

Compare your results with the wear limits. (Fig. 1.14). If the wear limits are exceeded, you have to replace the bush or the shaft. To replace the bush, proceed as follows: a

Remove the bush from the rocker lever, using tool 620.084.2500.01 (Fig. 1.15).

b

Insert the new bush in the rocker lever, again using tool 620.084.2500.01 (Fig. 1.15).

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 21/44 Ed. 08- 14/07/2017 – EN Cylinder head

Fig. 1.15

Extracting (left) and inserting (right) rocker lever bush with tool 620.084.2500.01

2.8

RE-ASSEMBLING THE ROCKER LEVER MECHANISM

2.8.1

Overview Re-assembling the rocker lever mechanism includes:

2.8.2

1

Removing the clearance between the valve bridge and the valve stem (page 21)

2

Installing the rocker levers (page 22)

3

Adjusting the valve clearance (clearance between rocker lever and bridge) (page 22)

4

Checking the lubrication (page 23)

Removing the clearance between the valve bridge and the valve stems Required staff One service man Procedure

File:

1

Place the valve pushrods in the seats.

2

Place the bridges (33, Fig. 1.1) on the valve stems and remove any clearance between them. Always do this when the engine is cold. Proceed as follows: a

Remove the lock nut (37, Fig. 1.1) and turn the set screw slightly back.

b

Take a dial gauge with magnetic foot and place it with the feeler on the top of the bridge (Fig. 1.16).

c

Manually press the bridge on the valve and turn the set screw until the gauge starts to move (0,01 – 0,02 mm).

d

Keep the set screw in this position and tighten the lock nut.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 22/44 Ed. 08- 14/07/2017 – EN Cylinder head

Fig. 1.16

2.8.3

Position dial gauge

Installing the rocker levers Required staff One service man Procedure 1

2.8.4

Execute the following checks: a

Check if the slotted spring is in place.

b

Check if the lock nuts (32, Fig. 1.1) are removed and the set screws are screwed back.

c

Check if the valve pushrods are at their lowest position (piston in TDC – injection).

2

Mount the valve lever assembly and the support. Make sure the pushrods are located in the middle of the sheaths.

3

Tighten the nuts (57, Fig. 1.1) and the central screw (56, Fig. 1.1) with a torque wrench to the torque listed in the torque table.

Adjusting the valve clearance (clearance between rocker lever and bridge) Required staff One service man Procedure Always adjust the valve clearance (i.e. the clearance between the rocker lever and the bridge) on a cold engine. Proceed as follows:

File:

1

Set the piston of the cylinder in question in TDC compression stroke.

2

Lightly grease the surfaces between the rocker lever and the bridge.

3

Put a 0,20 mm thickness gauge between the set screw (25, Fig. 1.1) and the pad (34, Fig. 1.1).

4

Turn the set screw until you feel a slight resistance on the thickness gauge. The gauge should not be jammed.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 23/44 Ed. 08- 14/07/2017 – EN Cylinder head

2.8.5

5

Keep the screw in this position with a wrench and tighten the lock nut.

6

Recheck the clearance.

Checking the lubrication Required staff One service man Procedure

File:

1

Start the engine.

2

Check if the oil reaches all areas that have to be lubricated.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 24/44 Ed. 08- 14/07/2017 – EN Cylinder head

3

INLET AND EXHAUST VALVES

3.1

DESCRIPTION Each cylinder has two inlet valves (48, Fig. 1.1) and two exhaust valves (49, Fig. 1.1). Both valves are slightly different: Valve

Seat

Vertex angle

Inlet valve

Hardened by induction

110°

Exhaust valve

Treated with stellite

90°

The valve stems are nitrated or hard chrome-plated. Each valve is equipped with two springs (50 and 51, Fig. 1.1). At the top, the springs are positioned by spring collars (MDO) (52, Fig. 1.1) or rotocaps (HFO) (73, Fig. 1.2). At the bottom, the springs are positioned by spring collars (52, Fig. 1.1 and Fig. 1.2).The top collars (MDO) (52, Fig. 1.1) or rotocaps (HFO) (73, Fig. 1.2) are fixed on the stem by two half conical collets (54, Fig. 1.1).

3.2

MASS Component

3.3

Mass (kg)

Inlet valve

1,10

Exhaust valve

1,25

RECAPITULATION OF MAINTENANCE JOBS Code

3.4

Description

M4-03

Checking the valve clearance and, if necessary, adjusting the clearance

M6-09

Checking the valve wear (measure).

O1-01

•

Checking the valve springs and collars

O2-01

•

Measuring the valves

•

Renewing the rotocaps

SPARE PARTS Fig.

File:

Ref. No.

Description

Number/Cyl.

Fig. 1.1

48

Inlet valve

2

Fig. 1.1

49

Exhaust valve

2

Fig. 1.1

50

Internal valve spring

4

Fig. 1.1

51

External valve spring

4

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 25/44 Ed. 08- 14/07/2017 – EN Cylinder head

Fig. Fig. 1.2

3.5

Ref. No. 73

Description Rotocap

4

TOOLS Code

3.6

Number/Cyl.

Description

620.083.1200.02

Tool for mounting and dismounting valve springs

100.933.012.000

Eye bolt

REMOVING THE VALVES FROM THE CYLINDER HEAD Required staff One service man Procedure

File:

1

Put the cylinder head on a wooden table so the valves stay in their seats during the operation. Be careful not to damage the sealing rim.

2

Carefully tap the upper spring collar (MDO) (52, Fig. 1.1) or rotocap (HFO) (73, Fig. 1.2) with a copper drift punch and a hammer to separate it from the valve collets (54, Fig. 1.1).

3

Mount eye bolt 100.933.012.000 in the cap nut.

4

Place tool 620.083.1200.02 on the upper spring collar and hook it in the eye bolt (Fig. 1.17).

5

Push the lever of the tool down and remove the valve collets from the valve stem.

6

Slowly release the springs and remove them from the valve stem. The valves are now completely free.

7

Remove tool 620.083.1200.02 and remove the valves from the cylinder head.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 26/44 Ed. 08- 14/07/2017 – EN Cylinder head

A

B Ref.

Fig. 1.17

Description

A

Tool 620.083.1200.02

B

Eye bolt 100.933.012.000

Tool and eye bolt for removing valves

3.7

MAINTAINING THE VALVES

3.7.1

Overview Maintaining the valves includes: 1

File:

Checking the straightness, concentricity and perpendicularity (page 26)

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 27/44 Ed. 08- 14/07/2017 – EN Cylinder head

3.7.2

2

Rectifying the valve seat (page 28)

3

Checking and replacing the valves (page 28)

4

Lapping the valve in the valve insert (page 29)

5

Cleaning, checking and replacing the springs (page 29)

Checking the straightness, concentricity and perpendicularity Required staff One service man Procedure The procedure is identical for all valves Proceed as follows: 1

Clean the valve and place it in the measuring bench as shown in Fig. 1.18.

Fig. 1.18

2

Checking valves on measuring bench

Check the following aspects of the valve and take the necessary actions if the tolerance is exceeded: Check

File:

Tolerance

Action

Straightness of valve stem

Max. 0,04 mm

Replace the valve.

Concentricity of valve seat

Max. 0,04 mm

Grind the valve seat.

Perpendicularity of valve head to valve centerline

Max. 0,04 mm

Replace the valve.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 28/44 Ed. 08- 14/07/2017 – EN Cylinder head

When measuring the concentricity of the valve seat, make sure the sensor of the dial gauge is placed perpendicularity in the center of the mating surface.

File:

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 29/44 Ed. 08- 14/07/2017 – EN Cylinder head

3.7.3

Rectifying the valve seat Required staff One service man Procedure 1

Check whether or not you have to rectify the valve seat: The seat…

If...

Needs rectification

Does not need rectification

3.7.4

•

It is damaged

•

Its disconcentricity exceeds the tolerance of 0,04 mm

It has a marble aspect. This is normal after a certain amount of working hours.

2

If necessary, rectify the valve seat with a fine grained grinding stone. Try to remove only a minimum of material. If the valve head gets to thin, you have to replace it.

3

Check the valve to see if the valve head did not get to thin. See step 4 of “3.7.4 Checking and replacing the valves” on page 28.

4

Recheck the disconcentricity of the valve seat. It cannot exceed the tolerance of 0,04 mm. See “3.7.2 Checking the straightness, concentricity and perpendicularity” (page 26).

Checking and replacing the valves Required staff One service man Procedure 1

Check the number of running hours of the engine. You have to replace the valve every 24000 running hours.

2

Check the valve stem, the valve stem end or the valve head for damage. If you detect severe damage on the valve, you have to replace the valve.

3

Check if the valve stem is straight. See “3.7.2 Checking the straightness, concentricity and perpendicularity” (page 26). If the stem is not straight, you have to replace the valve.

4

Check the valve wear. Proceed as follows: a

Adjust the valve clearance. See “2.8.4 Adjusting the valve clearance (clearance between rocker lever and bridge)” (page 22).

b

Measure the height between the valve spring collar and the top surface of the cylinder head (X and Y, Fig. 1.19). You have to do this with the cylinder in TDC.

c

Compare your result to the wear limit listed in Fig. 1.19 and do one of the following: If the wear limit...

File:

Do the following...

Is not exceeded

You do not have to replace the valve due to wear.

Is exceed

•

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

Replace the valve and the valve seat.

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 30/44 Ed. 08- 14/07/2017 – EN Cylinder head

If the wear limit...

Do the following...

•

Check the valve guide to see if it has to be replaced as well. See “1.8.5 Checking and replacing the valve guides (page 13).

Ref. X/Y

Fig. 1.19

3.7.5

Original measure

Wear limit

52,5 mm

55 mm

Measuring position valve wear and wear limit

Lapping the valve in the valve insert Required staff One service man Procedure 1

Check if you have to lap the valve in the valve insert. This is necessary:

•

Each time you removed a valve from the cylinder head

•

Each time you replaced a valve or a valve insert

•

Each time you grinded a valve or remilled a valve insert

2

3

3.7.6

If necessary, lap the valve in the valve insert. Remarks:

•

Use lapping tool 620.083.2100.01 and lapping paste.

•

Put the cylinder head on two wooden beams, with the valve head upwards. The valve can then move freely. Thoroughly clean the components, until all lapping paste is removed.

Cleaning, checking and replacing the springs Required staff One service man

File:

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 31/44 Ed. 08- 14/07/2017 – EN Cylinder head

Procedure 1

2

Clean the valve springs. Proceed as follows: a

Dip the springs in diesel fuel. Do not brush or polish the springs, as this can damage the protective layer of the springs.

b

Let the springs drip and dry them with compressed air.

Measure the free length of the springs to see if you have to replace them. The springs have to be replaced when their free length attains the following values: Spring

3.8

Ref. Fig. 1.1

Free length (mm)

Inner valve spring

50

90

Outer valve spring

51

100

RE-ASSEMBLING THE VALVES Required staff One service man Procedure 1

Check the state of the mating surfaces between the valves and the bridge and between the bridge and the rocker lever. If there are any irregularities or scratches on the surfaces, carefully remove them with an oiled whetstone.

3.9

2

Oil the valve stems and the valve guides.

3

Remount the valves and the valve springs in the cylinder head with tool 620.083.1200.02. This is the same tool you used for dismounting the valves and valve springs.

4

Tap the valve stem with a wooden or a plastic hammer until the half conical valve collets are positioned correctly. Do not support the valve during this operation.

RENEWING THE ROTOCAPS Required staff One service man Procedure

File:

1

Remove the rotocaps (73, Fig. 1.2). The procedure is described in §3.6 Removing the valves from the cylinder head (page 25)

2

Place new rotocaps on the valve springs (50 and 51, Fig. 1.2).

3

Mount with tool 620.083.1200.02 the half conical valve collets (54, Fig. 1.2) on the rotocaps.

4

Tap the valve stem with a wooden or a plastic hammer until the half conical valve collets are positioned correctly. Do not support the valve during this operation.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 32/44 Ed. 08- 14/07/2017 – EN Cylinder head

3.10

REMOUNTING THE CYLINDER HEAD

3.10.1 Overview Once you remounted the valves in the cylinder head, you can remount the cylinder head on the engine. Remounting the cylinder head includes: 1

Checking and replacing cylinder head studs (page 31)

2

Positioning the cylinder head (page 32)

3

Tightening the cylinder head nuts (page 33)

4

Finishing off the remounting of the cylinder head (page 35)

3.10.2 Checking and replacing cylinder head studs The cylinder head studs should only be replaced by skilled and authorized ABC service men.

Engines built before 1993 are equipped with non-marked (no X on top), steel cylinder head studs. To extend the reliability of the cylinder head studs, we recommend replacing these studs by marked (X on top), stainless steel studs.

1

Closely check all the cylinder head studs and do one of the following: If... One or more studs show damage, cracks or corrosion

Replace all cylinder head studs. To do so, continue with step 2.

All studs are in good condition

Continue with “3.10.3 Positioning the cylinder head” (page 32)

2

Remove the cylinder head studs by turning them counterclockwise. To dos o, use the nut that is on the stud and an extra counter nut.

3

Remove any remaining Loctite and metal deposit from the threaded holes. Proceed as follows:

4

a

Take a long threaded tap M24x2 and carefully insert it into the hole, until you reach the beginning of the thread.

b

Start turning the tap clockwise and tap the thread to the end. Be careful not to damage the thread.

c

Remove the tap by carefully turning it counterclockwise.

d

Blow the Loctite and metal deposits from the threaded hole with compressed air.

One by one mount the new cylinder head studs, with the X facing up (Fig. 1.20). Proceed as follows: a

File:

Do the following...

Put three straight stripes of Loctite 222 on the thread that will be mounted in the cylinder block. Put the stripes vertically, with 120° between each stripe (Fig. 1.20).

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 33/44 Ed. 08- 14/07/2017 – EN Cylinder head

b

Cover a section of 127 mm above the thread with low acidity grease (e.g. Ceran WR2 by Total).

c

Carefully insert the stud into the threaded hole, until you reach the start of the thread.

d

Turn the stud clockwise until it is completely screwed in.

e

Tighten the stud with a torque wrench to 100 Nm. Use the original nut and counter nut.

A

Ref.

Description

A

X mark

B

Grease (127 mm)

C

Loctite 222

B

C

Fig. 1.20

Replacing cylinder head studs

3.10.3 Positioning the cylinder head

File:

1

Replace the cylinder head gasket on the cylinder liner.

2

Remove and replace all the rubber sleeves 6x (8 and 32, Fig. 1.1) and 4x (66, Fig. 1.1).

3

Check the joints on the air intake manifold and the gas exhaust manifold. Replace them if they are damaged or show signs of leaks.

4

Mount the lifting eye bolt 100.933.012.00 in the cylinder head, lift the cylinder head and place it on the engine.

5

Mount the four fixing screws of the intake air manifold so the cylinder head aligns itself to the flange of the manifold. Do not tighten the screws yet.

6

Tighten the cylinder head nuts. See “3.10.4 Tightening the cylinder head nuts” (page 33).

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 34/44 Ed. 08- 14/07/2017 – EN Cylinder head

3.10.4 Tightening the cylinder head nuts Required staff One service man Introduction The cylinder head nuts are tightened in three steps. In the first step, you use a torque to determine how far you have tighten the nuts (e.g. 245 Nm). In the second and third step, you use an angular displacement. The angles are predefined by marks, placed on the circumference of the nut socket. To get a better understanding of how it works, take a look at Fig. 1.21. After you tightened the nut to the correct torque, you place a pin on the reference mark (0°). This allows you to further tighten the nut to the correct angular displacement: first you tighten the nut until the pin hits the second mark on the socket and finally you tighten the nut until the pin hits the last mark on the socket. B

C

Ref.

D

Description

A

Magnetic base

B

Pin

C

Torque wrench

D

Socket

A

Fig. 1.21

Tightening nuts on angular displacement

Overview The exact tightening procedure depends on whether or not you replaced the cylinder head studs.

•

If you replaced the studs, see Procedure 1: New studs (page 33)

•

If you did not replace the studs, see Procedure 2: Used studs (page 35)

Procedure 1: New studs If you replaced the studs, you have to tighten the nuts, loosen them and retighten them. Proceed as follows: 1

File:

Put Molykote G-n Plus on:

•

The upper thread of the studs and the upper face of the washers (Fig. 1.22)

•

The underside of the nuts and the thread of the nuts (Fig. 1.23)

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 35/44 Ed. 08- 14/07/2017 – EN Cylinder head

Fig. 1.22 2

File:

Fig. 1.23

Underside and thread of nut

Pretighten the nuts in three steps. Proceed as follows: a

One by one tighten the nuts with a torque wrench to 245 Nm, according to the tightening order indicated in Fig. 1.24.

b

One by one tighten the nuts over an angle of 85°, according to the tightening order indicated in Fig. 1.24.

c

One by one tighten the nuts over an angle of 85°, according to the tightening order indicated in Fig. 1.24.

Fig. 1.24 3

Upper thread of stud and washer

Tightening order

Loosen the nuts in two steps: a

One by one turn the nuts 85° back, according to the order indicated in Fig. 1.24.

b

One by one turn the nuts completely back, according to the order indicated in Fig. 1.24.

4

Definitively tighten the nuts in three steps. You do this exactly the same way as you did in step 2.

5

Mount the sealing ring (B, Fig. 1.25) and the cap nut (B, Fig. 1.25) on the cylinder head stud on position 1 (Fig. 1.24)

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 36/44 Ed. 08- 14/07/2017 – EN Cylinder head

A B

Fig. 1.25

Sealing ring and cap nut

Engines built before 1993 are equipped with non-marked (no X on top), steel cylinder head studs. The nuts of these studs have to be tightened in the same way, but to an angle of 75° instead of 85° (245 Nm, 75°, 75°). To extend the reliability of the cylinder head studs, we recommend replacing these studs by marked (X on top), stainless steel studs. Procedure 2: Used studs 1

2

Put Molykote G-n Plus on:

•

The upper thread of the studs and the upper face of the washers (Fig. 1.22)

•

The underside of the nuts and the thread of the nuts (Fig. 1.23) Tighten the nuts in three steps. Proceed as follows: a

One by one tighten the nuts with a torque wrench to 245 Nm, according to the tightening order indicated in Fig. 1.24.

b

One by one tighten the nuts over an angle of 85°, according to the tightening order indicated in Fig. 1.24.

c

One by one tighten the nuts over an angle of 85°, according to the tightening order indicated in Fig. 1.24.

3.10.5 Finishing off the remounting of the cylinder head

File:

1

Put Molykote HSC on the screws M16x40 (DIN 933 – 8.8) of the air intake part and tighten them with a torque wrench to 140 Nm.

2

Put Molykote HSC on the elastic screws of the gas exhaust manifold (620.021.9012.09) and tighten them with a torque wrench to 200 Nm.

3

Remount the nozzles, the bridges and the rocker levers.

4

Reconnect all the surrounding circuits.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 37/44 Ed. 08- 14/07/2017 – EN Cylinder head

4

TAPPET MECHANISM

4.1

DESCRIPTION The main components of the tappet mechanism are the valve pushrods, the sheaths and the tappets with rollers: Component Valve pushrods

Ref. Fig. 1.26 620.018.1300.01

Description The pushrods are identical for the inlet and exhaust valves:

•

The right hand pushrods operate the exhaust valves

•

The left hand pushrods operate the inlet valves

Both ends of the pushrods are equipped with a hardened pad.

4.2

Sheaths

620.018.1400.02

The valve pushrods are located in sheaths. The lube oil of the cylinder head comes back via these sheaths.

Tappets with roller

620.018.1200.02

The tappets with roller slide in the tappet bracket (1, Fig. 1.26), which is mounted at the front of the engine.

MASS Component

File:

Mass (kg)

Tappet bracket

11,30

Valve pushrod

1,40

Tappet with roller injection pump

1,46

Tappet with roller valves

0,94

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 38/44 Ed. 08- 14/07/2017 – EN Cylinder head

4.3

ILLUSTRATION

Fig. 1.26

File:

Exploded view tappet mechanism

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 39/44 Ed. 08- 14/07/2017 – EN Cylinder head

4.4

RECAPITULATION OF MAINTENANCE JOBS Code

Description

M6-03

4.5

Checking tappet mechanism (tappets, shafts and rollers)

SPARE PARTS Fig.

4.6

Ref.

Description

Number/Cyl.

Fig. 1.26

620.018.1100.02

Tappet with roller valves

2

Fig. 1.26

620.018.1200.01

Tappet with roller injection pump

1

TOOLS No special tools required.

4.7

DISMOUNTING THE TAPPET MECHANISM The tappet with roller, the shaft and the hardened pad are considered a single unit and should never be disassembled. You cannot order them separately as spare parts. Required staff One service man Procedure BE CAREFUL NOT TO MOVE THE STOP OF THE FUEL PUMP (LOCATED ON THE FUEL PUMP ROD) WHEN YOU DISMOUNT THE TAPPET MECHANISM. IF THE STOP IS MOVED, YOU HAVE TO RE-ADJUST THE FUEL PUMP WHEN YOU REMOUNT THE TAPPET MECHANISM.

1

Remove the rocker levers, the valve pushrods and the sheaths.

2

Remove the camshaft inspection door from the cylinder housing.

3

Disconnect the fuel injection pipes.

4

Remove the oil supply bolt of the lube oil manifold from the tappet bracket.

5

Disconnect the fuel feed pipe, which runs from the fuel feed manifold to the injection pump.

6

Remove the banjo bolt from the fuel drain manifold of the fuel pumps.

7

Remove the tappet bracket and the fuel pump. If you have to replace one of the valve tappets, you do not have to separate the pump from the tappet bracket. Proceed as follows to remove the bracket and the pump assembly (ca. 20 kg): a

File:

Loosen the six fastening screws (8, Fig. 1.26) from the tappet bracket.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 40/44 Ed. 08- 14/07/2017 – EN Cylinder head

8

b

Take two of the fastening screws and use them to push the tappet bracket from the guide. There are two threaded holes provided to do so.

c

Remove the tappet bracket and the fuel pump. While doing so, pull the control rod of the fuel pump towards you, so the spherical lever pin does not get stuck in the recess in the cylinder housing wall.

Loosen the screws at the back of the tappet bracket and remove the tappets with roller.

4.8

MAINTAINING THE TAPPET MECHANISM

4.8.1

Overview Maintaining the tappet mechanism includes:

4.8.2

1

Checking the tappets (page 39)

2

Measuring the tappets, bores and clearance (page 39)

3

Checking the pushrods (page 40)

Checking the tappets Required staff One service man Procedure

4.8.3

1

Check if the tappets can move freely in the tappet bracket. If not, replace the tappet.

2

Check the working surface of the tappet roller for damage. Replace the tappet if you detect any damage.

Measuring the tappets, bores and clearance Required staff One service man Procedure 1

Remove the tappet with roller from the tappet bracket. See “4.7 Dismounting the tappet mechanism” (page 38).

2

Execute the following measurements:

3

File:

•

The outside diameter of the tappet (C1, Fig. 1.27)

•

The inside diameter of the bore in the tappet bracket (C2, Fig. 1.27)

•

The clearance between the roller and the shaft (S, Fig. 1.27). Compare your results with the wear limits in Fig. 1.27. If a wear limit is exceeded, you have to replace the tappet and/or the tappet bracket.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 41/44 Ed. 08- 14/07/2017 – EN Cylinder head

S

Ref. C1

Description Tappet

Tappet pump OD (mm) LW (mm) 55,970 55,951

C2

Bore

56,000 56,046

S

Clearance between roller and shaft

0,022 0,082

Fig. 1.27

4.8.4

55,90

56,10

0,15

Tappet valves OD (mm) LW (mm) 44,975 44,936 45,000 45,039 0,018 0,076

44,90

45,10

0,15

Measuring positions and wear limits

Checking the pushrods Required staff One service man

File:

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 42/44 Ed. 08- 14/07/2017 – EN Cylinder head

Procedure 1

Check the pushrods for damage. Replace them if you detect any damage.

2

Check the straightness of the pushrods. The maximum tolerated deviation is 0,2 mm. Do the following if you find a warped push rod: a

Replace the pushrod.

b

Try to find out what caused the problem (e.g. stiffness in the valve gear, overspeed) and do the necessary to solve it (e.g. inspect and/or replace involved components).

4.9

REMOUNTING THE TAPPET MECHANISM

4.9.1

Overview Remounting the tappet mechanism includes:

4.9.2

1

Remounting the tappets in the tappet bracket (page 41)

2

Remounting the tappet bracket (page 41)

Remounting the tappets in the tappet bracket Required staff One service man Procedure 1

4.9.3

Oil the tappets and follow the procedure under “4.7 Dismounting the tappet mechanism” (page 38) in reverse order. Make sure that:

•

The protective sheath (620.018.1400.02) is correctly pressed against its lower stop.

•

The tappet slides freely in the tappet bracket.

Remounting the tappet bracket Required staff One service man Procedure 1

Clean the mating surfaces of the tappet bracket and the cylinder housing, until all residues of the sealing material are gone.

2

Degrease the surfaces with Loctite degreaser or an equivalent.

3

Put Loctite 547 on the surfaces and spread it with a toothed spatula. Make sure the entire surfaces are covered.

4

Tighten the fixing screws and check if the tappets can still slide freely in the tappet bracket.

5

If the fuel pump was separated from the tappet bracket, do the following to remount it: a

File:

Clean and degrease the mating faces between the tappet bracket and the fuel drip tray.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 43/44 Ed. 08- 14/07/2017 – EN Cylinder head

6

File:

b

Clean and degrease the mating faces between the fuel drip tray and the injection pump. Also put Curil-K2 on these faces.

c

Remount the fuel pump.

Remount all the surrounding pipes and components.

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES 6/8/12/16DZC Chapter 1 – Page 44/44 Ed. 08- 14/07/2017 – EN Cylinder head

File:

B24_01_dd2017_07_14_Ed008_EN_Cylinder_Head

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

CHAPTER 2 DRIVE UNIT (PISTON/CONNECTING ROD) (Assembly 9 – 10)

2.1. 2.2.

PISTON ......................................................................................................................................... 1 CONNECTING ROD ................................................................................................................ 12

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.1.

PISTON

2.1.1.

DESCRIPTION - fig. 2.1

Chapter 2 Pag 1 Ed. 6 E

The piston is of the "trunk" type and is cast in nodular cast iron (GGG). The piston head is cooled by oil circulation and by the so called “shaker effect". The piston pin is made from special chromium-molybdenum steel and is free in the piston when hot. The pin is retained by 2 circlips. The oil circulation from the connecting rod to the piston occurs through the central bore in the piston pin, which is closed by means of plugs and secured by circlips. The piston ring set, with low height is above the piston pin and is consisting of: - 1 chromium plated top ring - 2 taper shape compression rings (Upper and Lower) - 1 chromium plated oil scraper ring with helical spring There are 3 types of pistons: * Type 1 : code 620.009.9001.11 * Type 2 : code 620.009.9001.12 * Type 3 : code 620.009.9001.15

TOP RING

UPPER COMPRESSION RING

LOWER COMPRESSION RING

OIL SCRAPER RING

Fig 2.1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 2 Pag 2 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT Component: Type 1 (620.009.9001.11) - MDO Complete piston & light-con rod assembly. Piston type 1(620.009.9001.11)

30

Piston pin

12,55

Corresponding set piston rings

0,75

Component: Type 2 (620.009.9001.12) – HFO Complete piston & strengthened-con rod assembly. Piston type 2 (620.009.9001.12)

Mass (kg) 87,45 - 88,65 30

Piston pin

12,55

Corresponding set piston rings

0,75

Component: Type 3 (620.009.9001.15) – MDO & HFO Complete piston & strengthened-con rod assembly. Piston type 3 (620.009.9001.15)

2.1.2.

Mass (kg) 83 - 84,2

Mass (kg) 89,45 - 90,65 32

Piston pin

12,55

Corresponding set piston rings

0,75

RECAPITULATION OF MAINTENANCE JOBS Code O2-02

Jobs Take out the pistons, measure the clearance and wear of the piston rings, renew the piston rings.

2.1.3.

SPARE PARTS One complete set of piston rings for each piston. The correct types of rings may be ascertained by reference to the spare parts list. One anti-polishing ring (620.008.1105.05) for each liner.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.1.4.

Chapter 2 Pag 3 Ed. 6 E

TOOLS Code 100.933.012.000

Description Lifting eye bolt

*

Tap M12 for cleaning the hole in the piston head.

*

Straight jaws circlip pliers for inner diameters from 100 up to 200 mm.

*620.084.1200.01

Tool for mounting the piston-con rod assembly into the liner

*620.084.1900.02

Tool for dismounting anti-polishing ring.

*620.084.9004.01

Piston ring opener (removing and replacing piston rings)

* Special tools, not standard delivered with the engine (only delivered on request) 2.1.5.

DISMOUNTING Required staff: 1 service man and 1 assistant.

2.1.5.1. Dismounting of drive unit = (assembly piston/connecting rod) -

Remove the cylinder head (chapter 1) Rotate the crankshaft so that the piston is about 50 mm below TDC Stuff the space between the piston and the liner with grease Decarbonizes the upper part of the liner with a scraper.

Do not scratch the liner! - Lower the piston to BDC sufficient to wipe off grease and carbon - Raise the piston again to about 50 mm below TDC - Place an (old) compression ring on top of the piston. Attention Make sure that the ring is mounted with the sharp edge facing upward. - Mount the 2 bushes of special tool 620.084.1900.02 over 2 studs of the cilinder block to hold the liner in place when the piston is raised. Tighten the bushes with nuts M24. - Raise the drive unit futher up and push the anti-polishing ring out of the cilinder liner. Take apart ring and old compression piston ring.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 4 Ed. 6 E

Moer Nut

Bus Bush

Koolring Antipolishing ring

Kompressieveer Compression ring

Voering Liner

Zuiger Piston

- By means of the tap M12 clean out the hole in the piston head. - Remove the inspection doors adjacent to the drive unit to be lifted out and dismount the big end cap (see 2.2.5.) by removing the nuts. NOTE: To avoid the bolts to fall out they are mounted with a slight fit into the cap. Still, take care that bolts and cap do not fall into the crankcase.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 5 Ed. 6 E

REMARK: From engine number 11735 the connecting rod bolts and nuts are numbered and must remain together. - Mount the lifting eye 100.933.012.000 into the hole of the piston and fasten a rope on it. - Raise the assembly a little and as soon as possible, remove the upper bearing shell to avoid it falling down into the crankcase. Raise out of the cylinder liner. Take attention the piston does not touch the cylinder head studs. - Lower the assembly on a wooden support and let it hang into the rope, for: * dismounting the piston rings. * dismounting the piston pin and the connecting rod. 2.1.5.2. Dismounting of the piston - Dismount the piston rings, tool 620.084.9004.01 . - Remove the circlips with pliers. - Slide out the piston pin by pushing by hand, the con rod is hanging with a rope on a tackle during this operation. To facilitate this action the con rod can be lifted slightly. If this is not successful, strike out the pin with a wooden beam.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.1.6.

Chapter 2 Pag 6 Ed. 6 E

MAINTENANCE Required staff: 1 service man

2.1.6.1. Cleaning 1.

The piston: - Never use sharp metallic tools (scrapers or others) - Use for cleaning and decarbonizes suitable products Attention: Hazardous liquids For use refer to safety prescription card.

2.

The piston pin:

Clean the oil bores in the pin by immersing using an appropriate degreaser (example: Ultra Clean, Innotec), dry by clean compressed air. Attention: Hazardous liquids For use refer to safety prescription card. 2.1.6.2. General examination of the piston and pin 1.

The piston:

This consists in a visual inspection for possible cracks by mean of crack detection (Red - White). Attention: Hazardous liquids, for use refer to safety prescription card Examine in particular: - the piston head - the piston ring grooves - the ribs around the piston pin bosses. If any crack in this area is detected, the piston must be rejected. 2.

The piston pin

Inspect the piston pin by (Red – White) organol red or magnetic flux control. If any crack is present, the pin must be rejected.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 2 Pag 7 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.1.6.3. Geometrical control (fig. 2.2) - Limits of wear. 1.

The piston ring grooves.

Z

G

Measure the width "G" of each groove at 4 places equally spaced over 90°. Use thickness gauges and a new piston ring with correct dimensions.

SLOTOPENING-COUPE

B

A

0

A

0

A

0

C

C

A

GAP-ESPACIO

Pistion in use.

New segment

Fig 2.2

PEN-PIN-AXE

A

B

SLOTOPENING-GAP COUPE

C

ZUIGERVEER-RING SEGMENT

GROEF-GROOVE GORGE

S1

S2,3

S4

Z1

Z2,3

Z4

G1

G2,3 G4

4,940 4,925

3,990 3,975

7,987 7,965

5,17 5,15

4,17 4,15

OD

110,000 110,155 110,055 109,990 110,100 110,040

0,60 0,90

1,50 1,80

0,80 1,15

LW

109,935 110,270 110,075

2,0

3,5

3 0,40

(a) (a)= clearance

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

0,30

8,06 8,04

0,25

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.

Chapter 2 Pag 8 Ed. 6 E

The piston pin and bores.

Measure the outside diameter “A” of the pin on the indicated places. When one of the measurements exceeds the limit of wear, the piston pin must be replaced. Measure the bores in piston and the con rod small end bush bore as indicated on fig 2.2. - If the bores “C” in the piston exceed the limit of wear, it must be replaced. - If the bore “B” of the bush exceeds the limit of wear, it can be replaced. 3.

The piston rings.

The wear of the piston rings is determined indirectly by measuring the gap width. Use for this purpose a new cylinder liner, no difference whether or not it is mounted. Attention must be given to the parallelism between the piston ring and the upper face of the liner (see fig. 2.3). Fit a new piston ring if the limit of wear see fig. 2.2. is exceeded.

Zuigerveer Piston ring

Voering Liner

Fig. 2.3

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.1.7.

Chapter 2 Pag 9 Ed. 6 E

ASSEMBLING Required staff: 1 service man.

2.1.7.1. Preparing the piston rings - General inspection of rings - Check the gap width (2.1.6.3.-3) 2.1.7.2. Assembling the piston and connecting rod (Fig. 2.4) Because the piston is symmetrical to the piston pin, the piston cannot be mounted wrongly. Therefore it is also undependent of the sense of rotation of the engine. The piston is provided with 2 drain oil bores and 2 stop plugs. (See figure) Procedure: * Place 1 retaining circlip (7). * Oil the piston pin (1) and slide it through the bores. * Place the second circlip (7).

BOTTOM VIEW Stop plug

Oil drain hole

Oil drain hole

Stop plug

Fig. 2.4

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 10 Ed. 6 E

2.1.7.3. Fitting the piston rings - Use only tool 620.084.9004.01 - Fit in the following order * the scraper ring (sides are symmetrical) * the lower compression ring, with the marking "TOP" upside * the upper compression ring, with the marking "TOP" upside * the top ring, with the marking "TOP" upside - Check if the piston rings are free in their grooves. Arrange the gap openings out of line by appox. 120°. 2.1.7.4. Mounting the piston/connecting rod assembly. Take care of the right position of the assembly, i.e. the marks on the con rod are at injection pumps side. Verify that each piston is fitted in his corresponding cylinder. - Verify the cleanliness of piston and liner - Lubricate the piston rings and the liner with clean oil - Put the tool 620.084.1200.01 for mounting the piston-con rod assembly with piston rings on the piston, as follows (see Fig. 2.5). * place tool over piston rings and tighten up screw (tool is fixed on piston head) * then loose screw somewhat until the tool can be turned by hand - Insert mounting ring 620.084.9016.02 with the threaded holes upward into the liner (see Fig. 2.5). - Mount lifting eye bolt 100.933.012.000 in piston and lift the assembly with a tackle. (see Fig. 2.5). - Rotate crankshaft until crankpin is on TDC. - Place the upper bearing shell in the connecting rod, be sure that it is fixed firmly in place. - Attention to the location lugs! - Keep the back side of shell and con rod bore dry, neither oil nor grease. - Lower the assembly into the liner until a bit above the crankpin. - Attention to the position of con rod marks! - To lower the piston further and to slide the piston rings into the liner it is necessary to push somewhat by hand on the piston. - Lubricate the crank pin with clean oil. - Now, lower completely the piston/con rod assembly. Be sure that the upper bearing shell is in place. - Place the con rod cap with shell and bolts. To obtain this, the cap is introduced through the inspection door upside down (with 2 bolts downwards) and then turned over 180°. - Attention to the location lugs! - Tighten up the nuts following the elongation principle (see 2.2.7.4.) ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 11 Ed. 6 E

- Dismount the mounting ring 620.084.9016.02 out of the liner. - Mount a new anti-polishing ring 620.008.1105.05 into the liner, with the marking “TOP” upside. - Mount the inspection doors. - Fit the cylinder head (chapter 1). 100.933.012.000

620.084.9016.02

Tool

Fig, 2.5

620.084.1200.01

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 2 Pag 12 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.2.

CONNECTING ROD

2.2.1.

DESCRIPTION - fig. 2.6 The connecting rod shank (1) and the big end cap (2) are machined as an assembly and are kept together by means of 4 bolts (3) and nuts (4). The cap is positioned by a cylindrical pin (5) and by a center ring. Identification of the connecting rod: A = identification number of the piece B = mass C = value for the bolt elongation (stretch) D = engine number E = cylinder number F = numbering of the bolts, formed by the cylinder number followed by the bolt number There are 2 possible con rod types: * Type 1

: code 620.010.1100.02

* Type 2

: code 620.010.1100.06

F

Fig. 2.6

A

B

E

D

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

C

A

Chapter 2 Pag 13 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT Component : type 1 (620.010.1100.02) Connecting rod, complete with bearing shells, bush, bolts

Mass (kg) 40

and cap. Big end bearing shells

1,25

Small end bearing bush

1,60

Component : type 2 (620.010.1100.06) Connecting rod, complete with bearing shells, bush, bolts

Mass (kg) 45

and cap.

2.2.2.

Big end bearing shells

1,25

Small end bearing bush

1,60

RECAPITULATION OF MAINTENACE JOBS Code O2-04

Jobs Replace connecting rod big end bearing shells. Check the condition of the con rod small end bush, replace if necessary. Inspect the small end bearing bush.

O3-02

2.2.3.

Replace conrod bolts and nuts.

SPARE PARTS Fig. n° 2.6

Ref. n° 6

Description Small end bush

Qty/cylinder 1

2.6

7

Upper bearing shell half

1

2.6

8

Lower bearing shell half

1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.2.4.

Chapter 2 Pag 14 Ed. 6 E

TOOLS Code 620.083.1600.03

Description Torque wrenches with sockets and accessories

620.083.1800.02

Tool for measuring elongation of con rod bolts.

*620.084.1600.01

Tool for removing and refitting a small end bush

* Special tools, not standard delivered with the engine (only delivered on request) 2.2.5.

DISMOUNTING Required staff: 1 service man and 1 assistant.

2.2.5.1. Dismounting of the connecting rod - For removing the drive unit (piston/con rod), see 2.1.5.1. . - For removing the nuts and the bolts, use tools 620.083.1601.03, 620.083.1602.03, 620.083.1606.03 and 620.083.1608.03 (type 1 con rod) or 620.083.1609.03 (type 2 con rod). - Remove the bearing cap from the big end. 2.2.5.2. Dismounting the piston - For dismounting the piston, see 2.1.5.2

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.2.6.

Chapter 2 Pag 15 Ed. 6 E

MAINTENANCE Required staff: 1 service man

2.2.6.1. Measuring the clearance with the connecting rod in place. - Bring the crankshaft for the serviced connecting rod in its TDC. - Install with a magnetic mount a dial gauge under the connecting rod. And bring the bigg pointer to +20 and the small pointer to 5. - Once installed, lift the connecting rod up with a lifting bar and measure the clearance present. Assembled bearing shells Type X (MDO) Type Y (MDO) Type Y (HFO) R1 (MDO & HFO) R2 (MDO & HFO)

620.010.9001.01 & 620.010.9002.01 620.010.9001.04 & 620.010.9002.04 620.010.9001.05 & 620.010.9002.05 620.010.9101.05 & 620.010.9102.05 620.010.9201.05 & 620.010.9202.05

→

min. (mm)

max. (mm)

0,140

0,244

0,133

0,216

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 16 Ed. 6 E

2.2.6.2. Visual inspection of big end bearing shells The bearing shells utilized are of tri-metal-type. Inspection can only be done by skilled personnel by visual inspection. CAUTION Opening a bearing cap without a specific reason is not advisable. Visual inspection: - Clean the shells carefully by means of a soft cloth. - Examine very carefully the anti-friction coatings. Any shell must be exchanged in the following circumstances: * If a part of the anti-friction coating is absent or loose. Consequently, the hard Nickel intermediate layer becomes partly free. * if there is damage (severe scratching or many grooves due to dirt or particles) * minor roughness or slight wear does not necessitate the replacement. Slight and limited cavitation round the oil bore or round the location lugs do not necessitate the replacement. * Nevertheless ABC advises the replacement of the big end bearing shells after dismantling of a bearing cap of the connecting rod. - Attention: After a service time of 24.000 hrs (overhaul O2-04) due to normal wear, the big end bearing shells have to be replaced. - When the bearing shells need to be replaced eighter by inspection or normal wear it is necessary replacing them in pair. Always replace both the upper and the lower bearing shell. Undersize bearings: When the crankweb dimensions of the crankshaft (B see Fig 7.3 – Chapter 7: Crankshaft) reach beyond the wear limit (LW), the crankshaft can be reworked for which undersize bearings can be fitted. See the spare parts list (Sect. DZ.010) for the ordering codes.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 17 Ed. 6 E

2.2.6.3. Cleaning and visual inspection of the connecting rod - Clean completely the con rod: * the bores for the bolts. * bolts and nuts, special attention to the center holes ( utilized for elongation measurements). * small end bush. * blow out the oil bores with compressed air without dismantling the small end bush. - In case of damage, test the connecting rod and the bolts by means of crack detection (Red – White) or by magnetic flux control. - Renew any part showing cracks or damage. 2.2.6.4. Geometrical control - Fig. 2.7 1.

Control of the connecting rod:

Carefully clean all the parts of the connecting rod a)

Control of assembled connecting rod (Fig 2.7) -

-

b)

Insert the bearing shells in the big end and tighten the bolts and nuts (following the elongation principle see 2.2.7.4) and in the proper order. Measure diameter “A” on 6 places. Check also conicity and ovality of “A” If the measured diameters, conicity and /or ovality are beond the allowed clearance. Replacement is to be considered.

Control of the big end bore (Fig 2.7)

This is not a routine check. It only needs to be carried out in case of accident. Measure diameter “C" in the same way as "A", but without the shells. Give attention to the ovality. (Rondness of the bore max. 0.015mm and cylindricity max. 0.015mm) c)

Control of the small end bush (Fig 2.7)

Measure the diameter “B" in the vertical sense. Fit a new bush if the LW figure is exceeded (see 2.2.7.2.)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 2 Pag 18 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

A

A

A

C B

A

B

A

For reworked crank-pins 1 undersize

OD type X

type Y

A

178,140 178,133 178,199 178,191

B

110,100 110,155

C

186,000 186,029

LW

R1

2 undersize

LW

177,633 177,691

R2

LW

177,133 177,191

110,270

type X: -Upper half bearing shell : 620.010.9001.01 -Lower half bearing shell : 620.010.9002.01 type X: -Upper half bearing shell : 620.010.9001.04 -Lower half bearing shell : 620.010.9002.04 -Upper half bearing shell : 620.010.9001.05 -Lower half bearing shell : 620.010.9002.05

MDO

MDO HFO

Conicity

Ovality

0,04 max

0,08 max

0,03 max

0,05 max

R2 (1 nd undersize) : -Upper half bearing shell : 620.010.9101.05 -Lower half bearing shell : 620.010.9102.05 R2 (2 nd undersize) : -Upper half bearing shell : 620.010.9201.05 -Lower half bearing shell : 620.010.9202.05

Fig. 2.7

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MDO & HFO

MDO & HFO

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT 2.2.7.

Chapter 2 Pag 19 Ed. 6 E

ASSEMBLING Required staff: 1 service man.

2.2.7.1. Assembling the connecting rod and the piston See 2.1.7.2. 2.2.7.2. Replacement of the small end bush. (fig. 2.8) The small end bush is fitted in the con rod small end by contraction of the bush in liquid nitrogen. Replacement is only necessary by damage or exceeded LW, fig. 2.7 . Removing and refitting a new bush can be done by means of a press and with special tooling, code 620.084.1600.01 not delivered with the engine. REMARK: By fitting a new bush, special attention must be given to the relative position in regard to the small end. ASSEMBLY

REMOVING

5500-7000daN

Tool: 620.084.1600.01

Possible seam in bush

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Fig. 2.8

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 20 Ed. 6 E

2.2.7.3. Replacing the big end bearings shells - At 24000 hours (overhaul O2-04) due to normal wear, the big end bearing shells have to be replaced. - ABC advises replacement of the big end bearing shells after dismantling of a bearing cap of the connecting rod. CAUTION Opening a bearing cap without a specific reason is not advisable. - When the bearing shells need to be replaced eighter by inspection (see 2.2.6.2) or normal wear it is necessary replacing them in pair. Always replace both the upper and the lower bearing shell. 1.

On renewal: - Clean out the bore of the connecting rod. - Carefully note the dimensions of the shells: - Ø178 -OD = original dimension - Ø177,5 -R1 = 1st undersize - Ø177 -R2 = 2nd undersize - Remove any roughness in the bore of the connecting rod by means of a stone with fine grain. - Keep care for general cleanliness of all components.

2.

On assembly - Mount the half shell (foreseen with oil holes) in the con rod cap. - Mount the half shell (plain) in the con rod shank. - Place shells into the con rod with their backside dry. Neither oil nor grease. - Ensure that the locating lugs on the shells are free in the notches in the connecting rod shank and in the big end cap.

3.

After assembly

After renewal of bearing shells it is necessary to check the diametral clearance. See table in 2.2.6.1 with the allowable diametral clearance, min. and max., values according the different types of bearing shells.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 21 Ed. 6 E

2.2.7.4. Tightening the bolts The bolts are tightened on a predetermined elongation (stretch) and checked with a special measuring/tightening tool 620.083.1800.02 - fig. 2.9 Elongation value depends on the type of con rod used. (see 2.2.) - Type 1 con rod: code 620.010.1100.02 with corresponding con rod bolts M20x1,5 Tightening elongation : L = 0,60 ± 0,02 mm For pre-calibration of tightening apparatus, use measuring bar: - code 620.083.1804.01, with L = 254 mm. - centering anvil in pos. A (see fig. 2.9) - Type 2 con rod: code 620.010.1100.06 with corresponding con rod bolts M22x1,5 Tightening elongation : L = 0,70 ± 0,02 mm For pre-calibration of tightening apparatus, use measuring bar: - code 620.083.1804.02 , with L = 274 mm. - centering anvil in pos. B (see fig. 2.9) Method: - First if necessary, change the position of the centering anvil in position A or B according to the type of connecting rod used. (see fig. 2.9) In either case, make sure that the locking nut is tightened properly. - Adjust the apparatus with the correct measuring bar (L= 254mm) or (L=274mm), according to the type of con rod, in such a way that the small pointer of the small graduated scale points at 5. (see fig. 2.9) The zero of the large graduated scale must be set in conformity with the big pointer and this on both sides of the dial gauge. - Screw on manually the nuts of the connecting rod bolts, but do not tighten them. Hereby minding the numbering of the connecting rod bolts and nuts. - With an adjusted apparatus, measure and note the length of the not tightened con rod bolts. Add to this length the predetermined elongation l = 0,60 mm or 0,70 mm (according to type of con rod (-bolt)) and also note these values down. - On page 2-22 an example is given of a measuring sheet for noting the values. - Tighten crosswise the nuts in a first time on ± 200 Nm (20 kgm) with a torque wrench according the given sequence on page 2-22. - Place the box wrench on a nut and put on the measuring apparatus (unchanged after adjustment) in the center holes of the connecting rod bolt (see fig. 2.9). - Tighten crosswise the nuts according the given sequence (see page. 2-22) until the previously determined total elongation: L = 0,60  0,02 mm or 0,70  0,02 mm is reached. - After tightening the 4 bolts of a connecting rod, a final check has to be made. To this end, check again the initial adjustment of the measuring apparatus with the used measuring bar and check all bolts for correct elongation.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 22 Ed. 6 E

Double-sided dial gauge

Box wrench + torsion bar

Measuring apparatus elongation connecting rod bolt

Connecting rod

Connecting rod bolt

A : Type 1 (620.010.1100.02) Centering anvil + locking nut B : Type 2 (620.010.1100.06)

Fig. 2.9 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

DRIVE UNIT

Chapter 2 Pag 23 Ed. 6 E

MEASURING SHEET: CONNECTING ROD BOLTS – ELONGATION Engine No ………………………… ……………………………………… ………………………………………

Measuring apparatus Measuring bar

Number of cil.

Adjustment dial gauge small scale: large scale:

6-8

No.

Mechanic, name or No. WEIGHT CON ROD

Camshaft side

kg

= 0.60±0,02

BOLT ELONGATION*

= 0.70±0,02

Tot.elongation o,60/0,70 ±0,02*

Bolt No.

Cyl.No.

Tot.elongation 0,60/0,70 ±0,02*

Length of both before mounting

Bolt No.

Cyl. No.

Length of both before mounting

1°mouning

1°mouning

*elongation 0,60 or 0,70 depending on type of con rod bolt ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

CHAPTER 3 CYLINDER BLOCK (Assembly 8)

3.1.

CYLINDER BLOCK ................................................................................................................... 1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 3.1.

CYLINDER BLOCK

3.1.1.

DESCRIPTION - Fig. 3.1

Chapter 3 Page 1 Ed. 6 E

The cylinder block (1) is cast in nodular cast iron GGG42/50 and includes the cylinder liners (2). At the upper face, the liner is provided with a flange which is introduced in the bore provided in the upper deck of the block. In the part above the running surface of the piston rings, an anti-polishing ring (29) is inserted into the liner. This ring has to be replaced each time the piston is removed or is worn. (see 2.1.5.1) Under the flange, a flat steel packing (3) assures the tightness at this position. At the lower position, the tightness is assured by seal O-rings (4) made in special rubber. The cylinder block is fixed to the crankcase by means of studs (9) and nuts (24) with washers and by the screws (18). The cylinder head studs location is protected against ingress from the environment by means of rubber sleeves (32) that are slided over the studs and posed on the upper deck of the block.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 3 Page 2 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK

VOORKANT MOTOR ENGINE FRONT SIDE

Detail A

Fig. 3.1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 3 Page 3 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK

3.1.2.

Component Cylinder block with liners and cylinder head studs-6DZC

Mass (kg) 1685

Cylinder block with liners and cylinder head studs-8DZC

2238

Cylinder liner

67,5

Anti-polishing ring

2,30

RECAPITULATION OF MAINTENANCE JOBS Code O2-03

Jobs Measure the wear, ovalty and conicity of the liners. Remove and hone the liners, renew if necessary. Replace seal O-rings Replace anti-polishing ring, if required

O2-14

Wash out the cylinder block, remove the deposits and repaint the interior if necessary.

O3-04

Renew of cylinder liners

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 3.1.3.

Chapter 3 Page 4 Ed. 6 E

SPARE PARTS Fig. n°

Ref. n° 620.082.1200.01

Description Set of sealing material necessary by

Qty/Cyl 6-8DZC 1

dismantling a cylinder head and a liner. This set consists of: 3.1

3

Steel packing (0,6mm)

1

3.1

3

Steel packing (1,5mm)

1

3.1

4

Seal O-ring

3

1.1b

65

Metal packing

1

1.1a

66

Rubber sleeve (water passage)

4

1.1a

21-16

Joint (exhaust flange cyl. head)

2

1.1a

22-4

Joint (intake flange cyl. head)

2

1.1a

44-6

Joint (elbow water outlet)

1

1.17

18-16

Seal O-ring

2

1.17

18-17

Seal O-ring

2

1.1a

44-16

Joint

1

1.1a

44-16

Seal O-ring

1

3.1

32

Rubber sleeve

6

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 3.1.4.

Chapter 3 Page 5 Ed. 6 E

TOOLS Code 620.083.1600.03

Description Torque wrenches with sockets and accessories

*620.084.1100.01

Tool for mounting and dismounting the liner

*620.084.1900.02

Tool for dismounting anti-polishing ring

*620.084.3200.10

Tool for lifting the cylinder block

* Special tools, not standard delivered with the engine (only delivered on request) 3.1.5.

DISMANTLING Required staff: 1 service man and 1 assistant

3.1.5.1. Extracting of the cylinder liner - fig. 3.2 To extract a liner, it is not necessary to dismantle the cylinder block: - Empty completely the water circuit. - Remove the cylinder head (chapter 1) and the piston/con rod assembly (chapter 2). - Protect the crankshaft, for example by inserting strong paper in the crankcase or by gluing paper over certain items, in order to prevent damage or corrosion of the working surfaces by impurities, dust or water. - Extract the liner by using tool 620.084.1100.01 - fig. 3.2

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

Tool 620.084.1100.01

CYLINDER BLOCK

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 3 Page 6 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK

Chapter 3 Page 7 Ed. 6 E

3.1.5.2. Dismantling of the cylinder block

IMPORTANT REMARK Replacement of cylinderblock studs is a major operation and therefore needs to be serviced in the factory. Otherwise replacement on site by own means may only be executed in strict contact and supervision by ABC personnel.

The cylinder block needs to be removed only for renewing or repairing the crankcase, the crankshaft or the cylinder block itself. - Empty completely the water circuit. - Disconnect: * the fuel pipework at fuel feed pump and filters * feeding pipe to camshaft lub oil manifold (at cyl.2) * water pipework on delivery side of HT water pump * lub oil distribution manifold (oil inlet engine) * duplex oil filters with bracket * automatic stop device and closing plate * turbo charger and bracket * exhaust gas manifolds * intake air manifold. * water outlet manifold * timing gear case with governor case and governor * camshaft driving gear wheel * oil pipework supports to inlet oil cooler -

Remove the nuts (24) from the studs and also the screws (18) (fig.3.1). Place tool 610.084.3200.10 and lift off the cylinder block fig. 3.3. Pose the cylinder block on wooden cross supports. Bearing in mind the weight!

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK

Fig 3.3

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 3 Page 8 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 3.1.6.

Chapter 3 Page 9 Ed. 6 E

MAINTENANCE Required staff: 1 service man.

3.1.6.1. Inspection of the water passages The following situations may occur: 1.

Severe corrosion: Resulting from lack of an anti-corrosion water treatment.

2.

Scale deposits: Resulting from excessively hard water

3.

Erosion or pitting: Shows up as small holes in the wall of the liner or block, particularly around the water inlet and or outlet. It signifies: * ingress of air into the pump suction pipe or inadequate degassing of the system. * lack of pressure (height of the expansion tank too low) * unsatisfactory treatment of the water

3.1.6.2. Cleaning the water passages - By using a steel brush, remove the calcareous deposit down to the metal. - Paint the bare metal with a rust-proofing paint, such as "LEVIS GEOKOTE WF" YELLOW-827/1500 or equivalent. At the back of the manual (Chapter 13) the specifications of the paint are given to select an equivalent paint if necessary. Attention: Hazardous liquids For use refer to safety prescription card.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK

Chapter 3 Page 10 Ed. 6 E

3.1.6.3. Reworking the cylinder liners When a new piston or piston rings are to be fitted and if the surface of the liner is completely smooth, it is necessary to hone it. When the liner has been extracted examine the upper flange for possible cracks. For that purpose, thoroughly clean the flange and use crack detection “Red – White” to show up any cracks. In case of cracks in this area, the liner is to be rejected. There are two possibilities for reworking the liner: a) extract the liner and hone it on a suitable machine. b) hone the liner on place in the engine itself.

IMPORTANT REMARK If the honing operation is carried out in the engine, great care must be taken to ensure that no abrasives or metal particles fall into the crankcase or sump. To that purpose a bag should be suspended under the liner.

After reworking: - Clean the liner with water mixed with a cleaning product like “Oltec Clean 9100” (IAS) or another equivalent product. Attention: Hazardous liquids For use refer to safety prescription card. - Lubricate with light oil or protective oil such as “Rust Veto C3” (Houghton). - Finally clean the liner with a fluffless cloth.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 3 Page 11 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 3.1.6.4. Limits of wear (fig. 3.4)

Measuring instrument: dial gauge (Subito or similar). The diameter "B” is to be measured along the axes XX and YY at following distances from the top: - 75 mm: corresponding to the top ring at TDC - 375 mm: corresponding to the oil scraper at BDC - 540 mm: corresponding to the lowest part of the liner where there is practically no wear.

X-X

256,000 256,032

Y-Y

256,000 256,032

(a)

(b)

0,05 max.

0,1 max.

OD

RL

X-X Y-X

LW

X-X Y-Y

256,350 256,350 256,500 256,500

(a) = coniciteit (taper) (b) = ovaliteit RL = reworking limit LW = limit wear

Fig. 3.4

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK

Chapter 3 Page 12 Ed. 6 E

3.1.6.5. Hydraulic test of the water jacket (fig. 3.5) - Close the water inlet of each cylinder with a blank flange. - One of these flanges is provided with an orifice "1" for filling and emptying water. - Close the 4 water outlets at each cylinder on the block upper deck by the sealing plugs, one of these plugs being provided with an orifice and cock "2" - Fill the cylinder block with water through orifice "1" until water overflows out of orifice "2". - Close orifice "2" if all air is bleeded off. - Submit the cylinder block to a pressure of 5 bar and maintain that pressure for 15 minutes. - Carefully inspect the walls of the water jackets including inside the holes through the bosses for the holding down studs. Check also for leakage at the cylinder head studs. Verify the water tightness of the seal O-rings on the liners. No leakage can be tolerated. Should a leakage be discovered, ABC or one of its representatives should be informed with the fullest details of the leak or defect in order to set up further follow up and/or actions.

DOORSNEDE SECTION

DOORSNEDE SECTION

DOORSNEDE SECTION

Fig.3.5

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 3.1.7.

Chapter 3 Page 13 Ed. 6 E

ASSEMBLING Required staff: 1 service man and 1 assistant.

3.1.7.1. Reinstalling of the cylinder block (fig. 3.1)

Different components are mounted on the block using LOCTITE 574. Before assembly, all these surfaces must be disposed of the sealant rests and must be degreased. Special attention must be given to the Loctite between the crankcase and the cylinder block. On the whole surface Loctite must be applied which must be spread out with a toothed/flat spatula (see Chapter 6). Make sure to apply enough to cover the whole surface adequately. Procedure: - Carefully inspect all cylinderblock studs (9). If one of the studs shows damage, cracks, corrosion verified by means of spot check “red & white” or if one is broken, the stud needs to be replaced. Please follow the procedure below in n°1 “Replacement of cylinderblock stud”. - Follow the procedure as under 3.1.5.2. but in reverse order. - When the cylinderblock is correctly placed, the cylinderblock studs can be tightened according to the angular displacement method, as described below. (see n°2, 3 and 4) 1.

Replacement of a cylinder block stud. - Remove the old cylinderblock studs by unscrewing counterclockwise using the presently used nut and an additional countering nut. - After removing the studs some Loctite rests and/or metal deposits can still be present in the internal thread and need to be removed. For this use a long threaded tap M27x2. Carefully insert the threaded tap into the hole and carefully locate the beginning of the thread (while turning clockwise) Do this carefully to avoid damaging the thread. - Tap the thread completely to the end. - Remove the tap carefully turning back. - After the thread has been cleaned by tapping, the loctite rests and metal deposits can be blown out of the blind hole using clean compressed air. - Clean the thread of the crankcase with an appropriate degreaser like for example “Ultra Clean” (Innotec) or equivalent product. Attention: Hazardous liquids For use refer to safety prescription card. - Dry by compressed air.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 3 Page 14 Ed. 6 E

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK

1 2 3 4

magnetic base reference point ratchet socket

Fig. 3.6 - Mounting of a new cylinder block stud: * The stud is to be planted into the cranckcase with the completely threaded rodend facing upward. * For the thread that has to be inplanted into the cylinder block, 3 straight stripes of LOCTITE 245 have to be applied from top to bottom of the thread devided equally over 360° (3x 120°). See following picture. !Do this only for the thread to be implanted into the block! * Carefully bring the stud inside the block and carefully locate the beginning of the thread while turning the bolt clockwise. When the bolt is completely screwed in, tighten the bolt on a torque of 100Nm (10kgm) by use of a torque wrench. For tightening use the original nut with countering nut. Loctite

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 2.

Chapter 3 Page 15 Ed. 6 E

Tightening method based on angular displacement The method is comparable to the current method with torque wrench, but in several steps, usually 3 and according a given sequence, (fig. 3.8). - Step 1: A low pretightening torque in order to limit initial impression and deformation. - Step 2: Nuts are turned according to a predetermined angle until a mark placed on the circumference of the socket. See fig. here after. - Step 3: Nuts are turned once more according to a predetermined angle until a mark placed on the circumference of the socket. See fig. here after. The zero or reference for angular displacement is fixed by means of a pin fastened on a magnetic base.

3.

Tightening the nuts on cylinder block after replacement of studs (new) Remark: When a cylinderblock stud has been replaced also the washer and the nut need to be replaced with new ones. New studs have to be pretightened a first time in order to avoid wrong extensions and reducing initial setting. - Tighten the screws M20 (18 - fig. 3.1) on the indicated torque of 365 Nm (37 kgm) with a torque wrench according to the given sequence (fig. 3.7). - Lubricate the studs (9 – fig. 3.1) upper thread, the upper face of the washer (16 – fig. 3.1), the underside of nut (24 – fig. 3.1) and the thread of the nut with Molykote G-N plus. (See following figure)

- Tighten the nuts M27x2 (24 - fig. 3.1) with torque wrench on a torque value of 295 Nm (30 kgm) according to the given sequence (fig. 3.8). - Tighten next with a 60° angular displacement according to the given sequence. - A second time with a 60° angular displacement according to the given sequence. - Next, loosen the nuts in 2 steps according to the given sequence. First, turn back for about 60° - further, turn back completely. - Tighten definitively the nuts M27x2 in the same way in three steps: 295 Nm (25 kgm) + 60°+ 60° according to the given sequence.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 4.

Chapter 3 Page 16 Ed. 6 E

Tightening the nuts on cylinder block with the existing studs To be executed as described in “2”, though without loosening the nuts again. 6 cyl.

8 cyl.

Fig. 3.7

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK

Chapter 3 Page 17 Ed. 6 E

6 cyl.

8 cyl.

Fig. 3.8

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CYLINDER BLOCK 3.1.8.

Chapter 3 Page 18 Ed. 6 E

Assembly of the cylinder liner (fig. 3.2) 1.

Assembly: - Assembly is done with tool 620.084.1100.01 (fig. 3.2) - Replace the metal packing under the liner flange. Be sure that the packing fits well in the chamber provided at the upper side of the cylinder block. - The bores in the cylinder block must be clean and free from scale and rust. - The O-ring grooves on the liners must be clean. - Put the O-rings into the grooves with Ceran WR2 (Total) grease or equivalent and check if the O-ring is free in the grooves, in no case they may be twisted. - Before assembling, grease also the lower bore in the cylinder block with Ceran WR2 (Total) grease. - Keep the liner as much as possible in the centerline of the bores during assembly the liner in the block. - Always use original spare parts.

2.

Controls: - After fitting the liner, it is necessary to measure the bore diameter on two levels (at upper level and at lower level corresponding to the O-ring position) and in longitudinal and transversal direction by means of an adequate dial-gauge. This gauge must permit measurement of 0,005 mm and the calibration must be done with a calibration ring or calibration gauge at diameter 256 mm. - Fig 3.4. gives the measurement procedure. Diameters B1 and B3 have to be measured at least in the directions XX and YY. - In any case a negative value is unacceptable and it is necessary to disassemble the liner (check the seal o-rings for deformation). The procedure must be started again from the beginning i.e. assembling and measuring the liner.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

CHAPTER 4 INJECTION SYSTEM (Assembly 14-18-58-59)

10.1. 10.2. 10.3. 10.4.

NOZZLE HOLDER AND NOZZLE OR “INJECTOR” ..................................................... 1 INJECTION PUMP. .............................................................................................................. 13 INJECTION MECHANISM DRIVING THE FUEL-PUMP. ........................................... 23 FUEL PUMP CONTROL SPINDLE ................................................................................... 35

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.1.

NOZZLE HOLDER AND NOZZLE OR “INJECTOR”

4.1.1.

DESCRIPTION - Fig.4.1

Chapter 4 Page 1 Ed. 7 E

Fig. 4.1

The nozzle (1) is retained in the nozzle holder (2) by the retaining nut (3) which is provided at its lower face with a circular rim for the sealing with the cylinder head. The complete injector is secured into the cylinder head by means of a thrust cap (5) and a cup nut (4). Sealing is assured with gasket (11). The spindle (6) with guide (7), the spring (8) and the adjusting screw (9) press the nozzle needle against its conical seat. A coupling pipe (10) in the cylinder head brings the fuel from the fuel injection high pressure pipe to the injector. Component Nozzle holder with nozzle

Mass (kg) 2,3

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 4 Page 2 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.1.2.

RECAPITULATION OF MAINTENANCE JOBS Code M5-05

Jobs Check nozzles and opening pressure of nozzles and spray pattern. Replace nozzles if necessary.

M6-01

Thoroughly examine the nozzles and their holders. Replace nozzles if necessary.

4.1.3.

SPARE PARTS Fig. n° 4.1

Ref. n° 1

Description Nozzle

Qty/cylinder 1

4.1

8

Spring

1

4.1

11

Gasket

1

4.1

12

Seal O-ring

1

4.1

13

Seal O-ring

1

4.1

14

Seal O-ring

1

4.1

15

Seal O-ring

1

4.1

16

Seal O-ring

1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.1.4.

Chapter 4 Page 3 Ed. 7 E

TOOLS Code 620.083.1100.02

Description Lever for priming injection piping and pump

620.083.1300.01

Tool for removing nozzle holder from cylinder head

620.083.1609.03

Socket 32 (belongs to toolbox 620.083.1600.03)

620.083.1400.01

Tool for checking the opening pressure of nozzles

620.083.1500.01

Tool for checking the opening pressure of nozzles.

*620.084.6900.01

Nozzle test pump Bosh with pressure gauge.

* Special tools, not standard delivered with the engine (only delivered on request) 4.1.5.

DISMOUNTING Required staff: 1 service man

4.1.5.1. Dismounting of the injector - Fig. 4.1 - Remove the cylinder head cover. - Disconnect the nut (19) on the duo injection pipe at the lengthened coupling pipe (10) and loose the nut at the fuel injection pump, in this way the fuel pipe can be turned apart. - Remove the two screws with inner hexagon from the pressure flange (17). - Remove the flange (17) with coupling pipe (10). - Remove cup nut (4) and thrust cap (5). - Remove the injector (holder + nozzle) with provided tool 620.083.1300.01 (fig. 4.2).

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 4 Ed. 7 E

Note: Handle the nozzle holders with the greatest caution and cleanliness. Above all, take care that the nozzle needle is not damaged and that no dirt gets into the holes.

Tool : 620.084.1200.01

Fig 4.2

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 5 Ed. 7 E

4.1.5.2. Checking the nozzle opening pressure and the pulverization. Fig. 4.3 Connect the nozzle holder, with the special tool 620.083.1400.01 and pipe 620.083.1500.01 to a nozzle test pump equipped with an accurate and sufficiently damped pressure gauge. Use only filtered gas-oil or special test oil. Special part: 620.083.1400.01

Special part: 620.083.1500.01

Nozzle with nozzle holder

Nozzle test pump

Adjusting screw

Fig. 4.2 ATTENTION When operating the tool to check the opening pressure and pulverization, no person may be in the spraying zone of the nozzle. High pressure spray of fuel from the nozzle may cause severe injuries to the body. Make use of the necessary PPE’s like chemical resistant gloves, full protective glasses preventing fuel mist/vapour coming into the eyes and make use of chemical resistant mask to prevent inhalation of fuel vapour or mist during operation. Inhalation and injuries to the body can cause severe injury to bronchial air ways and can cause blood poisoning.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 6 Ed. 7 E

A good nozzle conforms: 1.

A good pulverization.

Pump with a rhythm of about 10 strokes per minute. The fuel will spray stroke by stroke in a fine mist, without any formation of drops at the nozzle tip. 2.

Right opening pressure.

The pressure which is adjustable by means of a screw (fig. 4.1/9) attains between 275 and 280 bar at the moment of injection. 3.

Tightness between the needle and the seat

The nozzle tip and holes remain dry when the pressure is raised and kept at 200 bar. 4.

Tightness between the holder and nozzle

Increase the pressure up to 200 bar. Stop pumping. The tightness is satifactory when the elapsed time before the pressure is fallen off to 150 bar is no less than 6 seconds or no more than 14 seconds. (The valves of the test pump are assumed to be completely tight) 5.

Nozzle holes:

All passages must be clear. Blocked holes can be pricked carefully. If the nozzle does not satisfy the above condition it must be inspected, corrected or replaced.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.1.6.

Chapter 4 Page 7 Ed. 7 E

MAINTENANCE

4.1.6.1. Removing of the nozzle - Fig 4.1 - Remove the retaining nut (3) from the nozzle (1). The holder is hereby gripped with its flat parallel faces in a vice or similar. - Remove the nozzle - Turn back the retaining screw (9) and lock nut (18) - Clean carefully and degrease a new nozzle with filtered gasoil or test oil used for the test pump - Check and clean the contact faces of nozzle and nozzle holder, avoid remaining fluffs. - Place the nozzle on the nozzle holder and screw on the retaining nut. Tighten the retaining nut on the prescribed torque (see chapter general 5.1 tightening torque table). If the seal-O-ring (12) is in good condition replacement is not necessary. - Replace the gasket (11) - Test the nozzle as explained under 4.1.5.2. 4.1.6.2. Repairing a nozzle. A nozzle can not be repaired. A nozzle must be replaced (4.1.5.2.) in case: - the pulverization is bad (blocked or jammed needle) - the tightness between needle and seat is unsatisfactory. - the blocked holes can not be pricked. 4.1.6.3. Complete examination of nozzle and holder This examination consists in a complete dismantling of the injector and detecting any damage or leakage. Note: The oil-tightness test can easily be carried out by inserting a blank nozzle in the holder or by increasing the opening pressure to about 320 bar. Raise the pressure up to 300 bar and examine the tightness. 4.1.6.4. Reconditioning the faces between the nozzle and its holder. This is not a routine job, it should be undertaken only in case of leakage or damages. The faces may be ground-in with special paste, that can be bought from injection material specialists or representatives. 4.1.7.

ASSEMBLY - Fig. 4.1 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 8 Ed. 7 E

Required staff: 1 service man. 4.1.7.1. Fitting the nozzle in the nozzle holder. - Inspect the seal O-ring (12). Replace in case of damage, if it is hard or flattened. - Check the cleanliness of the contact surfaces of nozzle and nozzle holder, and assemble them. - Tighten the nozzle retaining nut (3) following the torque table (see chapter general 5.1 tightening torque table). Note: By placing a new nozzle it is recommended to lap the sealing surfaces from nozzle and holder together slightly (see 4.1.6.4.) . 4.1.7.2. Adjusting the opening pressure. - Unscrew the nut (18). - Adjust the adjusting screw (9) to obtain the prescribed nozzle opening pressure of 275 bar. - Tighten the nut (18) and hold the set screw (9) firmly. - Check the opening pressure again.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 9 Ed. 7 E

4.1.7.3. Assembling the nozzle holder into the cylinder head. (Fig. 4.1) - Clean the housing in the cylinder head. Take care that the gasket (11) does not remain in the bore. - Fit a new gasket (11) and replace the seal O-rings (13), (14) and (16) in case of damage, if they are hard or flattened. - Introduce the injector in the cylinder head bore, it is located in right position with a slot and a dowel pin. Be sure that the injector is completely down on its location. The conical connection hole must be visible through the mounting hole for the coupling pipe (10). - Place the thrust cap (5) and grease in the top of the cap with Molykote G-n plus paste for lubricating the top surface. Before placing the cup nut (4) grease in the thread of the nut with Molykote G-n-plus paste and tighten on torque following the tightening torque table (see chapter General DZ).

Molykote G-n plus paste

- Mount the coupling pipe (10) into the cylinder head on its conical seat on the injector. Place the pressure flange (17) and screw the 2 screws with inner hexagon on to the torque given in the tightening torque table (chapter general DZ). - Mount the injection pipe to the lengthened coupling pipe (10) and the injection pump following the mounting procedure from NovaSwiss to be found at the back of this chapter and using following tightening torques. * Type 1: 620.058.1100.04 to torque of 60 ± 5 Nm (6,1 ± 0,5 kgm) * Type 2: 620.058.1100.05 to torque of 60 ± 5 Nm (6,1 ± 0,5 kgm) * Type 3: 620.058.1100.06 to torque of 105 ± 5 Nm (10,5 ± 0,5 kgm)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 10 Ed. 7 E

Note: All torque values are given in the tightening torque table in chapter "GENERAL" - Repeat the operation on the other cylinders - Replace the cylinder head cover after that the contact faces have been wiped from oil and/or dirt. In case the seal O-ring in the cover is damaged, hard or flattened it is to be replaced. (see Chapter 1)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 11 Ed. 7 E

4.1.7.4. How to fill up the fuel system after maintenance. - Fig. 4.4. After each inspection of the injector, the fuel pipes must be drained from air and filled up with fuel. The operation is as follows: - Open the fuel supply to the injection pump. (by-pass to open) - Open the inspection door on the camshaft cover - Place the priming tool 620.083.1100.02 as indicated on fig 4.4 . - The fuel rack is pulled in maximum fuel injection by moving the lever “A” in the direction of the arrow to the front. - Move the priming lever up and down to action the pump plunger until a resistance is felt. - Let come back the fuel rack to zero position, remove the priming tool and close the inspection door. - Do even so on the other cylinders. - The inspection doors are provided with a joint, if necessary, replace it.

Remark: In case the injection cam is upwards for the considered cylinder, it is not possible to fit the priming lever to action the pump plunger. In this case it is necessary to bar over the engine until the pump plunger becomes free.

Fuel rack (control rod)

Tool 620.083.1100.02

Inspection door to Camshaft

Fig. 4.4

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 12 Ed. 7 E

4.1.7.5. Putting back in service. - Now the engine can be started again for checking eventual leakages at the injection pipes. - Check if the leak flow from the nozzles is in the same quantity as before. A too big a flow can indicate a lack of sealing between the injector and the coupling pipe (2) & (10). In this case, it is recommended to disconnect the leak flow pipe at each cylinder head to discover the cylinder in cause. It is the lower connection on the cylinder head left side.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.2.

INJECTION PUMP.

4.2.1.

DESCRIPTION AND WORKING PRINCIPLE - Fig. 4.5

Chapter 4 Page 13 Ed. 7 E

4.2.1.1. Description There is an injection pump for each cylinder: The injection pump delivers the quantity of fuel to be injected at each stroke. The pump consists of a piston (2) moving in a sleeve. This sleeve is provided with orifices connecting the fuel inlet passages with the spaces above the piston or plunger. By the way of the delivery valve holder (12) & (14) mounted into the pump body (1). The fuel is let to the fuel injection high pressure pipe and to the injector. The piston has a helicoidal groove communicating with the space above the piston. The control sleeve (3) has teeth on its upper part engaging with those on the rack or control rod (4). By means of a protuberance on the piston foot, it is linked to the control sleeve. Any translation of the rack causes the piston to rotate.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Fig. 4.5 Component Fuel injection pump

Mass (kg) 9,08

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 4 Page 14 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 15 Ed. 7 E

4.2.1.2. Working principle of the injection pump: The space above the plunger is always full of fuel (a). At a point in its upward stroke the plunger closes the orifices (b). The plunger continues to raise driven by the injection cam and a pressure is build up in the space above the piston. The delivery valve (11) opens, pressure build-up further and at a given value causes the nozzle needle to lift from its seat. Pumping continues until the helicoidal groove reaches the orifices (c). At this moment pressure-side and suction-side are connected. The pressure falls off, the nozzle needle and than the delivery valve closes again. The piston has made a pumping stroke and a quantity of fuel has been injected. As the groove in the piston has a helicoidal shape, it is possible, by moving the rack and this by rotating the piston to vary the pumping stroke and consequently the quantity of fuel injected. The rack is moved by a lever with fork mounted on the control spindle and controlled by the governor (chapter 5). The piston spring (6) assures continuous contact between the pump tappet (5) and the cam mechanism. 4.2.2.

RECAPITULATION OF MAINTENANCE JOBS Code M5-06

Jobs Check condition of injection pump cavitation plug and

M6-08

renew if necessary.

O2-07

Complete overhaul of the fuel injection pumps.

Discarding criteria for injection pump cavitation plug: Injection pump cavitation plug (20 fig4.5) must be changed when the damage exceeds a depth of 2 mm.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 4 Page 16 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.2.3.

4.2.4.

SPARE PARTS Fig. n° 4.5

Ref. n° 6

Description Spring (tappet)

4.5

10

Circlip

1

4.5

11

Delivery valve

1

4.5

13

Delivery valve spring

1

4.5

15

Seal O-ring

1

4.5

16

Seal O-ring

1

4.5

17

Joint

1

4.5

20

Cavitation plug

1

4.5

25

Seal O-ring

1

4.6

59-16

Joint

1

4.6

59-23

Joint

1

TOOLS No special tools are required.

4.2.5.

DISMANTLING - Fig. 4.5 and 4.6 Required staff: 1 service man.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Qty/cylinder 1

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 17 Ed. 7 E

4.2.5.1. Removing from the engine. – Fig. 4.6 - Close the fuel supply and bleed of the fuel by the vent screw (59-18) on each pump. - Disconnect and remove the fuel leak pipe (58-3), if present - Disconnect and remove the fuel injection high pressure pipe (58-1) - Disconnect and turn away the fuel supply pipe (59-4) - Remove the 4 fixation screws (18-6) from the pump feet. Remark: Take attention that the injection cam is not upwards and sets pressure under the pump. In this case bare over the engine until the cam is free. - Remove the pump, bearing in mind that the spherical lever pin is still in the fork of the lever. The easy way to remove the pump is by pulling the lever in front position by hand.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.2.6.

Chapter 4 Page 18 Ed. 7 E

MAINTENANCE - Fig. 4.5 The most important factor for a proper functioning of the pump is the cleanliness of the fuel. Consequently, it is of the most importance to pay great attention to the conditions of the filters and the fuel system. The complete overhaul, the verification and the output tests can be undertaken by the engine manufacturer or by the fuel injection equipment manufacturer or its representative. Following checks can be made on the spot, note that cleanliness is most important and use only pure and filtered gasoil or test oil: 1.

Inspection of delivery valve unit (11) (valve and body for one entity) and spring:

Disconnect the delivery valve holder retaining nut (14). Inspect the spring, if signs of corrosion replace it. Check the valve and housing, in particular the tightening surfaces. In case they are damaged or untight, the entity, valve and housing must be replaced. By assembling again, the seal O-rings (15) and (16) and the joint (17) must be replaced. Mount the delivery valve holder unit (12) and the retaining nut (14). Tighten according to the torque table. See 5.1 “General” If no torque wrench is available which can give the required high torque. - Give marks on the retaining nut (14) and the pump body before dismantling. - By assembling, it is than sufficient to tighten the retaining nut (14) as far as the marks are corresponding again.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 2.

Chapter 4 Page 19 Ed. 7 E

Inspection of piston (2) and tappet spring (6)

Push the tappet (5) and spring (6) under tension and remove the circlip (10). Take care that the circlip doesn't jump apart! Now release the assembly out of the pump body. Inspect the spring, if signs of corrosion or damage replace it. The tappet (5) can show internally a certain impression due to the piston foot or spring collar. This is normal however. Push the piston out of the sleeve and check for damage or corrosion. It is recommended that only skilled persons replace the assembly piston-sleeve (complete element). Rinse everything thoroughly and mount in the reverse order. After assembly, check if the rack (4) moves freely. It must normally move under its own weight.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Fig. 4.6 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 4 Page 20 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.2.7.

Chapter 4 Page 21 Ed. 7 E

MOUNTING ON THE ENGINE. Required staff: 1 service man.

4.2.7.1. Mounting on the engine - Clean and degrease the contact surfaces, on: * pump mounting flange/drain tray or drip tray * drain tray/tappet bracket - Rub these surfaces with Curil K2. - Put back the injection pump with drain tray. Mind that the spherical lever pin on the rack fits in the fork of the lever. - Put back the 4 screws (18-6) and tighten by hand. - Turn back and connect the fuel supply pipe (59-4). - Put first, new joints (59-16) on the banjo bolt (59-17) and tighten. - Check the free movement of the fuel rack, by pulling the lever in front position - (max. fuel) by hand, when released it must return at once to zero position. - If not, this can be corrected by moving some what the pump on the bracket. - If correct, tighten the 4 screws (18-6) according to the torque table. See Chapter General table 5.1. - Place back the fuel injection high pressure pipe (58-1), tighten according to the torque table (See Chapter General table 5.1.). Take attention : the threads of the nuts must be lubricated with oil. For assembling please use the mounting instructions from Nova Swiss, to be found at the back of this chapter. - Place back the fuel leak pipe (58-3) if present. Remark: Take attention that the injection cam is not upwards and sets pressure under the pump. In this case bare over the engine until the cam is free. - Remove the pump, bearing in mind that the spherical lever pin is still in the fork of the lever. The easy way to remove the pump is by pulling the lever in front position by hand.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 22 Ed. 7 E

4.2.7.2. Filling the injection pump and fuel system after maintenance After maintenance and assembly of the injection pumps, the system must be drained from air and filled up with fuel. The operation is as follows: - open the fuel supply to the pump (by-pass to open !) - drain first the fuel filters. - open the drain screws (59-18) on each banjo bolt (59-17) at every pump and let fuel bleeding until all air is vented. If necessary replace the joint (59-23) - Close the drain screws. - fill up the fuel system as described under 4.1.7.4. REMARKS: In some installations where the fuel (day) tank is at lower position, the system is provided with a small hand priming pump, placed in the by-pass over the engine driven fuel feed pump. In this case, this hand pump is to be used for filling the injection pump and the fuel system.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.3.

INJECTION MECHANISM DRIVING THE FUEL-PUMP.

4.3.1.

DESCRIPTION - Fig. 4.7

Chapter 4 Page 23 Ed. 7 E

The injection pump is driven by a tappet assembly from an injection cam mounted on the camshaft. The tappet assembly consists of: - a tappet (1) - a cam follower (2) or roller with bearing bush - a shaft (3) - a hardened intermediate pad or button (4) The upward-down movement of the tappet, by the way of the intermediate push rod (5) with a hardened pad (6) results in a thrust on the injection pump. The combined length of push rod and pad (5) + (6) is adjustable by means of distance washers (7) to set the beginning of injection (BI). The tappet with the hardened pad, cam follower and shaft are to be considered as one assembly. The components should not be taken apart or be replaced separately. Therefore are the components not available as spare part but solely as assembly. Component Tappet assembly - injection pump

4.3.2.

Mass (kg) 1,46

RECAPITULATIONS OF MAINTENANCE JOBS

Code M5-04

Jobs Check combustion pressures at full load and at idling speed. Adjust if necessary.

O1-02

Control the injection timing - Beginning of injection (BI). Check tightness of injection pump plunjer and of the relieve valve.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.3.3.

Chapter 4 Page 24 Ed. 7 E

SPARE PARTS Fig. n° 4.7

Ref. n° 1,2,3,4

Description Tappet assembly

Qty/cylinder 1

4.7

5

Intermediate push rod

1

4.7

6

Hardened pad

1

4.7

7

Available distance washers:

as required

0.5; 0.6; 0.7; 0.8; 0.9 and 1.0 mm 4.7

8

Return spring

1

4.7

9

Seal O-ring

1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Fig 4.7 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 4 Page 25 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.3.4.

TOOLS Code 620.083.1900.01

4.3.5.

Chapter 4 Page 26 Ed. 7 E

Description Reference gauge (engine TDC mark)

INSPECTION AND MAINTENANCE - Fig. 4.7 Required staff: 1 service man.

4.3.5.1. Checking the beginning of injection (BI) 1.

Values for the beginning of injection.

The value of the BI is expressed in degree crank angle before TDC and depends on: * engine type * engine speed (see general information item 2.4.) The values of the crank angle can, in function of the flywheel diameter, be transformed in mm curve distance till TDC, with the following formula:

A

  3,1416  BI 360

“A”= curve distance in mm on flywheel exterior diameter. Ø = exterior diameter of flywheel or diameter on which A is to be set, in mm BI = beginning of injection or early injection, crank angle in ° (degree)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 2.

Chapter 4 Page 27 Ed. 7 E

Values for Begin Injection (BI) (fig. 4.7) a)

Standard: - Injection pump: 620.014.1100.02 - FCVAB200B0670 /= 830

6DZC

21°

21°

8DZC

21°

Nozzle:

620.014.1200.04 (9-holes) HL150T38K775P4

Dimension X 3,1 – 3,2 mm With intermediate rod 620.018.9003.03 60mm

21° 620.014.1200.02 (8-holes) HL150T44H718P5 620.014.1400.04 (10-holes) HL150T38L748P8

* Tolerance +/- 0,5° 3.

Curve distance “A” on flywheel:

The curved distance “A” is to be measured on the flywheel, from the mark corresponding to the TDC of the considered cylinder till the reference gauge on the crankcase. See fig. 4.8 . Using following rule the curve distance can be calculated by the diameter of the engines flywheel. In thist example we use a standard flywheel of Ø 950 mm. Circumference of flywheel (mm) : π D = π x 950 = 2984 mm Curve distance per degree(mm/°): (π D / 360°) = 2984/360° = 8,29mm/° Example calculation curve distance BI: For standard engine 6DZ with 750rpm -> BI = 19,5° before TDC Curve distance “A” before TDC:

19,5° x 8,29mm/° = 161,65mm

With a tolerance of ± 0,5 ° -> ± 4,15 mm -> “A” = 161,65 ± 4,15 mm

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

SIDE FOR MARKS

620.083.1900.01

INJECTION PUMP SIDE

INJECTION SYSTEM

Chapter 4 Page 29 Ed. 7 E

Fig. 4.8a ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM

Chapter 4 Page 30 Ed. 7 E

6 CYL.ENGINE View acc.to X Z = 22°à 23° after TDC (in expansion stroke)

START CYL. 1(K)

START CYL. 1(A)

Firing order: A: 1-2-4-6-5-3-1 K: 1-3-5-6-4-2-1

8 CYL.ENGINE View acc.to X Z = 22°à 23° after TDC (in expansion stroke)

START CYL. 1(K)

START CYL. 1(A)

Firing order: A: 1-4-7-3-8-5-2-6-1 K: 1-6-2-5-8-3-7-4-1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Fig. 4.8b

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.

Chapter 4 Page 31 Ed. 7 E

Check of the BI by means of a depth caliper - Fig. 4.5 and 4.7 - This way is based upon the fact that the supplier of the injection pumps gives a precise distance between: * the bottom of the pump socket (mounting surface) and * the pump spring housing in the position where the injection pump plunger just closed the orifices in the sleeve and shuts off the fuel supply. This is the very moment of beginning if injection (BI) - Remove the fuel injection pump and the drain tray from the engine as described under 4.2.5.1. - It is important to mark these trays with the cylinder number to prevent wrong re-assembly. - Rotate the engine until the mark BI of the concerning cylinder on the flywheel corresponds with the reference. - Mount the drain trays with 4 thick rings and screws. Take care of the cylinder number! - Measure the dimension “X” with a caliper gauge (fig. 4.7). This is the distance between the top intermediate push rod and the mounting surface of the drain tray. - This dimension “X” must be tuned between 1,6 and 1,7 mm or between 3,1 and 3,2 according to the type of engine (see page 4.3.5.1: values for beginning injection). Mount herefore more or less distance washers (7) under the hardened pad (6).

REMARK: By engines that are running for a longer period, there can be a small impression on the intermediate push rod and on the spring housing, this is normal. This impression can be measured using a caliper gauge, but normally it will not exceed 0,1 mm. In this case, the nominal dimension “X” will be increased to 1,7 mm instead of 1,6 mm or 3,2 mm instead of 3,1mm, according to the type of engine. When the dimension “X” exceeds the normal values for the engine necessary action should be taken by mounting more or less distance washers.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 5.

Chapter 4 Page 32 Ed. 7 E

Adjustment of injection timing or BI - Fig. 4.7

- Remove the injection pump as described under 4.2.5.1. and under item 2 here above - After removing the pump, the intermediate push rod (5) and the hardened button (6) with distance washers (7) is now free. - The beginning of injection is adjusted by modifying the length of the assembly by means of the washers. Thickness of 0,5; 0,6; 0,7; 0,8; 0,9; 1,0 mm are available as required. * Removing washers means delaying the BI (less ° crank before TDC) * Adding washers means advancing the BI (more ° crank before TDC) - After adjustment, recheck the timing again as under item 2 here above - If it is correct, remount the injection pump as described in 4.2.5.2. item 1 and 4.2.6. Remarks: * It is advisable to keep the number of washers as limited as possible. * As a guide, a difference of 0,1 mm on the washer gives a variation of approx. 0,5° cranck angle.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.3.5.2. Dismounting and mounting the injection tappet.

1.

Dismounting:

See chapter 1, (1.4.5.) 2.

Maintenance:

See chapter 1, (1.4.6.) For size and limits of wear see fig 4.10 3.

Mounting: see chapter 1

See chapter 1, (1.4.7.)

C1 C2 S

OD 55,970 55,951 56,000 56,046 0,022 0,082

LW 55,90 56,10 0,15

C1 = shaft C2 = bore S= Clearance between tappetroller and shaft

Fig. 4.10

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 4 Page 33 Ed. 7 E

Chapter 4 Page 34 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM Assembly- and operating instruction for NOVA SWISS® high pressure fuel injection pipe 0

General

1

The safety of the users of NOVA SWISS® fuel injection pipes is our prime concern. High pressure fluids can be dangerous when handled without care. Read these safety instructions carefully before assembling / operating the high pressure fuel injection pipe. In order to guarantee flawless operation of our products, only carefully selected materials have been used. In addition, each NOVA SWISS® fuel injection pipe is manufactured according to our stringent production requirements based on the international quality standards of ISO/TS16949. Function of the pressure fuel injection pipe Fuel injection pipes transport fuel under high pulsating pressures from the pump to the Injector. The engine manufacturer’s requirements and specifications regarding fuel quality, fuel temperatures, max. operating pressure etc. must be followed. High over pressures or excessive vibrations can result in leaking fuel injection pipes. If the fuel injection pipe is not equipped with a NOVA SWISS® shielding system, a defect fuel pipe could cause personnel injuries or engine room fires. The high pressure pipes shall not be o o o

2

used as a holding device during the mounting procedure. stepped on during assembly or service work. Used for fixation of other engine parts

Putting the fuel injection pipe into operation NOVA SWISS® fuel injection pipes should be used only by experienced personnel trained in correct use. Users should be aware of the potential dangers of high pressure fluids.

3

Assembly To ensure the product’s reliability and performance requirements, NOVA WERKE AG recommends to take the following precautions:

3.1 Remove all plugs by hand. Do not damage the sealing surfaces by using tools (see also pt. 5 trouble shooting). 3.2 Lubricate all threads, sealing cones and, if possible, the 60° cone at the power sleeve end (refer to picture 1), Lubrication makes assembly easier, helps preventing the sealing cones from getting damaged and ensures that the calculated pre-load force can be reached with the specified lightening torque. 3.3 Pull back the gland nuts until the sealing cones are visible. Any dirt particles must be removed carefully from the sealing cones. 3.4 Set the fuel injection pipe simultaneously into the appropriate position at both the pump’s and the injector’s/connection pieces joints. Tighten the fuel injection pipe manually with the pipe’s gland nuts. Fuel injection pipes that are not assembled in stress-free condition can reduce the product s performance and service life. 3.5 Tighten the fuel injection pipe intermittent up to the torque value according to the engine manufacturer’s torque specifications. 3.6 Mounting of clamps for pipe fixation: In order to fix fuel injection pipes, specially designed calming components might be required. The assembly of those clamps must be carried out always after the fuel injection pipe has been properly assembled according to 3.1-3.5. Any clamps are to be mounted so that the fuel injection pipe’s correct position cannot be altered, thus any assembly stress induced on the fuel injection pipe must be avoided. 4 Maintenance / Service

5

NOVA SWISS® fuel injection pipes have virtually an indefinites service life if the product is properly handled and assembled according to specifications. However, if the fuel injection pipe is equipped with o-rings, they should be replaced after a period of 10 years. Troubleshooting If limited or small leaks are observed on the sealing cones, proceed as follows:

5.1 Visually inspect the joints for dirt or defects on the sealing cones. If the fuel injection pipe’s seating cones have grooves or marks, carefully polish them. If there are no improvements, replace the fuel injection pipe or if required the counter pieces (i.e. pump and/or injector). 5.2 Use a torque wrench and tighten the joints with the max. allowed torque. If the fuel injection pipe is over torqued. the sealing cones can be deformed resulting leaks. If extensive leaking is observed caused by a broken injection pipe: 5.3 The fuel injection pipe (shielded or non-shielded) must be replaced immediately. 6

Address NOVA WERKE AG Vogelsangstrasse 24 CH-8307 Effretikon / Schweiz Tel.: Fax:

Pull back the union nut / gland nut lubricate the cone

thread lubricated

0041 (0) 52 354 16 16 0041 (0) 52 354 16 90

seating cones lubricated

Internet: www.novaswiss.com E-Mail: [email protected] Picture 1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.4.

Chapter 4 Page 35 Ed. 7 E

Fuel pump control spindle

4.4.1.1. DESCRIPTION The fuel control spindle is connected with the speed governor and regulates the amount of fuel that is injected by the injection pumps. The control rod of each injection pump is connected with a lever on the control spindle. The turning of the control spindle changes the position of the control rods

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.4.2.

ILLUSTRATION

Fig. 10.13 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 4 Page 36 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

INJECTION SYSTEM 4.4.3.

RECAPITULATION OF MAINTENANCE JOBS Code O3-06

4.4.4.

Jobs Renew all bearings of the fuel control spindle.

SPARE PARTS Refer to the spare parts list of the 6/8DZC engine.

4.4.5.

TOOLS Special tools:

4.4.6.

- Tool for tightening the spring on the control spindle - Tool for regulating the injection pumps Renewing all bearings of the fuel pump control spindle

4.4.6.1. Overview Renewing all bearings includes: 1

Removing the control spindle

2

Removing the components from the control spindle

3

Mounting the levers

4

Mounting the control spindle

5

Mounting the components on the control spindle

6

Connecting the control spindle to the speed governor

7

Mounting the injection pumps

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 4 Page 37 Ed. 7 E

CHAPTER 5 GOVERNOR SYSTEM (Assembly 12-13)

5.1. 5.2. 5.3. 5.4. 5.5. 5.6.

GOVERNORS .............................................................................................................................. 1 UG GOVERNORS ....................................................................................................................... 1 THE GOVERNOR DRIVE MECHANISM. ........................................................................... 11 INJECTION PUMP CONTROL MECHANISM. .................................................................. 15 HEINZMANN ............................................................................................................................ 19 INJECTION PUMP CONTROL MECHANISM. .................................................................. 25

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.1.

Chapter 5 Page 1 Ed. 7 E

GOVERNORS In regard to the application or to the necessity for a certain engine type, we have the choise between different governors, namely Woodward UG governors and Heinzman governors. (We refer to the operation manual or to the description and applications manual).

5.2.

UG GOVERNORS

5.2.1.

DESCRIPTION The UG-governor is a mechanical hydraulic governor manufactured by the Woodward company. Reference should be made to the description of the governor in the separate documentation. 5 main types are utilised: Mainly for engines running at constant speed (gen-sets, propulsion with variable pitch propeller,…) - UG-8D or dial control. (Fig. 5.1.) - UG-8D MAS or dial control with remote signal control (4-20mA). (Fig. 5.2.) Mainly for engines running at variable speed (propulsion with fixed propeller,…) - UG-8L or lever control. (Fig. 5.3.) - UG-8L-P or lever control with pneumatic speed setting device. (Fig. 5.4.) Mainly for engines for propulsion and gensets (general applied) and synchronization. Main advantage: can work with 4 – 20 mA speed input signal. - UG-25+ or microprocessor controlled mechanical hydraulic governor. (Fig. 5.5.) Working diagram UG-25+. (Fig. 5.6.) Component UG-8D

Mass (kg) 22

UG-8D MAS

23

UG-8L

20

UG-8L P

23

UG-25+

26

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 2 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR Fig. 5.1 (UG-8D or Dial control) 190.6

OIL FILLER CAP

MIN POSITION TYPE UG 8

42* SPEED DROOP KNOB

MAX POSITION 318.3

SPEED DROUP

LOAD LIMIT KNOB

(OPTIIONAL CONNECT TO BOOSTER INLET)

SPEED SETTING

SPEED SETTING KNOB

SPEED SETTING INDICATOR KNOB

LOAD UNIT

COMPENSATION NEEDLE VALVE ACCESS

DRAIN PLUG OR CONNECT TO BOOSTER INLET

(OPTIIONAL CONNECT TO BOOSTER INLET)

Fig. 5.2 (UG-8D MAS) 190.5

14 PINS CONNECTOR

TYPE

398.8

139.7

DRAIN PLUG OR CONNECT TO BOOSTER INLET

27.9

OIL FROM BOOSTER OUTLET

22.2 FULL SERRATIONS 4X Ø 11.2 THRU

152.4

PRESSURE TEST POINT

69.85

146.3

D30-328 D30-332

* Dimension in mm 134.11

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 3 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR Fig 5.3 (UG-8L) 190.6

OIL FILLER CAP

MIN POSITION WOODWAR

TYPE

UG BL

42* COVERNOR R.P.M.

PART NO.

CUSTOMER’s NO.

SERIAL NO.

MAX POSITION

318.3

(OPTIIONAL CONNECT TO BOOSTER INLET)

DRAIN PLUG OR CONNECT TO BOOSTER INLET

COMPOSITION NEEDLE VALVE PLUG

(OPTIIONAL CONNECT TO BOOSTER INLET)

Fig 5.4. (UG-8L-P)

SCREW (1)

DIAPHRAGM(5) RETAINER PLATE (6)

SPEEDER SPRING (22)

SPRING SEAT (11)

PISTON (7) SPEED SETTING SPRING (9) HIGH SPEED STOP RING (10) SPRING SEAT (12)

SPEED SETTING ROD (13)

SET SCREW (24)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR Fig 5.5 (UG-25+) Electrical Connector L-Series Governor

Oil Fill Plug/Breather

User Interface Panel

Oil Level Sight Glass

Terminal Shaft

Case Oil Drain Plug

Base

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 4 Ed. 7 E

Chapter 5 Page 5 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR Working diagram UG-25+

USER INTERFACE TO ACTUATOR CABLE L-SERIES GOVERNOR

RETURN SPRING CUSTOMER INTERFACE CABLE

OIL LEVEL GUIDE PLATE

ROTARY TO LINEAR CONVERSION MECHANISM

TERMINAL LEVER

DRAG LINK

FLDATING LEVER TERMINAL SHAFT USER INTERFACE PANEL

DRIVESHAFT SPEED DISC

SPEED SENSOR POWER PISION ROD POWER PISION

3-WAY PILOT VALVE

RELIEF VALVE

PUMP

PUMP DUTLET PRESSURE

PILOT VALVE CONTROL PRESSURE

DRIVESHAFT

DRAIN/SUMP PRESSURE

Fig. 5.6

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

263-048 06-6-8

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.2.2.

Chapter 5 Page 6 Ed. 7 E

RECAPITULATION OF THE MAINTENANCE JOBS Code M5-03

Jobs Change oil in the hydraulic governor.

O2-06

Control of the hydraulic governor, return to the manufacturer if necessary.

5.2.3.

SPARE PARTS Refer to the spare partslist of DZ engine.

5.2.4.

TOOLS No special tools are needed.

5.2.5.

REMOVING OF THE GOVERNOR FROM THE GEAR CASE- Fig. 5.7. Required staff : 1 service man. - Disconnect the electrical wiring. - Lower the coupling rod (5) by removing the bolt and nut(18). - In case the lever (7) must be removed, mark the position in regard to the terminal shaft. - Only for UG8-L governor: Remove the connection with lever (8) for remote speed setting. - Remove the nuts (20). - Lift carefully the governor out off the gear case. Remarks : 1. Do not loosen more connections than indicated in this chapter. Otherwise we run the risk of loosing the factory setting. 2. Do not invert the governor, otherwise the oil will be spilled.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 7 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

30

OIL OUTLET

620.012.1200.10

OIL INLET

27

25

GOVERNOR

Fig. 5.7 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.2.6.

Chapter 5 Page 8 Ed. 7 E

INSTALLING THE GOVERNOR ON THE ENGINE - Fig. 5.7.

PREINSTALLATION WARNING When receiving a new/spare UG-governor from ABC, the Woodward governor is filled with preserving oil that is only suited for storage. Running the governor with this oil can results in serieus wear, damage and loss of governor. Herefore the preserving oil needs to be changed with governor oil. (see. 5.2.7) Required staff : 1 service man. - Before installing, make sure the drive shaft of the UG governor rotates freely. - Dispose the mating surfaces of the governor and the gear case from any remaining Loctite rests and degrease the surfaces. - Coat the mounting faces with LOCTITE 574 and spread it with a toothed flat spatula. - Place the governor squarely on the gear case. Pay much attention to the meshing of the governor keyed driving shaft. Do not use any force to prevent that you push the drive shaft into the governor. - Mount the coupling rod (5) and connect the electric wiring (reverse order as 5.2.5.) - Only for UG-8L: connect the lever (8). - Replace cover (8) – (fig 5.8) back with LOCTITE 574 in case it has been removed. - Check if the governor can slide the racks of the fuel injection pumps to their "Zerooutput" setting. The stop lever, during this check, must be pushed in working position (upwards). For UG-8D and UG-8D MAS: Turn the "load-limit" knob to zero and at the same time help to rotate the control shaft in the "stop" position. For UG-8L: By means of an open-end wrench, set the control shaft in the "stop" position. For UG-8L-P: As UG-8L

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 9 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.2.7.

MAINTENANCE AND ADJUSTMENTS. 1.

OIL SUPPLY

All UG governors use governor oil that is a lubricating and a hydraulic oil. Select an oil according to the operating temperature range and that has the proper additives which causes it to remain stable and predictable over this range. Use following chart and table to select a suitable lubricating/hydraulic oil. RECOMMENDED RECOMMENDED UPPER LIMIT OFF UPPER LIMIT OF PETROLEUM OIL SYNTHETIC OIL IS 250 F IS 200 F

ANY OIL LISTED IS ONLY A SUGGGESTION. USE THE OIL OF YOUR CHOICE WITH THE CORRECT VISCOSITY AS INDICATED IN THE CHART.

GOV OIL -40 °F OPERATING -40 °C TEMPERATURE

00 °F -18 °C

40 °F 40 °C

80 °F 27 °C

120 °F 49 °C

160 °F 71 °C

200 °F 93 °C

240 °F 118 °C

SAE 40 POUR POINT

SAE 30

SAE 20 50 SUS LIMIT (7.5 CST)

SAE 10

PETROLEUM OILS

SAE 10W30

SAE 10W40 SAE 20W40 SAE 15W40 TYPE A-F DEXRON II

AUTO TRANS FLUID

ALL PROOF 10W50 (POLYOLESTER) AMSOIL 10W40 (DIESTER) DN 600 (HYDROCARBON)

SYNTHETIC OLS

MOBIL 1 (SYNTHESIZED HYDROCARBONS ) DELVAC 1 (SYNTHESIZED HYDROCARBONS)

LIMITED OPERATION AT LOW TEMERATURE

IDEAL OPERATING RANGE

LIMITED OPERATION AT HIGH TEMPERATURE

POUR POINT 50 SUS (7.5 CST) LEGEND 3000 SUS (650 CST)

300 SUS (65 CST)

100 SUS (20 CST)

ACCEPTABLE OPERATING RANGE

RECOMMENDED UPPER TEMPERATURE LIMITS

VISCOSITY COMPARISONS CENTISTOCKES (CST, CS, OR CTS)

SAYBOLT UNIVERSAL SECONDS (SUS) NOMINAL AT 100 DEGREES F

SAE MOTOR (APPROXIMATE)

15

80

5w

22

106

5w

32

151

SAE GEAR (APPROXIMATE)

ISO

15 22

10w

75

32

75

46

46

214

10

68

310

20

80

68

100

463

30

80

100

150

696

40

85

150

220

1020

50

90

220 320 460

320

1483

60

115

460

2133

70

140

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 2.

Chapter 5 Page 10 Ed. 7 E

OIL MAINTENANCE

Following the sequence of the maintenance jobs and overhauls (see chapter General), the governor oil needs to be changed twice a year. Also replace the governor oil if it is contaminated or when it is suspected to be contributing to the instability of the governor. Take attention to the state of the drained off oil, if there is: - a change in colour (darker than new oil) - presence of water or an apparent change in viscosity. - presence of dirt and/or metallic particles. - any dought prior to put fresh oil, the governor must be flushed according following procedure. When changing oil, always use clean containers to store and transfer oil. 3.

OIL CHANGING/FLUSHING PROCEDURE: * Remove the drain plug and drain out the oil. Drain while the oil is still hot and agitated. * Fill the governor with a clean solvent having some lubricating quality (such as fuel oil or kerosene) and then flush the governor with the engine running at low speed. * Open the needle valve two or three turns to let the governor hunt for two minutes, then stop the engine and drain the governor. * Flush the governor once again. (If the drain time is insufficient for the solvent to completely drain or evaporate, flush the governor with new governor oil to completely remove the solvent) * Refill the governor with oil to the top mark on the oil sight glass. * Approx. 1,4 liter for UG-8 * Approx. 2,1 liter for UG-25+

4.

ENGINE START UP:

Refer to the operating manual of DZ engine.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 11 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.3.

THE GOVERNOR DRIVE MECHANISM.

5.3.1.

DESCRIPTION - Fig. 5.7 and 5.8 The shaft, - fig.5.8 (3) is rotating on one tapered roller bearing -fig 5.8 (12) and obtains the movement by two gears -fig. 5.7 (1) and (2) from the camshaft and timing gears over the two bevel gears -fig. 5.8 (4) and (5) to the governor. 2

1

18 2 6

11

9

19

12 7 16 18 5

B

3

10

17

15

12

A 8

13 4 14

Fig. 5.8

Component Governor gear case complete.

Mass (kg) 12

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 12 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.3.2.

5.3.3.

5.3.4.

RECAPITULATION OF THE MAINTENANCE JOBS

Code M6-02

Jobs Check gearwheel of governor. Measure backlash.

O2-17

Overhaul of governor gear drive.

SPARE PARTS

Fig. n° 5.2.

Ref. n° 9

5.2.

12

Description Distance washer (to peeled off) Tapered roller bearing

Qty/engine 1 2

TOOLS

Code *620.084.9005.01

Description Tool for dismounting bevel gears.

* Special tools, not standard delivered with the engine (only delivered on request)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.3.5.

Chapter 5 Page 13 Ed. 7 E

VERIFICATION OF GEAR BACKLASH ON BEVEL GEARS - fig. 5.8 Required staff : 1 service man. Equipment: miniature dial gauge "puppitaster" - Remove the governor case cover (8). - Pose the dial gauge “puppitaster" with magnetic socle on face A and the pointer at square angle on a tooth flank (5) Arrow B. - Block the gear (4) with a screw driver. - Move the gear (5) from one to the other sence and read the deviation on the dial gauge scale. Nominal backlash values: * Minimum : 0,12 mm * Maximum : 0,18 mm - In case the backlash is too significant, one or more layers of the distance washer (9) can be peeled off to correct the backlash. Be sure that a too great backlash is not caused by wear on the bevel gears and/or on the tapered roller bearings. - To do the adjustement correctly, the governor must be removed from the gear case (5.2.5).

5.3.6.

VERIFICATION OF GEAR BACKLASH OF DRIVING GEARS – fig. 5.7 Required staff : 1 service man. The backlash between the driving gear (1 fig. 5.7) and driven gear (2 fig. 5.7) is also important to keep the engines timing and running correct. Procedure: - Keep the gears from turning by bracing the crankshaft/flywheel. - Check with a dial gauge/ puppitaster the backlash on a tooth of gear (2 fig. 5.7) and should be between following nominal values. * Minimum : 0,08 mm * Maximum : 0,16 mm

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.3.7.

Chapter 5 Page 14 Ed. 7 E

DISMANTLING - Fig. 5.7 & 8 - Remove the governor as under 5.2.5. - Remove the nuts (25) and disconnect the oil pipe (fig 5.7.) - Remove the gear case - Dismantle the shafts (1) and (3) with bearing housings (6) and (7) with bevel gears (4) and (5) by removing the screws (18). - Remove the nuts (15) - Pull off the bevel gears with tool 620.084.9005.01. - Dismantle the tapered roller bearings and shafts.

5.3.8.

MAINTENANCE AND CONTROL Replace the worn parts and if necessary distance washer (9).

5.3.9.

MOUNTING - ASSEMBLY In case, the tapered roller bearings have been replaced. It is necessary to replace the distance washer (9) to become the necessary backlash in the bevel gears. - Assemble the gearbox inverse order as 5.3.6. - Remove the remaining sealant and degrease all mounting surfaces: * timing gear case - governor gear case * gear case – governor - Coat these faces with LOCTITE 574 and spread it with toothed spatula. - Do the verification of the backlash as given under 5.3.5. - Mount the governor as under 5.2.6.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.4.

INJECTION PUMP CONTROL MECHANISM.

5.4.1.

DESCRIPTION - Fig. 5.9 & 5.10

Chapter 5 Page 15 Ed. 7 E

By means of a coupling rod system (fig. 5.9.) the governor adjusts the required engine speed or load and keeps it constant between given limits, by deplacing the injection pump fuel rack by means of an injection pump control mechanism (fig. 5.10). Two parts are to be considered: - The coupling rod system of the governor (Fig. 5.9). * It consists of two levers (3) and (7) connected by a coupling rod (5). - The injection pump control mechanism (Fig. 5.10). It consists of: * a control spindle (14) provided with an excentric lever (7) which is connecting the spindle to the injection pump fuel rack * a stop-lever (18) with handle (23) * a two part collar (15) and (16), torsion spring (17). This lock collar or coupling is necessary to be able to stop the engine manually by moving the fuel racks to zero fuel by the stop-lever (18) against the governor by over-riding the action of the actuator shaft. 5.4.2.

RECAPITULATION OF THE MAINTENANCE JOBS

Code M2-04

Jobs Lubricate levers, Injection pump control rack and linkage of the governor and control spindle bearing bushings. Check freedom of the fuelpump rack of the injection pump.

It is very important to keep all moving parts of this system clean and free from corrosion, this to avoid governing-, start-, stop-, or overspeed problems. 5.4.3.

SPARE PARTS Refer to our spare parts book.

5.4.4.

TOOLS No special tools required.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.4.5.

Chapter 5 Page 16 Ed. 7 E

ADJUSTMENT OF COUPLING ROD ON WW-GOVERNOR For each engine type of DZC by the manufacturer ABC, the coupling rod is adjusted during assembly and testing in acc. to next table (fig 5.9). In no case these values may be modified. (2)  (%)

R (mm)

L (mm)

6 & 8DZC-900-120

(1) Displacement of fuel rod (mm) 21,5

68,62

58,6

126,6

6 & 8DZC-750-135

21,7

69,26

58,6

126,6

6 & 8DZC-1000-120

22,2

70,85

58,6

126,6

6 & 8DZC-750-150

23,5

75

58,6

126,6

6 & 8DZC-900-135

23,5

75

58,6

126,6

6 & 8DZC-1000-135

24,4

70,11

54,2

127,4

6 & 8DZC-720-166

25,1

72,13

54,2

127,4

6 & 8DZC-750-166

25,1

73,13

54,2

127,4

6 & 8DZC-900-150

25,5

73,28

54,2

127,4

6 & 8DZC-1000-150

26,1

75

54,2

127,4

6 & 8DZC-720-179

26,5

71,49

51,5

128

6 & 8DZC-750-179

26,5

71,49

51,5

128

6 & 8DZC-900-166

26,8

72,30

51,5

128

6 & 8DZC-1000-166

27,8

75

51,5

128

Engine Type

Note: - The values given under (1) and (2) are theorical values. - The angle  is the used angle of the governor terminal shaft given in % of the total angle of 42°.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 17 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR

3

145

11

38,10

R

L

100%

STOP

STOP

35 r

31°30' 7°

Fig. 5.9

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 18 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

27 19

28 22

Zicht volgens pijl Y

31 16 17 22 15 4 5 1 3

18

23

STOP

X

2

Fig. 5.7 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

STOP

11

13

8

12

7

Zicht volgens pijt X

2 6

29

10 9

A

A

21

14

30

B

B

Doorsnede AA

24 25

Doorsnede BB

26

20

Y

GOVERNOR

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.5.

HEINZMANN

5.5.1.

DESCRIPTION

Chapter 5 Page 19 Ed. 7 E

The digital speed governor Heinzmann consists of 3 main parts: a control unit (1) with a micro processor controlled actuator (2) and a speed sensor (3) on the engine, placed in opposition to the tooth rack on the flywheel that pics up the RPM rate of the engine. Working principle: the microprocessor (CPU) in the digital control unit compares the signal from the sensor with the preseted desired RPM rate. If there is a deviation then a new position is calculated by the CPU for the actuator shaft. As source of force the actuator shaft is driven by a disc anvil motor which on his part drives the control spindel of the injection pumps by means of gears. (see sectional views)

"1"

4

5

6

26

8

"2" 17 18 9 13 27 7

25

"3"

Fig 5.11

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 20 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR PART 1 : DIGITAL CONTROL UNIT DC 162-01-55

DC 162-01-00 148 110 13,5 13,5

15 6,5

2,5 2,5

6,5

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 5 Page 21 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR PART 2 : ACTUATOR StG 16 – 01 216

180 30

81

SAE 1/2" - 36 Kerbverzahnung 1/2"-36 SAEKerbverzahunug

42°

Combustible Fūllun Fuel Fuel Combustible Füllung g 50 0 100

38

for BasicSystem E for BasicSystemE Range Voltage Voltage Range Patents pending

D-79677 SchÎnau Germany Telefon: (07673) 8208-0 Telefax: (07673) 8208-88

Pate nts pending

Diese schraube Schraube darf Diese darf nicht nichtverstellt verstelltwerden! warden! Never turn this screw! Never this screw! Ne pasturn toucher a cette vis! Ne pas toucher a cette vis!

11

12

2

18

72

B 74

AA

Serial No.

Serial No.

Am Haselbach 1

238

M8 M8

R

GmbH + C o.

289

66

HEINZMANN

70

72

79,5 79,5 151,5 151,5

180 81

Schnitt A-B Combustible Fūllun Fuel Fuel Combustible Füllung g 50 0 100

125,4 125,4

HEINZMANN

R

Serial No.

GmbH + C o.

217

Serial No.

Am Haselbach 1 D-79677 SchÎnau Germany Telefon: (07673) 8208-0 Telefax: (07673) 8208-88

for BasicSystem E for BasicSystemE Range Voltage Voltage Range Patents pending

Pate nts pending

166

146

42°

38

Schnitt A-B 112,7

Diese Schraube Diese schraube darf darfnicht nichtverstellt verstelltwerden! warden! Never turn this screw! Never this a screw! Ne pasturn toucher cette vis! Ne pas toucher a cette vis!

134

Stellgerät ohne Sockel Sockel Stellgerät ohne

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR

Chapter 5 Page 22 Ed. 7 E

Sectional view of actuator (StG 16 – 01)

ACTUATOR SHAFT

FEEDBACK PROBE

FEEDBACK CAM

DRIVE GEARS

DC DISC ANVIL MOTOR

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR

Chapter 5 Page 23 Ed. 7 E

PART 3 : RPM SENSOR (IA 02 – 76) 1.

Technical specifications:

Voltage output

0,5 till 10 Volt ~ (AC)

Resistance

± 52 Ohm

Distance to gear

2.

0,5 tot 0,8 mm

Clearance of the RPM sensor to the gear:

The distance of the RPM sensor to the teeth head diameter must be 0,5 till 0,8mm. (The RPM sensor can be screwed against the teeth head diameter and then turned back 1/2 of a turn back.) min. 4 mm

min. 2,5 mm min. 4 mm

0,5 - 0,8 mm

3.

Dimensions:

Maat Type 02 – 76

L(mm)

G

76

M 16 x 1,5

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.5.2.

Chapter 5 Page 24 Ed. 7 E

RECAPITULATION OF MAINTENANCE JOBS No specific maintenance needs to be done.

5.5.3.

TOOLS No special tools need to be used.

5.5.4.

REMOVING OF THE GOVERNOR – Fig. 5.12 Required staff: 1 service man * Disconnect the electrical wiring. * Lower the coupling rod (12) by removing the bolt and nut (20/23). * In case the lever (15) must be removed, mark the position in regard to the actuator shaft. * Lift carefully the governor off from the support. (5,0°)

Fig 5.12

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.5.5.

Chapter 5 Page 25 Ed. 7 E

INSTALLING THE GOVERNOR ON THE ENGINE Required staff: 1 service man * Before installing, the mating surfaces of the governor and the gear case should be disposed from any remaining sealant and degrease. * Place the actuator on the support * Mount levers (10-15) and coupling rod (12) and the electrical connections * Check if the governor actually can put the injectionpumps in position “zero injection”. Otherwise take necessary actions. * 0% actuator position must have a 0 mm injection position on racks. Remark: After every disassembly and before start up, a self test (Auto_adjust) needs to be carried out by the actuator in the Heinzmann programm DC-Desk. This test must be carried out with DISASSEMBLED injection rack.

5.6.

INJECTION PUMP CONTROL MECHANISM.

5.6.1.

DESCRIPTION - Fig. 5.12 & 5.13 By means of a coupling rod system (fig. 5.12) the governor adjusts the required engine speed and keeps it constant between given limits. This is done by deplacing the fuel rack of the injection pumps. (fig. 5.13) Two parts are to be considered: - The coupling rod system of the governor (Fig. 5.12). * It consists of two levers (10-11) and (15) connected by a coupling rod (12). - The injection pump control mechanism (Fig. 5.13). It consists of: * a control spindle (14) provided with an excentric lever (7) which is connecting the spindle to the fuel racks of the injection pumps. * a stop-lever (18) with handle (23). * a two part collar (15) and (16) with torsion spring (17). This lock collar or coupling is necessary to be able to stop the engine manually by moving the fuel racks to zero by the stop-lever (18/23) against the governor by over riding the action of the actuator shaft

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR 5.6.2.

Chapter 5 Page 26 Ed. 7 E

RECAPITULATION OF THE MAINTENANCE JOBS

Code M2-04

Jobs Lubricate levers, Injection pump control rack and linkage of the governor and control spindle bearing bushings. Check freedom of the fuelpump rack of the injection pump.

It is very important to keep all moving parts of this system clean and free from corrosion, this to avoid governing-, start-, stop-, or overspeed problems. 5.6.3.

SPARE PARTS Refer to our spare parts book.

5.6.4.

TOOLS No special tools are required

5.6.5.

ADJUSTMENT OF COUPLING ROD ABC has tuned the Heinzmann governor and the coupling rod during mounting and on test bench following the dimensions on fig. 5.12 . Under no circumstances may these fixed dimensions be altered or changed.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

GOVERNOR

Chapter 5 Page 27 Ed. 7 E

Fig 5.13 5.13

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

CHAPTER 6 CRANKCASE (Assembly 1 – 31 - 32)

6.1. 6.2. 6.3. 6.4. 6.5. 6.6.

CRANKCASE. ............................................................................................................................. 1 THE STUDS OF THE MAIN BEARING CAPS (Fig.6.6). .................................................... 16 THE MAIN BEARINGS. (Fig. 6.6) .......................................................................................... 18 CYLINDER BLOCK HOLDING DOWN STUDS. ................................................................ 27 CRANKCASE BREATHER ELEMENT ................................................................................ 28 CLOSED CRANKCASE VENTILATION ............................................................................. 30

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 6 Page 1 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.1.

CRANKCASE.

6.1.1.

DESCRIPTION (Fig. 6.1.a, b, c & d) The crankcase is made from nodular cast iron grade GGG 42/50 cast in sand. The design is of the box construction combining the maximum of rigidity with the minimum of weight. After casting, internal stresses are released by heat-treatment. All non-machined surfaces are coated by a rust-preventing epoxy paint. At both sides, the crankcase is provided with large access doors allowing easy maintenance and/or parts replacement. The crankcase can be used, either - as a dry sump, with a deep oil pan, see fig 6.1.a and 6.1.b. - or as a wet sump, with an oil sump bolted under the crankcase, see fig 6.1.d The crankcase also includes: -

removable bearing caps and main bearing shells suction basket with filter tray (strainer) and suction pipe two oil galleries one on front side, one on back side a number of explosion relief valves or crankcase safety valves oil filling elbow with strainer and cap on inspection door (fig 6.1.c) centrifugal oil filter(s) on inspection door(s) an oil dip-stick (wet sump) Component Crankcase complete with oil pan or oil sump - 6DZC

Mass (kg) 2144

Crankcase complete with oil pan or oil sump - 8DZC

2685

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.1.2.

Chapter 6 Page 2 Ed. 7 E

RECAPITULATION OF THE MAINTENANCE JOBS

Code M1-04

Jobs Check position of contamination indicator on oil filters at operating temperature and nominal speed and replace filter elements if necessary.

M2-02

Clean centrifugal filter or earlier depending on contamination.

M4-01

Replace elements of the oil filters.

M5-01

Change engine oil – clean crankcase and replace crankcase breather element. Depending application / working conditions / regular oil analysis may indicate the necessity to replace the oil change at a shorter / longer interval.

O2-21

Perform an overhaul of the crankcase safety valves.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Chapter 6 Page 3 Ed. 7 E

620.001.2500.01 620.001.2500.03

620.001.2400.03 620.001.2500.03

Fig. 6.1a

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Chapter 6 Page 4 Ed. 7 E

Doorsnede BB Section

Doorsnede Section

AA

Doorsnede CC Section

Doorsnede DD Section

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Fig. 6.1b

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Chapter 6 Page 5 Ed. 7 E

Fig. 6.1c

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

DOORSNEDE A-A SECTION A-A COUPE A-A

620.003.1200.01

CRANKCASE

Chapter 6 Page 6 Ed. 7 E

Fig. 6.1d ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.1.3.

Chapter 6 Page 7 Ed. 7 E

SPARE PARTS Fig. n°

Ref. n°

Description Common spare parts for fig.

Qty(6DZC) Qty(8DZC)

6.1.a - 6.1.b – 6.1.c 6.1.a.

23

Joint

1

1

6.1.d.

10

Joint

1

1

6.1.b.

41

Seal O-Ring

2

2

6.1.b.

42

Joint

12

16

6.1.a.

65

Seal O-ring

1

1

6.1.a.

66

Seal O-ring

1

1

6.1.a.

67

Joint

2

2

6.1.a.

68

Joint

1

1

6.1.c.

6

Joint

1

1

Additional spare parts for wet sump - fig. 6.1.

6.1.4.

6.1.d.

5

Seal O-ring

1

1

6.1.d.

14

Joint

1

1

6.1.d.

30

Joint

1

1

TOOLS No special tools are needed for. Handling of a crankcase can be done in the best way according to fig. 6.2 .

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Fig. 6.2

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 6 Page 8 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 6 Page 9 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.1.5.

Chapter 6 Page 10 Ed. 7 E

DISMANTLING - Fig. 6.3. It is not necessary to dismantle the crankcase completely unless it has to be exchanged. Required staff: 2 service men and 1 assistant. As a general guide line, the dismantling can be done as follows: * empty: - the water circuit - the oil circuit (6.1.6.1.) * remove: - the exhaust pipes (1) and the water outlet manifold (2) - the cylinder heads (chapter 1) and air manifold - the pistons with connecting rods (chapter 2) - the air cooler (3) turbo charger (4) and its supports - the timing gear case (5) with governor case and governor - the camshaft gear wheel (7) - the oil filters (8), pipe work and support - the control box and support (9) - the fuel filters (10), pipe work and support - the water pump(s) (11) and pipe work - the oil pump(s) - (12) - the pump gear case (13) - the oil filling elbow (20) * disconnect: - all remaining pipe work between cylinder housing and crankcase such as camshaft lubricating feed pipe - the cylinder bloc from the crankcase (chapter 3) * attach tool 610.084.3200.10 to the cylinder housing and raise it (chapter 3) Attention: The cylinder housing may be somewhat out of balance. Pose it on solid cross supports. * remove: - the flywheel (16) and upper & lower side covers (17) - the vibration demper (18) and intermediate flange (19) (dismountling the vibration damper is not strictly necessary but in this case the intermediate flange must be taken from it pins and temporary attached to the damper) - the distribution intermediate gear and support and oil pipes - the luboil pipe to the main bearings and bearing caps with upper shell. - lift out the crankshaft - Note: protect the crankpins by interposing of soft materials (plastic, rubber, leather,...) * Release the crankcase from the bed-plate or chassis by removing the foundation bolts. Remove all remaining fittings, luboil galeries and oil pan or oil sump. ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

6.1.6.

Chapter 6 Page 11 Ed. 7 E

MAINTENANCE Required staff: 1 service man.

6.1.6.1. Change the engine oil (fig. 6.1.a, b, c, d, 6.3. & 6.4.) Draining the oil: (see also Operating Manual chapter 5) Allow the oil to drain out by opening or removing: - dry sump: The plugs (26) or covers (28) on the separate oil tank (fig.6.3.) The plugs (10) fig(6.1.a) if accessible or plug (66) for the deep pan. If not accessible the crankcase must be emptied through the inspection doors (p.e. by a separate pump) - wet sump: The plugs (30) if accessible. If not, the crankcase must be emptied through the inspection doors (p.e. by a separate pump)(Fig.6.1.b) - oil filters : The plugs (12). Place a suitable recipient under the filter cases to collect the oil - oil cooler : The lower plugs. Collect the oil Cleaning: (see also Operating Manual chapter 5) Cleaning is preferable carried out by means of a brush with gasoil (pressure jet is also allowed) Drying can be done by a sponge or fluffless rag. -

clean the separate oil tank through the covers clean the crankcase and/or oil sump or oil pan the oil filling elbow the centrifugal filter (fig. 6.5. and Operating Manual chapter 5) replace the elements of the twin luboil filters and clean the filter cases (fig. 6.4. and Operating Manual chapter 5)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Chapter 6 Page 12 Ed. 7 E

6.1.6.2. Filling with fresh oil. Consult the "Operating Manual" for the list of recommended luboils . Replace all plugs or removed covers - Dry sump: Fill up the oil tank to max. level (sight glass or dipstick). The crankcase, by the way of the filling elbow, pour approx. 10 litres per cylinder. By means of the hand pump, fill up the oil circuit and release the air from the twin oil filters (see "Operating Manual”) When the engine is put in service again, repeat the air venting on the twin luboil filters. (The oil cooler is self venting). Check oil level after first stand still and add al if required. - Wet sump: Fill up the oil sump to max. level (dipstick) By means of the hand pump, fill up the oil circuit and release the air from the twin oilfilters. When the engine is put in service again, repeat the air venting on the twin luboilfilters (the oil cooler is self venting). Check oil level after first stand still and add oil if required. REMARK: The centrifugal oil filter and the twin element oil filter are cleaned according the "Operating Manual" Chapter 5. However, special attention must be given to the oil filter. The elements are mounted between a lower and an upper cover. This upper cover is provided with a 2 rubber seal O-rings (6). It is most important that this seal ring is strongly attached to the cover. If not, bound it with strong bounding such as cyano acrylate.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Fig. 6.4 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 6 Page 13 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

LOCATING PIN To avoid rotor imbalance during operation, please ensure rotor cover slot and rotor body pin are aligned

Fig. 6.5 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 6 Page 14 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.1.7.

Chapter 6 Page 15 Ed. 7 E

ASSEMBLY (fig 6.3.) Required staff: 2 service man and 1 assistant. As a general guide line assemble in reverse order from dismantling See other chapters for mounting other components: -

cylinder heads (chapter 1) pistons and con rods (chapter 2) cylinder housing (chapter 3) crankshaft and vibration damper (chapter 7) timing gear (chapter 8) pump gear case and pumps (chapter 9)

REMARK: A lot of components such as covers; oil pan, oil sump, flywheel side covers, gear case intermediate flange, pump gear case, timing gear case, governor gear case, between cylinder housing and crankcase, are mounted with sealant "LOCTITE 574".

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.2.

THE STUDS OF THE MAIN BEARING CAPS (Fig.6.6).

6.2.1.

DESCRIPTION

Chapter 6 Page 16 Ed. 7 E

These studs are secured in the main bearing webs of the crankcase by means of Loctite. Their purpose is to secure the bearing caps. 6.2.2.

TOOLS Code 620.083.1600.03

Description Torque spanner with sockets and accessories (tightening stud nuts)

6.2.3.

DISMANTLING THE MAIN BEARING CAPS Required staff: 1 service man. Remove the nuts and lift off the caps. The studs should not be removed.

6.2.4.

ASSEMBLY OF THE MAIN BEARING CAPS Required staff: 1 service man. Consult the tightening torque table for the tightening of the nuts. Be sure that contact faces between cap and crankcase are clean.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Stellippen Ergots de positionnement Location lugs

CRANKCASE

Fig. 6.6

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Mounting instructions The bearing caps must be mounted so, that the location lugs of the two half bearing shells are at the same side in their corresponding groove.

Note pour le montage Les chapeaux palier doivent être montés de telle Façon que les ergots de positionnement, des deux Demi-coussinets, se trouvent à la meme côté dans leur Rainure correspondante

Nota voor het monteren De lagerkappen moeten derwijze gemonteerd worden dat de stellippen, van de twee halve lagerschalen, aan dezelfde kant komen te staan, in hun overeenkomstige groef

MAINTENANCE MANUAL DZC ENGINES Chapter 6 Page 17 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.3.

THE MAIN BEARINGS. (Fig. 6.6)

6.3.1.

DESCRIPTION

Chapter 6 Page 18 Ed. 7 E

The bearing is in two half shells, an upper (2) and a lower shell (1). Identical shells are used for all bearings: the intermediate (3 fig 6.1a), the larger intermediate (4 fig 6.1a) and the guide (2 fig 6.1a) bearing cap. The shells are located in their place by lugs engaged in notches machined in the housing. The guide bearing is provided, in addition to the shells with two semi-circular thrust rings (3), for locating the crankshaft in axial position.

6.3.2.

Component Lower shell

Mass (kg) 0.8

Upper shell

0.7

Thrust ring

0.5

RECAPITULATION OF THE MAINTENANCE JOBS Code O2-05

Jobs Check the condition of the main bearings, inclusive axial bearing. Renew if necessary.

O3-01

6.3.3.

Replace the main bearings and axial bearing.

SPARE PARTS Fig. n° 6.6

Ref. n° 1

Description Lower main bearing shell

Qty/6DZC 8

Qty/8DZC 10

6.6

2

Upper main bearing shell

8

10

6.6

3

Halve thrust ring

2

2

Undersize main bearing shells Oversize thrust rings

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Chapter 6 Page 19 Ed. 7 E

REMOVING OF LOWER MAIN BEARING SHELL Stellip Ergot de positionnement Locating lug

620.084.7300.01

Fig. 6.7 6.3.4.

TOOLS Code *620.084.1500.01

Description Tool for mounting main bearing shells

*620.084.7300.01

Carrier for dismounting / mounting main bearing shell

* Special tools, not standard delivered with the engine (only delivered on request) 6.3.5.

DISMANTLING (Fig. 6.7) Required staff: 1 service man and 1 assistant. The main bearing shells can be removed without dismantling the crankshaft. - Disconnect the oil pipe to the bearing cap - Loose the nuts and take away the bearing cap - Lift out the upper shell, using special tool 620.084.1500.01 - Rotate the crankshaft untill the oil bore becomes visible - Place the carrier 620.084.7300.01 in the bore - Rotate now the crankshaft in the right way to free the lug from its notch (the lugs on upper and lower shell are at the same side) - Continue turning untill the lower shell is completely free. ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.3.6.

Chapter 6 Page 20 Ed. 7 E

MAINTENANCE Required staff: 1 service man.

6.3.6.1. Measuring the clearance (Fig.6.8) with crankshaft in place. Disconnect the oil pipework and remove the bearing cap and upper bearing shell. Place a strip of "Plastigage" in the shell and reinstall it. (A). Remove it again and measure the clearance by means of the "Plastigage" scale (B). "Plastigage" material can be obtained from the following address : Perfect Circle Corporation HAGERSTOWN Indiana U.S.A. or from local "Perfect Circle" distributors. 6.3.6.2. Clearance and limits of wear. The clearance indicates indirectly the combined wear of the crankshaft and bearing shells. 1.

Clearance between the crankshaft and the main bearing shells. OD, R1, R2 (A – Fig. 6.9) Type X (OD) Clearance 0.11 - 0.20 mm Type Y (OD), R1 , R2

Clearance 0.19 - 0.28 mm

Replacement of main bearing shells: - At 48000 hours (overhaul O3-01) by normal wear the main bearing shells have to be replaced. - ABC advises replacement of main bearings shells after dismantling of a bearing cap. CAUTION Opening a bearing cap without a specific reason is not advisable. - When the bearing shells need to be replaced eighter by inspection (see 6.3.6.3) or normal wear it is necessary replacing them in pair. Always replace both the upper and the lower bearing shell.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Chapter 6 Page 21 Ed. 7 E

Undersize bearings: When the main bearings dimensions of the crankshaft (A see Fig 7.3 – Chapter 7: Crankshaft) reach beyond the wear limit (LW), the crankshaft can be reworked for which undersize bearings can be fitted. See the spare parts list (Sect. DZ.004) for the ordering codes. 2.

Clearance between the crankshaft and the thrust bearing OD, R1, R2 (B – Fig. 6.9) Clearance 0.12 - 0.28 mm

LW 0.4 mm

When the LW figure is exceeded, it is necessary to repeat the measurement using new thrust bearings. Two cases are possible: * If the clearance is less than the LW figure, the engine can continue to work with the new bearing. * If the LW figure is still exceeded, it is necessary to have recourse to "oversize" thrust bearing, size Rl, R2 . 3.

Journals

When the limits of wear of the thrust bearing (See fig. 6.9) is measured, it is highly recommended that the deflection of the crankshaft is also measured. See “7.1.8. Verification of the crankshaft deflection”.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

Chapter 6 Page 22 Ed. 7 E

6.3.6.3. Visual inspection of the main bearing shells. The bearing shells used are of the tri-metal type. Inspection can only be done by skilled personnel by visual inspection. Clean the shells by means of a soft cloth. Examine very carefully the anti friction coatings. Any shell must be exchanged in the following circumstances: - if the coating is loose - if there is damage (severe scratching or many grooves due to dirt or particles) - Minor roughness or slight wear do not necessitate the replacement of the shell. Slight cavitation around the oil bore and in the roundings of the lugs do not necessitate the replacement. - Nevertheless ABC advises the replacement of the bearing shells after dismantling of a bearing cap of the crankcase. Attention: - At 48000 hours (overhaul O3-01) by normal wear the main bearing shells have to be replaced. - ABC advises replacement of main bearings shells after dismantling of a bearing cap. CAUTION Opening a bearing cap without a specific reason is not advisable. - When the bearing shells need to be replaced eighter by inspection or normal wear it is necessary replacing them in pair. Always replace both the upper and the lower bearing shell.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

A

PLASTIGAGE

B

Fig. 6.8

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 6 Page 23 Ed. 7 E

Chapter 6 Page 24 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE

LIMITS OF WEAR OF THE MAIN BEARING AND THRUST BEARING

1st undersize OD A B

Type X Type Y 184,110 184,195 184,169 184,254 12,940 12,900

LW

R1

LW

183,695 183,754

FOR REWORKED JOURNALS 2ndundersize 1st oversize R2

LW

R1

2nd oversize

LW

R2

13,150

13,940 13,900

LW

183,195 183,254

12,65 0

13,440 13,400

Taper

Ovality

0,04 max

0,08 max

13,650

Bearing shells Type X: - Upper half bearing shell : 620.004.9002.01 - Lower half bearing shell : 620.004.9001.01 Type Y: - Upper half bearing shell : 620.004.9002.02 - Lower half bearing shell : 620.004.9001.02 - Upper half bearing shell : 620.004.9002.03 - Lower half bearing shell : 620.004.9001.03 Thrust bearings OD -620.004.9003.01 (MDO & HFO)

MDO

MDO HFO

R1(1st Undersize) - Upper half bearing shell : 620.004.9102.03 - Lower half bearing shell : 620.004.9101.03 R2(2nd Undersize) - Upper half bearing shell : 620.004.9202.02 - Lower half bearing shell : 620.004.9201.02 - Upper half bearing shell : 620.004.9202.03 - Lower half bearing shell : 620.004.9201.03

R1 (1st Oversize) - 620.004.9103.01 (MDO & HFO)

MDO & HFO

MDO HFO

R2 (2nd Oversize) - 620.004.9203.01 (MDO & HFO)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.3.7.

Chapter 6 Page 25 Ed. 7 E

ASSEMBLY OF THE BEARING SHELLS (Fig. 6.10) Required staff : 1 service man and 1 assistant. - pay particular attention to the cleanness of the shells, at the back as well as in the bore. - place the carrier 620.084.7300.01 in the oil-bore in the crankshaft. - place the lower shell in the assembly tool 620.084.1500.01 . - install the assembly tool, paying attention to the lug. - rotate the crankshaft to slide the shell into place. - remove the assembly tool. - fit the upper bearing shell and the cap. - Tighten the nuts with a torque wrench to the specific torque to be found in the tightening torque table. (See chapter General)

6.3.8.

VERIFICATION AFTER ASSEMBLY Verify: - the alignment of the crankshaft ( see chapter 7) - the clearance between the crankshaft and the thrust bearing, by means of a dial gauge. - the clearance between the crankshaft and the main bearing shells (6.3.6.2.)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE ASSEMBLY OF LOWER MAIN BEARING SHELL

620.084.1501.01

620.084.7300.01

Fig. 6.10

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 6 Page 26 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.4.

CYLINDER BLOCK HOLDING DOWN STUDS.

6.4.1.

DESCRIPTION

Chapter 6 Page 27 Ed. 7 E

These studs hold the cylinder block down on the crankcase. They are made of hightensile steel. They are secured in the crankcase with "Loctite" and the nuts are tightened in 3 times according to the angular displacement method. New studs have to be pretightened a first time in order to reduce initial setting (see chapter 3). 6.4.2.

DISMANTLING See Chapter 3: “3.1.5 Dismantling” .

6.4.3.

ASSEMBLY See Chapter 3: “3.1.7 Assembling” .

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.5.

CRANKCASE BREATHER ELEMENT

6.5.1.

DESCRIPTION (Fig. 6.11)

Chapter 6 Page 28 Ed. 7 E

The crankcase breather element has the function of collecting any oil that has been evaporated from in carter during operation. The filter element collects the oil from the oil mist and resends it to a collector where it again drops into the engine carter. This way the evaporated oil during operation is preserved.

Fig. 6.11 6.5.2.

RECAPITULATION OF THE MAINTENANCE JOBS Code M5-01

Jobs Change engine oil – clean crankcase and crankcase breather element. Depending application / working conditions / regular oil analysis may indicate the necessity to replace the oil change at a shorter / longer interval.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.5.3.

Chapter 6 Page 29 Ed. 7 E

SPARE PARTS We refer to the spare parts manual section 032.

6.5.4.

TOOLS No specific tools are required.

6.5.5.

MAINTENANCE (Fig. 6.11) Replacement of the breather filter element (5) consists of the following procedures: - When the engine has cooled down remove knob (4) with joint (6) from the assembly. Replace the joint if damaged. - Remove bolts (15). - When this has been done, the cover (2) can be carefully lifted. - Make sure not to damage the Seal O-ring (7). Check the condition of the O-ring, replace if necessary. - When the top cover is removed, the filter element (5) is visible. Replace with a new filter element. - Check the condition of oval joint (12), replace if necessary. - Place back the top cover (2). For this grease in the O-ring (7) with a grease like CERAN WR2 (Total) or equivalent. Attention: Hazardous liquids For use refer to safety prescription card. - When the cover is good in place over the central chaft (3). Place back the joint (6) and knob (4) and tighten it. - Place back bolts (15).

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 6.6.

CLOSED CRANKCASE VENTILATION

6.6.1.

DESCRIPTION

Chapter 6 Page 30 Ed. 7 E

Some applications have a closed crankcase ventilation. This means that the crankcase ventilation is connected to the suction side of the turbocharger. To avoid overpressure and too much oil in the air collector, the engine is then equipped with a filter and a pressure regulation system. 6.6.2.

MASS Component Closed crankcase ventilation breather

6.6.3.

Mass (kg) 4,2

RECAPITULATION OF THE MAINTENANCE JOBS Code M3-02

Jobs Replacing filter element of closed crankcase ventilation breather

6.6.4.

SPARE PARTS Refer to the spare parts lis of the 6/8DZCengine.

6.6.5.

TOOLS No special tools required.

6.6.6.

REPLACING THE FILTER ELEMENT (RACOR) Note: The filter element of the ABC crankcase breather does not have to be replaced, you just have to clean it every 3000 running hours. The filter element of the Racor crankcase breather, however, has to be replaced every 1000 running hours.

6.6.6.1. Required staff One service man 6.6.6.2. Procedure (fig. 6.12) 1.

Loosen the four bolts (1) and remove the cover.

2.

Replace the filter element and the two seals (10). You always have to replace the seals with the element.

3.

Remount the cover and tighten the four bolts (1).

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 4.

Chapter 6 Page 31 Ed. 7 E

Check the crankcase pressure. See 6.6.9CHECKING CRANKCASE PRESSURE AFTER FILTER REPLACEMENT.

Fig. 6.12 6.6.7.

CHECKING THE PRESSURE REGULATOR In theory, the pressure regulator does not need any maintenance. We recommend, however, to execute a visual and functional check every 3000 hours.

6.6.8.

CHECKING THE NON-RETURN VALVE In theory, the non-return valve does not need any maintenance. We recommend, however to execute a visual and functional check every 3000 hours.

6.6.9.

CHECKING CRANKCASE PRESSURE AFTER FILTER REPLACEMENT

6.6.9.1. Required staff One service man. 6.6.9.2. Procedure Each time you replaced the filter element, you have to check the crankcase pressure with a U-pipe (fig. 6.13). Proceed as follows: 1.

Check the crankcase pressure at idle. There should be no more than 5 mm overpressure.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKCASE 2.

Chapter 6 Page 32 Ed. 7 E

Check the crankcase pressure at 50 % load. There should be no more than 10 mm under pressure.

3.

If necessary, adjust the pressure regulation by turning the screw of the pressure regulation valve (11).

4.

Shut down the engine and wait 10 minutes.

5.

Dismount the filter and check if the oil was drained.

Fig. 6.13

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

CHAPTER 7 CRANKSHAFT (Assembly 6 – 29 – 93)

7.1. 7.2. 7.3. 7.4. 7.5. 7.6. 7.7.

CRANKSHAFT............................................................................................................................ 1 TORSIONAL VIBRATION DAMPERS. ................................................................................ 11 VISCOUS DAMPER ................................................................................................................. 11 FLEXIBLE PUMP DRIVE ....................................................................................................... 21 SPRING COUPLED DAMPER ............................................................................................... 24 FLEXIBLE PUMP DRIVE ....................................................................................................... 41 SECONDAIRY POWER-TAKE-OFF (PTO) ......................................................................... 45

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.1.

CRANKSHAFT.

7.1.1.

DESCRIPTION (fig.7.1. and 7.2.)

Chapter 7 Page 1 Ed. 7 E

The crankshaft is forged, in one piece and made from chrome-molybdenum steel alloy. Oil passages are bored within the crankshaft and are highly polished. Additional borings necessary during machining are closed by plugs (5). At the power take off end, the crankshaft is provided, integrally with a flange for attaching the flywheel. The flywheel is carrying the flexible coupling which type is depending upon the application of the engine. The timing gear is mounted on the crankshaft between main bearing nr. 0 (additional bearing) and main bearing nr. 1 (cylinder 1). This gearwheel is in two halves and has helicoidal cut teeth. The free end of the crankshaft consists of a cone 1/80 provided for the torsional vibration damper which is mounted by hydraulic expansion following the SKF system. The vibration damper, is foreseen with an elastic coupling on which the pump driving gear is mounted. This gear has helicoidal cut teeth. The crankshaft for the 6DZC engine (Fig.7.1.) is carrying 4 balance weights and the crankshaft for the 8DZC (Fig. 7.2.) is carrying 8 balance weights. The balance weights are attached by dynamic screws (3). The flange on the primary part of the damper can be provided with an extension shaft for a secondary power take-off by means of flexible coupling. Then a supplementary shaft bearing is foreseen on the pump driving gearcase. Component Crankshaft 6DZC

Mass (kg) 980

Crankshaft 8DZC

1386

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 2 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

Fig. 7.1

CRANKSHAFT

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

8cyl

Fig. 7.2

CRANKSHAFT

Chapter 7 Page 3 Ed. 7 E

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.1.2.

Chapter 7 Page 4 Ed. 7 E

RECAPITULATION OF THE MAINTENANCE JOBS Code M6-06

Jobs Measure complete crankshaft deflection (all cylinders) and the crankshaft axial clearance.

7.1.3.

SPARE PARTS As 7.1.2., for spare parts see chapters 2 and 6.

7.1.4.

TOOLS Code * 620.084.9003.02

Description Crankshaft deflection gauge

* special tools, not standard delivered with the engine (only delivered on request) 7.1.5.

DISMANTLING. Required staff: 2 service men and 1 assistant. The crankshaft needs to be removed only if it has to be reworked, repaired or exchanged, or if the crankcase has to be exchanged. The dismantling procedure is as indicated for the crankcase (chapter 6).

7.1.6.

MAINTENANCE (Fig. 7.1. and 7.2.)

7.1.6.1. Cleaning and examination. Required staff: 1 service man and 1 assistant. - Remove the plugs (5) and clean the oil-bores with a tube brush of synthetic material. - Pass a rolled-up fluffless cloth through the oil bores, make certain that nothing remains in the holes. - Clean plugs and place back with Loctite 275 or equivalent. - Thoroughly examine the crankshaft on cracks by means of organol red or Magnetic flux control, in this case the crankshaft must be degaussed afterwards. This examination must particularly be concentrated to the radii between: -

crank webs and journals crank webs and crank pins, flange for flywheel and journal crank web and cone for damper Also corrosion or pitting in this area is not acceptable and must be elminated by polishing or even by local machining. ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 5 Ed. 7 E

- Scorings -and or other minor degradations on the journals and crank pins may be corrected by means of emery cloth, use fine grain n° 300 to 400, soaked in oil. Final polishing by very fine polishing cloth or "Scotchswitch" pads should be used. - Thoroughly clean the crankshaft with a clean cloth. Take care to protect the crankshaft from rusting. 7.1.6.2. Limits of wear (Fig. 7.3) Measure the main bearing journals and the crank pins with a micrometer. Measure first the taper and ovality and compare the values with those given under fig. 7.3. Next measure the diameters and compose the average of the four measurements with the LW (limit of wear) figure. Check the distance (between the thrust faces) NOTE: Observe whether the sizes are the originals or the first or second rework dimensions. If reworking is found to be necessary, consult the spare part list, in order to machine to the dimensions of the undersize bearing shells or oversize thrust rings. Deflexion or bending of a crankshaft should not be measured when it is supported on two points. The right why is to measure the crankshaft supported on bearings mounted in a crankcase both in good condition. From the precision of such measurements it is recommanded to contact our representative, the after sales dept. or technical dept. of ABC .

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Fig

LW

183,850

177,850

146,500

OD

183,971 184,000

177,975 178,000

146,000 146,063

A

B

C

Diemensions in mm

C

A

A

7.3

7.1.6.3.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

177,350

183,350

183,471 183,500 177,475 177,500

LW

R1

1st reworking

176,975 177,000

182,971 183,000

R2

176,850

182,850

LW

2nd reworking

The crankpin of cylinder no 1 must be at TDC throughout the measurements

B

R3

LW

3d reworking

0.060

0.040

OVALITY max

A

TAPER max

0,030

0,030

B

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 6 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 7 Ed. 7 E

Reworking of the crankshaft. It is recommended that this work should be undertaken by ABC or by another specialized company. Verify after reworking : - The parallelism of the crank pins relative to the axis of the crankshaft, max. deviation 0,03 mm on 80 mm distance. - The parallelism of the journals relative to the axis of the crankshaft, max. deviation 0,03 mm on 90 mm distance. - The co-linearity of each main journal relative to those of the two adjacent main journals: max. deviation 0,03 mm. - The co-linearity of any main journal relative to that of any other main journal: max. deviation 0,06 mm. 7.1.7.

ASSEMBLY. Required staff: 2 service men and 1 assistant. - Thoroughly clean the bearings shells. Put the lower shells in position in the crankcase. - Remove any protective coating from the crankshaft, wash it with gasoil and lubricate it with clean engine oil before putting in place. - Clean the oil-bores with a tube brush of synthetic material. Pass a rolled-up fluffless cloth through the oil bores, make certain that nothing remains in the holes. - Clean plugs and place back with Loctite 275 or equivalent. - Install the thrust rings and proceed with the assembly of the upper bearing shell, caps, etc. (see chapter 6) - Finally, verify the crankshaft deflection. See 7.1.8 .

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.1.8.

Chapter 7 Page 8 Ed. 7 E

VERIFICATION OF THE CRANKSHAFT DEFLECTION. The deflexion must be verified whenever the bearing shells or the crankshaft have been removed. Normally, the faces of the crankwebs are provided with depressions for the pointers of a dialgauge. In the other cases, such places must be marked at distances of R + D/2 , as indicated in Fig. 7.4 . Place the two pointers of the dial gauge on the marked places and adjust the needle reading to +20 (this setting is better than 0, because it evades any error of the interpretation of positive and negative readings). Rotate the dial gauge several times around its own axis and observe whether the reading changes. If it remains constant, the measurement may proceed, otherwise it is necessary to verify the arrangement (measuring places, pointers, dial gauge,etc.).

7.1.8.1. Measurement of the deflection: engine dismantled. If the crankshaft has been reworked or exchanged, that is to say, after the engine has been dismantled, the measurements are to be made at four positions as indicated in the sketch below. Turn the crankshaft slowly and make the measurements at four places. It is good practice to repeat the measurements, turning the crankshaft in the opposite sense and comparing the figures with the first set. Compare the results of the measurements with the figures of graph. Fig. 7.4. 7.1.8.2. Measurement of the deflection: engine assembled. When the engine is assembled, the measurements are to be made at five places, as indicated in the sketch. The average of the measurements at 1 and 5 may be reduced to one figure. Compare the figures obtained with those on the graph. Fig. 7.4. Take care that the connecting rod does not touch the dial gauge.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 9 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Deflection “X”

Comparator for alignment on 20

Length of stroke in mm

THE DEFLETION FROM O TO X MUST BE MEASURED IN THE VERTICAL PLANE AND IN THE HORIZONRTAL PLANE BETWEEN TWO CRANK PIN FLANGES OR CRANK WEBBS.

Deflection “X”

engine DZC

Deflection

A – SATISFACTORY DEFLECTION (NEW ENGINE) B – PERMISSIBLE DEFLECTION (RECONDITIONED ENGINE) C – REALIGNMENT IS ADVISAVLE D – PERMISSIBLE DEFLECTION ONLY BETWEEN THE CRANK PIN FLANGES OF CYL. 1 FLYWHEEL SIDE (NEW ENGINE) E – REALIGNMENT IS NECESSARY

Fig 7.1.8.3.

7.4

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 10 Ed. 7 E

Tolerances. See graph Fig. 7.4 NOTE: Because of the mass of the flywheel, a greater deflection will be measured for cylinder n°1. Same remark in case the torsional vibration damper is mounted to the crankshaft without additional bearing (i.e. in this case at the cylinder the closest to the damper).

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.2.

Chapter 7 Page 11 Ed. 7 E

TORSIONAL VIBRATION DAMPERS. In regard to the application or to the necessity for a certain engine type, we have the choise between different torsional vibration dampers, namely spring blade type and viscous type. (We refer to the Operating Manual or to the Description and Applications Manual).

7.3.

VISCOUS DAMPER

7.3.1.

DESCRIPTION The torsion vibration damper damps the torsion vibration using the effect of the silicon oil as a powerful elastic coupling between the secundair (inertia ring) and primair (housing) mass. When the crankshaft rotates without torsion vibration, the inertia ring rotates without any slip in the housing. When there arise some vibrations, there will be a relative movement between the housing and the ring. This results in alternating elasticities in the siliconoil. Whole the elasticities over the surface between ring and housing results in a damping action. housing plate

bearing intertia ring

Siliconoil stop

welding line

Fig. 7.5 Component: (vibration damper) Type ASK 2204A

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Mass (kg) 304

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Fig. 7.6 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 12 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

Coat THIS FACE WITH FLANGE SEALANT

M8X40 DIN 912-88

C = 50,5 á 52

CRANKSHAFT

Chapter 7 Page 13 Ed. 7 E

Fig. 7.7 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 14 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

7.3.2.

RECAPITULATION OF MAINTENANCE JOB Code O1-04

Jobs For viscous damper, sample of silicon oil of damper to be analysed.

O2-09

Complete overhaul of a viscous vibration damper.

After 24000 running hours an oil sample needs to be taken of the fluid in the damper. This to check the condition of the damper. Under 7.3.5.5. the complete procedure can be found for extraction of an oil sample. Sample containers can be requested at ABC. 7.3.3.

SPARE PARTS Fig. n° 7.6

7.3.4.

Ref. n° 13

Description Nylon ring

Qty/damper 1

TOOLS Code 626.084.3500.01

Description Tools for mounting and dismounting vibration damper - Viscous damper - Spring blade type

100.933.016.000

Lifting eye bolt M16 DIN 580

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.3.5.

Chapter 7 Page 15 Ed. 7 E

MAINTENANCE Complete overhaul of the damper is only necessary in case of severe wear, broken parts or damage. We advise you to send the damper to engine-builder or vibration damper producer, bearing in mind the difficulty of the task and special tools you will need.

7.3.5.1. Dismounting of the damper from the hub (Fig 7.6 – 7.7) - Before we can reach the damper, previously following parts must be removed or dismounted: * Oil filter and its support - oil pipes and connections * Control panel and its supports - wiring and connections * The waterpumps, eventually the oil pumps (chapter 9) - Before removing the pump driving gearbox with all connections, remove plug (15) from the flange bearing support (6) and remove the 6 fixing bolts (17) through the opening in the flange. Following this screw in 2 bolts M8x40 to be found in opposition to each other (see fig 7.7). - Remove the pump driving gearbox with all connections (chapter 9). - The flexible spring coupling with its gear is visible. - Remove the 2 bolts M8x40 from the flexible spring coupling. (see fig. 7.7) - Unscrew all 16 bolts (16) to remove the whole flexible spring coupling from off coupling boss (12). - The viscous damper is now visible. - Unscrew the 8 bolts (18) from the damper. - To safely remove the damper, first mount a lifting eye bolt M16 (100.933.016.000) in one of the M16 threads beside the mounting holes of bolts (18). The other M16 thread can be used by another bolt M16x30 to push the damper evenly off the hub when the eye bolt is completely screwed in. - Secure the damper with the screwed in eye bolt with a rope to a tackle. Bring some tension to the rope. The rope and the tackle must be able to lift a load of at least 350 kg. - Pull the damper of the boss and place on a wooden surface.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 16 Ed. 7 E

7.3.5.2. Dismounting hub from the crankshaft (Fig 7.2 - 7.8a) When also the hub (12) needs to be removed, tool 626.084.3500.01 can be used together with a hydraulic hand pump and the injection kit. Use following procedure: - Install the tool assembly 626.084.3500.01 according to Fig.7.8a . (Dismounting damper / hub) * Unscrew plug (14) and cone plug ¼”G (6 - Fig. 7.2) out of the crankshaft. * Screw the tie-rod(l) in the central thread in the crankshaft. * Slide over the tie-rod: - the distance bush (2). - the hydraulic jack with thrust piece (3) provided with an extracting plate (4). - the knurled nut (5). * Connect the oil injection kit to the provided hole 1/4"G in the crankshaft. (The extracting plate (4) is provided with a sleeve hole with diameter of 40 mm to clear the high pressure pipe of the oil injection kit). * Fit the extracting plate with the 11 screws (6) to the damper inner star. FOR SECURITY! :The knurled nut(5) is mounted at a clear distance of approx. 25 mm from the hydraulic jack body; this nut is used as a stop to avoid jumping away from the damper when it is releasing from the crankshaft cone. * Connect the hand pump to the hydraulic jack and the high pressure pipe to the oil injection kit and bring both pumps under pressure. - Prime the pumps until the hub releases. The oil injection kit gauge reaches pressures from 1400 to 1650 bar herefor for releasing the hub. On the hydraulic piston, pressures of 160 to 200 bar are applied for release. ATTENTION : Generally, the hub is released suddenly, all at once. - Remove tool 626.084.3500.01 and then remove the hub from the cranckshaft. Remark: When both the damper and the hub need to be dismounted,the procedure above can be used while the damper is still on the hub (12). Attention needs to be taken to slightly tighten the rope of the tackle while using the tool 626.084.3500.01 . as indicated in 7.3.5.1 .

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 17 Ed. 7 E

7.3.5.3. Mounting hub on the crankshaft (Fig 7.8b) - Inspect the cone of the crankshaft and polish with fine emery cloth. Inspect and polish, if necessary, also the collar against which the damper is applied. Clean with a fluffless cloth and oil slightly. Place the nylon ring (13) over the crankshaft cone and apply it against the collar, perhaps with some grease to keep it on its place during assembling of the damper. - Move the hub over the crankshaft cone and push it as far as possible over the cone. - Install the tool assembly 626.084.3500.01 according to fig. 7.8b (mounting of the damper / hub) * Screw the tie-rod (1) in the central thread in the crankshaft. * Slide over the tie-rod, - the thrust plate (7) with slot for clearing the high pressure pipe. - the hydraulic jack with thrust piece - the knurled nut (5) * Connect the oil injection kit to the provided hole 1/4"G in the crankshaft. - Tighten firmly the knurled nut (5) by hand. - Connect the hand pump to the hydraulic jack and give some pressure to slide the hub partly over the crankshaft cone. - Increase the pressure on the injection kit and do evenso on the hand pump to slide the hub further over the cone. Go on with this action on both pumps until the damper is applied firmly against the crankshaft collar. The oil injection kit gauge reaches pressures from 1400 to 1650 bar. On the hydraulic piston, pressures of 160 to 200 bar are applied. To this end check this with a 0.05mm feeler gauge to be certain there is no space between the hub (12) and nylon collar (13) and between the nylon collar (13) and the crankshaft. When the hub is on its final position, release first the pressure of the oil injection kit, then on the hand pump of the hydraulic jack. -

Remove all tooling. Remount the oil circulating plug (14) in the crankshaft. Remount cone plug ¼”G (6 - Fig. 7.2) in the crankshaft. Remount the flexible gear driving coupling see 7.4 for details. Mount the pump driving gear box with all connections (chapter 9). Remount the secondary power take off if existent. Remount the water and oil pump (chapter 9). - Remount control panel with wiring and connections. - Remount oil filters and their support. Reconnect oil pipes connections. Refer to the spare part book for necessary spares, etc.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 18 Ed. 7 E

Remark: When the damper is still on the hub and needs to be mounted, the previous procedure can be used also. During mounting slightly loosen the rope of the tackle (-> same as for dismounting) while using the tool 626.084.3500.01 . Tool : 626.084.3500.01

from handpump

from oil injection kit

DISMOUNTING DAMPER / HUB

Fig. 7.8a

from handpump

from oil injection kit

MOUNTING DAMPER / HUB

Fig. 7.8b ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 19 Ed. 7 E

7.3.5.4. Mounting of the damper on the hub (Fig 7.6 - 7.7) - Check if the mounting surface is completely clean. Clean with a non-fluffing cloth and oil. - Use the same tackle as for dismantling. Screw in the lifting eye bolt M16 (100.933.016.000) into one of the 2 threaded holes M16 in the damper. - Carefully lift the damper with the tackle. Push the damper carefully over the mounting surface of boss (12). When the damper is on the mounting surface, loosen the rope and position while turning the mounting holes on the boss (12). - Mount the 8 bolts (18) with washers (21) with locktite nr. 243 and tighten crosswise to a mounting torque of 500Nm (50kgm). - Mounting of the spring coupling: * Position and mount coupling using 2 screws M8x40 DIN 912-8.8 (See fig 7.7). * Mount all 16 bolts M8x20 (16) with loctite nr. 243 with a tightening torque of 25Nm (2,5kgm) * Mount pump gear casing without bearing journal 620.029.1200.08 . * Check dimension “C” from front side of pump gear casing till secondary coupling flange when axial clearance between primary and secondary flange of the coupling is taken away. “C” = 50,5 to 52 mm (see detail fig 7.7) * Check dimension “D” between flange sides of journal and bearing housing. “D” = 4900,,64 (see detail fig 7.7) AFTER MEASURING REMOVE SCREWS NR.2 (detail fig 7.7), THEN MOUNT 6 FIXING BOLTS (17) (with Loctite nr. 243 on a tightening torque of 120Nm (12kgm)) THROUGH THE OPENING IN THE FLANGE. - Place back plug (15) of the flange.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 20 Ed. 7 E

7.3.5.5. Taking oil sample of torsional vibration damper Procedure: - To make extraction of the oil sample more easy, the engine is preferably still hot, the viscous oil is then fluid. Take the sample as soon as possible after engine standstill. Make sure to make use of the necessary personel protective equipment such as gloves, goggles,... to avoid personal injury from the hot engine (+80°). - Remove the rectangular cover (1) from the pump gearbox. - Turn the flywheel until you can see the extraction plug (2). - Prepare the sample container (6) by removing one of its caps (7). - Remove the extraction plug (2). - Replace the extraction plug by the sample container. - If the container is put in and meets the inertia ring (5), unscrew the sample container one revolution. - unscrew the second cap (7) from the sample container. - Wait until silicon fluid begins to flow out of the free end of the sample container (8). - Screw the cap back on and remove the sample container. - Screw the second cap back on the sample container. - Clean the surface, renew the sealing (4) and screw the plug (2) back in. - Tighten the plug with 20 Nm. - Seal both plugs (2) by caulking their grooves (position indication). - Fill out the complete label inserted with the sample container. - Attach the label to the ABC maintenance document. Remark: Max. 10 samples may be taken from the same damper. Each container has a volume of 1 cm³.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.4.

FLEXIBLE PUMP DRIVE

7.4.1.

DESCRIPTION (fig 7.6)

Chapter 7 Page 21 Ed. 7 E

A flexible coupling, on which the pump driving gear is mounted, is fixed against the flange or lateral plate of the vibration damper. This flexible coupling is a spring blade coupling with similar principle as the damper itself. The outer clamping ring, the lateral plate and the intermediate plates form the outer parts, which are solidly mounted on the damper. The luboil is that of the engine and is fed over the damper to the coupling. 7.4.2.

RECAPITULATION OF MAINTENANCE JOB Code O2-12

7.4.3.

SPARE PARTS Fig. n° 7.6

7.4.4.

Jobs Complete overhaul of flexible pump drive.

Ref. n° 4

Description Spring

Qty/damper 12

TOOLS Code 620.084.3400.01

Description Tool for mounting and dismounting compression springs flexible gear driving coupling

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.4.5.

Chapter 7 Page 22 Ed. 7 E

MAINTENANCE

7.4.5.1. Dismounting To remove the flexible gear driving coupling, follow procedure described in 7.3.5.1 without removal of the damper. 7.4.5.2. Dismantling (fig 7.6) After the removal of the flexible gear driving coupling, the coupling can be dismantled as follows: - Unscrew the 6 bolts (5) to remove fastening flange (1). - Now the springs are visible. In order to remove the springs use tool 620.084.3400.01 as indicated in figure 7.9 .

Fig. 7.9 - Remove all the springs that have come loose. - Remove the tool 620.084.3400.01 . - Now the last springs can be removed from the assembly and the 2 rings (1) & (2) are seperated. 7.4.5.3. Inspection of the internal parts of the coupling - Clean the complete assembly to remove dirty oil or sludge or metal particles. - Inspection to be carried out on following parts: * Spring pack: check if there are no broken springs replace if necessary. * Inspection of the internal surfaces of the spring mounting sections. * Inspection of the gear. Check the contact surface with the vibration damper, small scratches or grooves should be removed with fine sandpaper.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 23 Ed. 7 E

7.4.5.4. Assembling (Fig. 7.6 – 7.9) - Place flange (3) on a wooden surface with the mounting holes for the springs upward. - Place the primary flange (2) with the flat surface into the flange (3) and with its flanged side upward. - Grease in the hollow mounting spaces for the springs. - Insert the first set of 6 compression springs alternating into the spring mounting holes starting between 2 visible threaded holes in flange (2) and (3). (See Fig 7.9) - Install tool 620.084.3400.01 (like in fig 7.9) and tighten to compress the first set of compression spring that are installed. - Insert the second set of 6 compression springs into the remaining hollow mounting spaces. - Release the tool 620.084.3400.01 . - Place flange (1) on top of the assembly with its flat side upward with the countersunk holes visible. - Mount the 6 bolts (5) with Loctite nr. 270 and tighten on a tightening torque of 69Nm (6,9kgm) 7.4.5.5. Mounting (Fig 7.6) To mount the flexible gear driving coupling, follow procedure described in 7.3.5.4 starting from: “ - Mounting of the spring coupling:”

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.5.

SPRING COUPLED DAMPER

7.5.1.

DESCRIPTION ( Fig. 7.10)

Chapter 7 Page 24 Ed. 7 E

The vibration damper, of the spring coupled type, is located on the free end side of the engine within the pump driving gear case and is mounted on the crankshaft cone by hydraulic expansion. The working principle is based on: - a tuning effect obtained by connecting the inner star (8) and the outer parts flange and/or lateral plate (1) + (6), tightening ring (3) and intermediate ring (2) by means of spring packs (5). - a damping effect obtained due to the pumping of lub oil from one side of the spring pack to the other side due to the relative displacement between inner and outer parts. The luboil is that of the engine and is fed to the damper through a bore in the crankshaft. Component: (vibration damper, flexible coupling) Type D50/1/1 + C41/2/58U

7.5.2.

Mass (kg) 171

Type D50/2 + C41/2/58U

171

Type D63/62 + C44/2/98U

296

Type D72/66/1 + C44/2/98U

449

RECAPITULATION OF MAINTENANCE JOBS

Code O2-16

Jobs Check condition of the spring blade type flexible pump drive. Renew if necessary.

O3-03

Complete overhaul of a spring blade type torsional vibrations damper.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 25 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.5.3.

7.5.4.

SPARE PARTS

Fig. n° 7.10 -7.11

Ref. n° 4

Description Seal O-ring

Qty/damper 1

7.10 -7.11

5

Seal O-ring

1

7.10 -7.11

8

Seal O-ring

2

7.10 -7.11

9

Seal O-ring

2

7.10 -7.11

11

Nylon protection ring

1

TOOLS

Code * 620.084.3500.02

Description Tools for mounting and dismounting vibration damper type D50 – D63 – D72

* special tools, not standard delivered with the engine (only delivered on request)

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT D50/1/1 – D50/2

0.2

0.1

M10, 2x180 An beiden Seiten des Dampfers. Onboth sides of damper

0.15 0.08

OIL RETURN HOLE

Fig. 7.10

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 26 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 27 Ed. 7 E

D63/62 – D72/66/1

0.05 0.2

D-72/66/1

M10, 2x180 An beiden Seiten des Dampfers. Onboth sides of damper

OIL RETURN HOLE

0.15

0.08

D72/66/1

Schnitt / Section D-D

M10, 2x180 An beiden Seiten des Dampfers. Onboth sides of damper

Fig. 7.11

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.5.5.

Chapter 7 Page 28 Ed. 7 E

MAINTENANCE. Required staff: 1 service man and 1 assistant.

7.5.5.1. Removing the damper from the engine - Fig. 7.10 - 7.11 – 7.12 - Before we can reach the damper, previously following parts must be removed or dismounted: * Oil filter and its support - oil pipes and connections * Control panel and its supports - wiring and connections * The water pumps, eventually the oil pumps (chapter 9) * The secondary power-take off, if existing * The pump driving gearbox with all connections (chapter 9) - Remove cover (15) with screws (14). Use 2 M10 bolts to pull off the cover. Be carefull for the sealing O-ring (13). - Remove cover (10) with screws (12). - Remove the flexible gear driving coupling from the damper after removing the 36 screws (7) and disc springs (6). - Keep care of the seal-O-rings (4) and (5). - Install lifting eye appliance delivered therefore and follow the lifting instructions below (see fig 7.11). Apply specific tightening torque per damper. * For damper D50/1/1, D50/2; tighten eye bolts on a torque of 40Nm * For damper D63/62, D72/66/1 ; tighten eye bolts on a torque of 60Nm VERWENDUNG DER ANSCHLAGMITTEL USE OF LIFTING APPALIANCES (Prinzipskizze ohne maβstab / Sketch not to scale)

im Betrreb: during service:

zum Heben: for lifting: Anzugsmoment Tightening torque

Dampfer

Dampfer

Max. 30

o Nur dos mitgelieferte Anschlagmittel (730) verwenden

o Use only the lifting appliances(730) which are supplied

o Gesamtgewicht nicht an eniem Anschlagmittel allein heben

o Do not lift total damper mass on one lifting appliance only.

o Anschlagmittel vor inbetriebnahme entfernen

o Lifting appliances must to be removed before running the engine.

Fig. 7.12

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 29 Ed. 7 E

- Secure the screwed in eye bolts with a rope to a tackle. Bring some tension to the rope. The rope and the tackle load limit must be adequately high to lift the damper masses as mentioned in 7.5.1. . - Install the tool assembly 620.084.3500.02 according to Fig.7.13a (dismounting of the damper): * Screw the tie-rod(l) in the central thread in the crankshaft. * Slide over the tie-rod: - the distance bush (2). - the hydraulic jack with thrust piece(3) provided with an extracting plate (4). - the knurled nut (5). * Unscrew cone plug ¼”G (6 - Fig. 7.2) out of the crankshaft. * Connect the oil injection kit with lengthened coupling (9) to the provided hole 1/4"G in the crankshaft (The extracting plate (4) is provided with a sleeve hole with diameter of 40 mm to clear the high pressure pipe of the oil injection kit). * Fit the extracting plate with the 8 screws (6) to the damper inner star. FOR SECURITY! :The knurled nut(5) is mounted at a clear distance of approx. 25 mm from the hydraulic jack body; this nut is used as a stop to avoid jumping away from the damper when it is releasing from the crankshaft cone. * Connect the hand pump to the hydraulic jack and the high pressure pipe to the oil injection kit and bring both pumps under pressure. - Prime the pumps until the hub releases. The oil injection kit gauge reaches pressures from 1400 to 1650 bar for damper D50/1/1 and D50/2 and pressures from 1750 to 2000 bar for dampers D63/62 and D72/66/1 for releasing the damper. On the hydraulic piston, pressures of 160 to 200 bar (for D50/1/1 and D50/2) and pressures of 200 to 280 (for D63/62 and D72/66/1) are applied for release. ATTENTION : Generally, the hub is released suddenly, all at once. - When the damper is removed form the crankshaft, remove the tooling and place the damper on wooden beams. - The tackle can be removed when the damper is fully at rest on the wooden beams.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

from handpump

from oil injection kit

DISMOUNTING DAMPER

Fig. 7.13a

from handpump

from oil injection kit

MOUNTING DAMPER

Fig. 7.13b ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 30 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 31 Ed. 7 E

7.5.5.2. Dismantling of the damper for inspection - Fig.7.10-7.11 - Pose the damper with its front side on wooden beams, taking care that only the lateral plate or flange (17) is in contact with the beams. - Release and remove all screws (18) & (19), * For D50/1/1 : in total 16 items * For D50/2 , D63/62 : in total 32 items * For D72/66/1 : in total 40 items (20x M12, 20x M20) - Remove the lateral plate or flange (20); the threaded holes used for lifting the damper (see lifting symbol) may be used to lift up the lateral plate or flange (20) from the tightening ring (21). - Again, mount provisionally a few screws (18) & (19) through the intermediate ring (22) - tighten by hand. - Turn over the damper and remove the provisionally mounted screws (18) & (19) from under the damper. Remove the lateral plate or flange (17), now on top, in the same way as for the piece (20); - The internal part of the damper is now ready for cleaning and inspection. 7.5.5.3. Inspection of the internal parts of the damper (fig.7.10 - 7.11) - Clean the complete assembly to remove dirty oil or sludge or metal particles. - Clean particularly the small oil holes in the lateral plate or flange (20) and corresponding oil groove. Do the same for the small oil holes in the inner star (8). - Inspection to be carried out on following parts: * Spring pack (25): Check if there are no broken springs. Inspect the extremity of the spring blades for wear. A slight pitting is admitted as far as the limit of wear "dimension Z" is not exceeded - see Fig. 7.14. or the wear limit “W” is not exceeded measured with the measuring wedge according the used damper. * Adjusting shims: Between the spring blades (5) is a brass shim (12). Between the spring blades and intermediate ring (2) there are adjusting shims (11). Check if these shims are not damaged, displaced out of their places. * Intermediate ring(2): Inspect for damages. * Inner star (8): Inspect the notches for the spring blades. A slight pitting is admitted as far as the limit of wear "dimension Z" is not exceeded see fig. 7.14 . Inspect the inner cone for scratches or scores, correct with emery cloth. Do the same on the contact face with the crankshaft.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 32 Ed. 7 E

* Flange and/or lateral plate (1) + (6): Inspect for roughness and possible contact with the spring blades. Remove any contact marks or roughness by emery cloth. - If no real damages are found, a further dismantling of internal damper parts is not necessary, of course as far as the limits of wear are not exceeded. 7.5.5.4. Limits of wear and allowed tolerances.

Fig. 7.14 Damper type D50/1/1

Z (mm) 0.1

D50/2

0.12

D63/62

0.26

D72/66/1

0.28

Remark for Z: Z is the max.allowed clearance on both sides of the spring blades. If the blades are pushed against one flanc of the notch on the inner star the max. allowed clearance is than 2 x Z.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 33 Ed. 7 E

A measuring wedge can be used as a testing tool. The measuring wedge is to be produced by the customer if no measuring wedge is supplied. Hereby the tool and procedure for the damper.

ca. 80mm “GO” side

“NOT GO” side

wedge length gradient 1:30 hole for dismounting

thickness of central shim – 0.2mm tolerance ±0.05 mm

thickness of central shim + “W” tolerance ±0.02 mm

spring pack

measuring wedge

inner star

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT Damper type

Chapter 7 Page 34 Ed. 7 E

Thickness central shim (mm) 1

W (mm)

B (mm)

0.2

11.5

D50/2

2

0.24

11

D63/62

2

0.52

15

D72/66/1

2

0.56

15

D50/1/1

Thickness of central shim

Permissible total wear: engagement spring with inner star groove

Measuring wedge

Seal-O-ring (general) Regardless the wear or good state apparently of the Seal O-rings, replacement of all is strongly indicated. Use only good quality of O-rings in moulded execution (seemless) we refer to the spare parts pt. 7.2.3. Seal-O-ring (8): -

The total wear must not exceed 10% of the rope diameter “d” (see fig.)

-

The total wear is the sum of the wear of the O-Ring + the depth of the run-in grooves on inner star + the depth of the run in grooves on the lateral plates (17 or 20)

-

O-Ring nominal diameter see parts list

0.1 x d

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 35 Ed. 7 E

7.5.5.5. Assembling of the damper after inspection (fig. 7.10 - 7.11) - Clean every single part carefully. Attention: All supply and venting holes must be clean and free of dirt. - Exchange all seals (O-rings,…). - Clean the screw threads on all screws (18) & (19) and the internal threads in the lateral plate or flange (17). - Exchange all disc springs under screws (18) & (19). - Grease carefully all seal O-rings (8) & (9) and the appropoiate grooves with silicone grease MOLYCOTE 111 or equivalent. - Insert O-rings 2x (8) & 2x (9) into the appropriate grooves in plate (17) and (20). - Coat inner-star (24) running surface of O-ring (8) carefully with MOLYKOTE D3484 paste or equivalent. Attention: Hazardous liquids For use refer to safety prescription card. - The coated running surfaces of O-ring (8) must be dry before damper assembly. - Coat rest of inner-star (24) with ANTICORIT OHK 380A or equivalent. Attention: Hazardous liquids For use refer to safety prescription card. - Specific coating need to be applied to the spring washers (23 & 28) under bolts (7, 12, 18 & 19) and to the threads of the bolts themselves before assembly. Make sure the bolts and washers are adequately degreased and completely dryed before coating. The specific torques (Nm) or tightening angles (°) are given in the table on next page. - Assemble the damper in the reverse order of the dismantling. Take all precautions concerning neatness. * Place flange plate (20) onto a centering table (O-ring are visible) * Place spring assembly (1, 21 & 22) onto the flange plate (20). * Insert inner star (24) Special attention needs to be taken for mounting lateral plate (17). The plate must be placed in such a way that the oil return holes (see fig. 7.10 & 7.11) are positioned in between the oil supply holes for the damper in the mounting hub (24). * Place lateral plate (17) onto spring assembly (1, 21 & 22). - Centre flange plate (17), spring assembly (1, 21 & 22) and lateral plate (20) according to the permissible concentricity / runout values as stated on page 37.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 36 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Note: An excess of 30% of the stated circularity value is still permissible, if no unbalance ploblems arise from that. - Apply enough LOCTITE 275 onto both sides of the disc spring (23 & 28) Attention: The disc spring (23 & 28) and the apropriate seat-engaging surfaces must be dry and free of grease (oil). - Mount the damper main bolts (18 & 19) according to the mounting instructions indicated below. Tightening prescription for bolts 1. Surfaces must be cleaned (degreased) 2. Enough sapecified LOcTITE must be LOCTITE applied to both sides of all marked disc spring (washers). Threading treatment according to table. a) If tightening torque is stated : Tighten bolts acc. to table (TOLERANCE + 10%) b) If twist angle is stated  Tighten bolt until disc spring rests just flat on flange or use stated initial tightening torque  Then turn bolt head further through the stated twist angle ATTENTION: Values for tightening torques (initial or final) are valid only if all surfaces are treated as stated below !

Fig. N°

Ref. N°

7.10 7 (M8-10.9) 7.10 12 (M10-8.8) 7.10 18 (M12-8.8) 7.10 18 (M10-8.8) 7.11 7 (M8-10.9) 7.11 12 (M10-8.8) 7.11 18 (M12-10.9) 7.11 18 (M20-10.9) 7.11 19 (M12-10.9) (1) : Loctite 275 (2) : Loctite 242 (3) : Molycote 1000

D50/1/1 D50/2

36 Nm 45 Nm 90 Nm

D63/62 D72/66/1

36 Nm 45 Nm 52 Nm 36 Nm 45 Nm 130 Nm

36 Nm 45 Nm 53°-58° 70°-75°

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

thread coating (2) (2) (3) (3) (2) (2) (3) (3) (3)

Disc spring coating (2) (1) (1) (2) (3) (1) (1) (1)

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 37 Ed. 7 E

Permissible concentricity / runout values Fig. N°

Damper

7.10

D50/1/1 D50/2 D63/62 D72/66/1

7.11

(1, 21, 22) in opposition to B 0.2 mm

(20) in opposition to B 0.1 mm

0.2 mm

0.05 mm

Check of concentricity / runout after tightening main bolts (18 & 19): - An excess of 30% of the concentricity / runout value is still permissible, if no unbalance problems arise form that. Exceeding this limit or when unbalance arises requires remounting and correction to obtain better values. - Exchange disc springs and clean appropriate seat-engaging surfaces. All seat-engaging surfaces must be dry and free of grease (oil). - Use the same tightening method as before. - Check concentricity / runout again. If concentricity / runout is still out of permissible values. Repeat as long as the permissible values are not reached. Note: The flange (20) and the lateral plate (17) of the D50/1/1 and D50/2 damper are not provided with centerings. Consequently center as good as possible in regard to the inner star. The best way is to have equal clearance all around it to measure with thickness gauges.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 38 Ed. 7 E

7.5.5.6. Remounting the damper on the engine. Fig. 7.10 - 7.11 - 7.13a - 7.13b - Inspect the cone of the crankshaft and polish with fine emery cloth. Inspect and polish, if necessary, also the collar against which the damper is applied. Clean with a fluffless cloth and oil slightly. - Place the nylon ring (11) over the crankshaft cone and apply it against the collar, perhaps with some grease to keep it on its place during remounting of the damper. - Mount the lifting eye appliance delivered therefore with the engine as described in 7.5.5.1 and Fig. 7.12 . - Attach the lifting appliance to a crane or tackle with a rope and lift up the damper. Mind the lifting precautions described in Fig. 7.12 . - Move the damper over the crankshaft cone and push it as far as possible over the cone. The clear distance to the crankshaft collar is about + 137 mm for 6DZCdampers and + 127 mm for 8DZC-dampers. For security reasons the tackle and rope remain, but release some tension to the rope. - Install the tool assembly 620.084.3500.02 in the way according to fig. 7.13b (mounting damper) * Screw the tie-rod (1) in the central thread in the crankshaft. * Slide over the tie-rod - the thrust plate (7) with slot for clearing the high pressure pipe. - the hydraulic jack with thrust piece and lengthening bush (8). - the knurled nut (5) * Connect the oil injection kit with lengthened coupling (9) to the provided hole 1/4"G in the crankshaft (The extracting plate (4) is provided with a hole with diameter of 40 mm to clear the high pressure pipe of the oil injection kit). - Tighten firmly the knurled nut (5) by hand. - Connect the hand pump to the hydraulic jack and give some pressure to slide the damper partly over the crankshaft cone. - Increase the pressure on the injection kit and do evenso on the hand pump to slide the damper further over the cone. Go on with this action on both pumps until the damper is applied firmly against the crankshaft collar. The oil injection kit gauge reaches pressures from 1400 to 1650 bar for 6DZCdampers, and 1750 to 2000 bar for 8DZC-dampers. On the hydraulic piston, pressures of 160 to 200 bar (6DZC) and 200 to 280 bar (8DZC) are applied. To this end check this with a 0.05mm feeler gauge to be certain there is no space between the hub (12) and nylon collar (13) and between the nylon collar (13) and the crankshaft.

-

When the hub is on its final position, release first the pressure of the oil injection kit, then on the hand pump of the hydraulic jack. When the damper is on its final position, release first the pressure of the oil injection kit, then on the hand pump of the hydraulic jack. Remove all tooling. Remount cone plug ¼”G (6 - Fig. 7.2) into the crankshaft Remounting of cover (15) with screws (14): ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 39 Ed. 7 E

* Inspect the condition of the sealing O-ring (13). Replace if necessary. To mount the sealing ring in the O-ring groove, the O-ring itself and the groove must be greased in with CERAN WR2 (Total) or equivalent. Insert the O-ring into the groove. * Inspect the mounting surface inside the hub (24). Make sure it is clean, herefore polish the surface with a fine emery cloth. * Insert carefully cover (15) with the seal O-ring (13) and mount the cover inside the hub and onto the crankshaft with bolts 4x M8-8.8 (14) to a torque of 20Nm (2 kgm). -

Remount the oil circulating plug in the crankshaft. Remount the flexible gear driving coupling see 7.6 for details. Mount the pump driving gear box with all connections (chapter 9). Remount the secondary power take off if existent. Replace the water and oil pump (chapter 9). - Remount control panel with wiring and connections. - Remount oil filters and their support. Reconnect oil pipes connections. Refer to the spare part book for necessary joints, seal-O-rings, etc. 7.5.5.7. First service of a new damper or after inspection. A new damper or an inspected one is empty of oil internally. Despite the fact that the damper is automatically vented by oil circulation over the oil circulation screws, it is advised by the prelubricating hand pump or electric pump to apply pressure on the engine oil system. If possible, through one of the free openings in the pump driving gear case, check if oil is circulating over the oil circulation screws. In this case, the damper is filled with oil, vented and ready for service. 7.5.6.

COMPLETE OVERHAUL. Complete overhaul of the damper is only needed in case of heavy deteriorations, broken parts or exceeded wear. Because of the extension of this job and the need for special tools, we advise in such cases to send back the vibration damper to the engine builder, the damper manufacturer or licencees. At this purpose consult the 'maintenance instructions' delivered with every vibration damper.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.5.7.

Chapter 7 Page 40 Ed. 7 E

TROUBLESHOOTING Inspected condition

Corrective measure

Pressure oil supply with the prelubrication pump; No oil escapes from one or more venting holes

Dismount damper; Check oil supply holes on the damper and on the crankshaft; Free oil discharge must be guaranteed

Total wear of the O-Rings (850) does not exceed the permissible value of wear

Exchange O-ring(s); Smooth and polish the run-in grooves

Total wear of the O-Rings (850) exceeds the permissible value of wear

Exchange O-ring(s); and exchange or repair worn parts.

The total wear at the spring tips (engagement with inner star grooves) exceeds the permissible value “w”

Exchange inner star (9) and spring assembly (1,2,3)

Bad oil quality / oil change or higher water content in the engine oil as permitted Effect: no damage to the engine bearings

Remove venting screw (756) (if existing) Drain damper totally (drain hole in 6 o’clock position) Fill up damper with fresh engine oil and drain damper again; repeat flushing several times

Bad oil quality or higher water content in the engine oil as permitted Effect: damage to the engine bearings

Carry out a 28.000 – 30,000 service hours inspection according to chapter 12.2

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.6.

FLEXIBLE PUMP DRIVE

7.6.1.

DESCRIPTION(Fig. 7.10 - 7.11)

Chapter 7 Page 41 Ed. 7 E

A flexible coupling, on which the pump driving gear is mounted, is fixed against the flange or lateral plate (17) of the vibration damper. This flexible coupling is a spring blade coupling with similar principle as the damper itself. The outer clamping ring (29), the lateral plate (30) and the intermediate plates (31) form the outer parts which are solidly mounted on the damper. The inner star (32) of the coupling is oscillating over the inner star of the damper. The mouvement is limited by the spring packs (33). The gear is mounted on it. The coupling inner star (32) is retained by the cover (10). The lub oil is that of the engine and is fed over the damper to the coupling.

7.6.2.

Component Coupling Type C41/2/58U for 6DZC

Mass (kg) 24,7

Coupling Type C44/2/98U for 8DZC

29

RECAPITULATION OF THE MAINTENANCE JOBS Code O2-16

7.6.3.

Jobs Check condition of flexible pump drive. Renew if necessary.

SPARE PARTS See 7.5.3.

7.6.4.

TOOLS No special tools are needed for.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.6.5.

Chapter 7 Page 42 Ed. 7 E

MAINTENANCE. Required staff: 1 service man.

7.6.5.1. Dismantling. By removing the damper from the engine (7.5.5.1), the flexible coupling becomes available in the same operation. 7.6.5.2. Inspection of the internal parts of the coupling (Fig.7.10 - 7.11) - Clean the complete assembly to remove dirty oil or sludge or metal particles. - Inspection to be carried out on following parts * Spring pack (33): Check if there are no broken rings. Inspect the extremity of the spring blades for wear. A slight pitting is admitted as far wear "dimension W" is not exceeded. See fig. 7.11 . * Spring spacer (34) Between the spring blades and the intermediate pieces (31) are coper spring spacers (34). Check if these spacers are not damaged or displaced out of their places. * Expansion shim(35): Inspect for damage. * Inner star (32): Inspect the notches for the spring blades. A slight pitting is admitted as far as the limit of wear "dimension W" is not exceeded - See fig. 7.15 . Inspect the inside diameter of the bush or bronze coating. Small scratches or scoves can be polished with emery cloth. Comprehensive damage is not allowed. Inspect the lateral faces (thrust faces), small scratches or scoves can be polished with emery cloth. See limit of wear for the radial clearance' * Cover (13): The cover has also a thrust function to absorb all lateral forces from the coupling on a small area on the outer diameter. Consequently this face may be subject to wear. See limit of wear for the axial clearance. If no real damages are found, a further dismantling of the internal coupling parts is not necessary, of course as far as the limits of wear are not exceeded.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 7 Page 43 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.6.5.3. Limits of wear and allowed tolerances.

Fig. 7.15 Coupling Type

C41/2/58U

Total wear (mm) 0.6

W(mm)

X(mm)

0.3

0.5

For 6DZC C44/2/98U for 8DZC

0.6

0.3

0.5

Axial coupling clearance mounted damper (mm) New: 0.30 – 0.40

Radial coupling clearance (mm) New: 0.08 – 0.14

Used: max. 0.60

Used: max. 0.19

New: 0.30 – 0.40

New: 0.08 – 0.14

Used: max. 0.60

Used: max. 0.19

Remark for W: "W" is the max. allowed clearance on both sides of the spring blades. If the blades are pushed against one flanc of the notch on the inner star, the max. allowed clearance is then 2 x W. This total wear limit must not be exceeded by the sum of spring wear and spline flank wear. Seal-O-rings: The wear may maximally be 5% of the original rope diameter.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 44 Ed. 7 E

7.6.5.4. Assembling of the coupling after inspection (fig.7.10 - 7.11) The assembling of the coupling is included in the remounting of the vibration damper on the engine (7.5.5.6). However, following points are to be considered : - The outer diameter, clamping ring (29), must be concentric to the damper lateral plate or flange (17) within 0,15 mm. - The outer diameter, side plate (30), must be concentric to the damper lateral plate flange (17) within 0,08 mm. - The spring washers (6) under the head of the screws (7) must be coated with OMNIFIT 250 VIOLET-M, LOCTITE GASKET 549 or equivalent. - Tighten screws (12) to the torque given in the table see 7.5.5.5. .

7.6.5.5. Pump driving gear wheel. This gear wheel is mounted on the inner star of the coupling. Inspect gear wheel for damage and/or pitting. If in good condition, no dismantling is necessary. For the gear wheels refer to chapter 9 also.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.7.

SECONDAIRY POWER-TAKE-OFF (PTO)

7.7.1.

DESCRIPTION (Fig 7.16)

Chapter 7 Page 45 Ed. 7 E

Gedeelteljjk zichf vig pijl Partial view aac. to arrow

Fig. 7.16 The strength of the crankshaft gives the possibility to drive secondary machines at the front-side of the engine. Therefore a shaft (14) is connected with the vibration damper by means of a tightening set (5). The shaft (14) is supported by a bearing housing (1) with a bush (2) that extends out of the pump gear case. The whole is sealed by a oil seal (4). An appropriate elastic coupling (12/13) brings over the necessary torque. 7.7.2.

RECAPITULATION OF MAINTENANCE JOB Code O2-09

Jobs Complete overhaul of the viscous vibration damper

O2-22

Perform an overhaul of the PTO bearing, if present

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

“x”

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT 7.7.3.

Chapter 7 Page 46 Ed. 7 E

SPARE PARTS Check the spare parts list of DZ engine.

7.7.4.

TOOLS No special tools required.

7.7.5.

MAINTENANCE

7.7.5.1. Dismantling secondary power-take-off on the engine (Fig. 7.16) Next parts first need to be dismounted before the PTO shaft (14): -

Elastic coupling (12/13). Lubricating oil pipe on top of the bearing housing (1). Dismount the bearing housing (1). The tightening set is now ready to be dismounted: * Loosen the tightening bolts evenly and crosswise in multiple steps. * In case the tightening set (5) is jammed, the outer and inner ring can be dismounted by making use of the push-off threads that are foreseen in the tightening set. * Prior to pull the PTO shaft (14) out of the tightening set (5), any rust on the shaft has to be removed to avoid damaging the tightening set (5).

- Remove the shaft (14) out of the vibration damper in the engine. 7.7.5.2. Inspection of the secondary power-take-off Inspection of the following parts is necessary: - Check the bush (2) and the oil seal (4), replace if the wear is to bigg. - Clean carefully the shaft (14), inspect the shaft for damage. - Check thoroughly the condition of the tightening set (5).

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

CRANKSHAFT

Chapter 7 Page 47 Ed. 7 E

7.7.5.3. Mounting secondary power-take-off after inspection The mounting is similar to the dismantling, but in reverse order. The bearing housing should be tightened between bearing housing and gear case with Loctite 518. Tighten the screws of the tightening set (5) with the following procedure: - Degrease the inside bore of the shaft of the vibration damper and also the PTO shaft. - Mount the tightening set over the hub of the vibration damper. The outer surface of the hub needs to be clean and slightly oiled. Leave the bolts of the tightening set loose until after the PTO shaft has been mounted into the vibration damper. - Place the PTO shaft into the vibration damper. - Tighten crosswise all the bolts to an initial tightening torque of 10Nm (1kgm). - Torn the engine and measure with a dial gauge the runout tolerance of the PTO shaft. Measure as close as possible to the tightening set. The runout measured here may be maximal be 0.03mm. (preferably even less) - If necessary, adjust shaft by tapping slightly on the shaft by means of a rubber hammer. - If the runout is 0.03mm or less, the tightening set may be permanently tightened on the prescribed tightening torque of 100Nm (10kgm) with a torque wrench. Tighten the bolts crosswise and evenly every time. Also tighten in as much steps as possible. - Measure once more the runout. Adjust if necessary. - Mounting the bearing housing with bush: * Torn the engine until dial gauge shows a runout of max. 0.03mm downward. * Mount the bearing housing with bush over the PTO shaft, and push it upward 0.03mm. This is called shifting the clearance to one side. (for information: when the engine is turning, the crankshaft and the PTO shaft will rise about 0.03mm upward “floating”). * Mount the bearing housing to the pump gear case. - Measure the runout as indicated in following figure. Runout may be max. 0.04mm .

Max. 0.04mm

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

CHAPTER 8 TIMING GEAR (Assembly 16 - 17)

8.1. 8.2.

CAMSHAFT ................................................................................................................................. 1 TIMING GEAR WHEELS ......................................................................................................... 9

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.1.

CAMSHAFT

8.1.1.

DESCRIPTION (fig. 8.1 – 8.2)

Chapter 8 Page 1 Ed. 7 E

The camshaft is located within a box integrally cast in the cylinder housing or block. For each cylinder there is a separate stump or stub assembled by means of flanges provided with centering and positionned by a dowel pin (20) and snap ring (33). Between each cylinder the camshaft is supported by means of cast iron bearing brackets (1 up to and with 4, for engines with camshaft plain bearing shells also includes 2x nr. 34 fig. 8.2). At the driving side a special stub (18) is supported by a cast iron guide bearing (23) fixed against the cylinder housing rear face. The end stub (17) is slightly different from the others. All bearings are pressure lubricated. Each stub can be removed separately. So it is not necessary to remove the complete shafting. The drive end is foreseen with a hub (17 – fig. 8.3) with shrink disc (19 – fig. 8.3) on which is mounted the camshaft gear wheel (16 – fig. 8.4). This gear is driven from the crankshaft by means of a crankshaft gear and a set of intermediate gears. All gears have helicoidal cut teeth. On each stub there are 3 cams: - Left - Centre - Right

: intake cam : injection cam : exhaust cam

Component Driving stub

Mass (kg) 8.0

Cylinder stud

18.6

Intermediate flange

1.7

End stub

15.3

Bearing bracket without camshaft bearing shells

3.8

Bearing bracket with camshaft bearing shells

3.8

Guide bearing

4.0

Half bearing shell

0.18

Remark: For prolonging reliability, engines without camshaft bearing shells can be upgraded without any adjustment to the engine with new camshaft brackets plus camshaft bearing shells.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 8 Page 2 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

Fig. 8.1 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

DOORSNEDE BB

DOORSNEDE AA

TIMING GEAR

MAINTENANCE MANUAL DZC ENGINES

Sect. 008 626.008.1100.03

TIMING GEAR

Fig. 8.2 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 8 Page 3 Ed. 7 E

Chapter 8 Page 4 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.1.2.

RECAPITULATION OF THE MAINTENANCE JOBS

Code O1-05

Jobs Visual inspection of the distribution: gearwheels, cams, camshaft bearing taps and bearings.

O2-20

8.1.3.

Renew the camshaft bearings, if present.

SPARE PARTS

Fig. n°

Ref. n°

8.1

1-4

Description

6DZC 8DZC QTY/cyl QTY/cyl

Bearing bracket for engines without camshaft bearing shells 620.017.1100.02

8.2

1-4

Bearing bracket camshaft for engines

1

1

2

2

with camshaft bearing shells 620.017.1100.03 8.2

34

Half bearing shell (620.017.9016.03)

For joints, gaskets, etc. we refer to the spare parts lists. 8.1.4.

TOOLS. No special tools are needed for.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.1.5.

Chapter 8 Page 5 Ed. 7 E

DISMANTLING OF THE CAMSHAFT (Fig. 8.1 – 8.2) Required staff: 1 service man and 1 assistant. Dismantling is only necessary in case of damage on cams, taps or bearings. CAUTION Opening a camshaft bearing without a specific reason is not advisable ! 1.

Removing a cam stump or stub.

From the considered cylinder dismount: - the cylinder head cover, the complete rocker levers with bracket and bridges (chapter “Cylinder head”) - the fuel injection pump in order to release the pump spring pressure on the tappet and roller. (chapter “Injection system”) Remove: - the camshaft box cover and the luboil pipes to the bearing brackets where necessary. - unscrew the six fixing screws (29) on the flange. - unscrew the bearing 2 screws (27) with each one washers (22). Make sure not to lose the screws and washers. - separate the two flanges by pushing the shaft to the free end side by approx. 15/18 mm. The dowel pin (20) is visible now. - tap slightly the dowel pin in such a way to free the snap ring. Remove the snap ring and tap the dowel pin out of the hole. - Remove the cam stump with bearing bracket. - Dismantle the bearing bracket (1 up to and with 4 fig. 8.1 – 8.2) . - For engines with cam shaft bearing shells (Fig. 8.2), remove the half bearing shells (34) from out of bearing bracket (1 and 2 - Fig. 8.2) Remark: To be able to remove a determined stub, it may be necessary to remove first some or other stub(s) following the table here bellow:

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR

Chapter 8 Page 6 Ed. 7 E

6DZC: Stub to remove

Stub to remove + additional stub to remove Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 X X X X X X

Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6

Cyl. 6

X X

8DZC: Stub to remove Cyl. 1 X X

Stub to remove + additional stub to remove Cyl. 2. Cyl. 3 Cyl. 4 Cyl. 5 Cyl. 6 Cyl. 7 Cyl. 8

Cylinder 1 Cylinder 2 X Cylinder 3 X X Cylinder 4 X Cylinder 5 X Cylinder 6 X X Cylinder 7 X X Cylinder 8 X By removing stub 1 and/or 2 it is also necessary to dismount the oil feed pipe to the camshaft bearing lubricating manifold. 8.1.6.

DISMANTLING OF THE GUIDE BEARING (Fig. 8.1 – 8.2) See point 8.2. Timing gear. If cam stubs and/or bearing brackets (with or without bearing shells) have to be replaced, it is advisable to remove the camshaft driving gear wheel in order to be able to rotate the shaft freely. This is usefull to check the smooth rotation and/or if no sticking of the shaft is occuring.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.1.7.

Chapter 8 Page 7 Ed. 7 E

MOUNTING OF THE CAMSHAFT (fig. 8.1 – 8.2) Required staff: 1 service man and 1 assistant. - Mount all components in reverse order from dismounting. (8.1.5.) - For engines with camshaft bearings: - For mounting bearing shells the bearing seat (1) and cap (2) must be fully dry. Neither oil nor grease present. - The half bearing shells must also be fully dry especially the back side that is to be mounted. - When mounting a camshaft bearing shell, no special attention must be given on which bearing shell to mount in the seat or the cap because the shells are identical. - Attention : when mounting a shell, pay special attention that the locating lugs of the shells are placed correctly in the notches of the bearing seat and cap. - Make sure the bearing shells are even with the mounting surface per half bearing seat. - Refer to the tightening torque table for the different torques for mouting bearing bolts. (See chapter general: 5. Tightening torques) - Pay much attention to locate the dowel pin (20) and snap ring (33) in order to adjust correctly the camshaft stubs. - The intermediate flange is mounted with both faces coated with LOCTITE 549 or equivalent. - For other components see pt.8.2. and chapters 1 & 4 . Clearance verification (See fig. 8.1 – 8.2) After the complete camshaft has been mounted, the camshaft diametrical and axial clearance needs to be verified. The following table indicate the min. and max. values for new built engines. Diametrical camshaft clearance (mm) in guide bearing (23)

min 0,07 – max 0,13

in bearing brackets (1)

min 0,10 – max 0,16

in bearing brackets (1) with camshaft bearing shells

min 0,10 – max 0,17

Axial camshaft clearance (mm) at guide bearing (23)

min 0,08 – max 0,12

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.1.8.

Chapter 8 Page 8 Ed. 7 E

RUNNING-IN AFTER PARTS REPLACEMENT. If camstubs, bearing shells or bearing brackets are replaced it is advisable to slowly increase the engine speed to obtain the full speed only after a few hours. Temperature measurement on bearing brackets can be usefull to check running in process.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.2.

TIMING GEAR WHEELS

8.2.1.

DESCRIPTION (fig. 8.3 – 8.4)

Chapter 8 Page 9 Ed. 7 E

The timing gear includes the following gear wheels: - a gear wheel in 2 parts (1 & 2) mounted against a flange integral with the crankshaft. For this purpose special screws (4) are used. - a set of two roller gear wheels (9 & 11) running on a shaft (12) which is fixed in a bearing bracket (5). The two gears are bolthed together with screws (13) and located by an elastic pin (15). - the camshaft drive gear (16) is mounted on a hub or boss (17) which is fixed on the camshaft by a clamping system “Dynamobloc” (19). All gears are inclosed within the engine by the flywheel side covers, the crankcase and timing gear cover (18) and some small lateral covers. Gear tooth flanc clearance is adjustable. All gears are made from high tensile steel and have helicoidal cut teeth. The idler gears shaft is pressure lubricated and gearwheels are lubricated by oil jets arranged between them. This arrangement is different depending the rotation direction A or K.

8.2.2.

Component Crankshaft gear wheel

Mass (kg) 10.35

Idler gears and bracket bearing

33.25

Camshaft gear wheel

19.10

Timing gear cover

47.00

Recapitulation of the maintenance jobs. Code O1-05

Jobs Visual inspection of the distribution: gearwheels, cams, camshaft bearing taps and bearings.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

Doorsnede

BB

CIL. 1

TIMING GEAR

Chapter 8 Page 10 Ed. 7 E

5 17 33

13

19 31

14

22 12 6

15 10

7 8

11

9 30

20

32 3

21

4 2

Fig. 8.3

1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR

Chapter 8 Page 11 Ed. 7 E

34

B Doorsnede

AA

18 27

90,10±0,05

(198,7708)

C

323,32 ±0,03 Instelbaar

Instelbaar

16 290,63±0,03

580,4±0,05

380,4±0,08

26

B

200±0,03

23

C 28 25

A

A

29

24

Fig. 8.4 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.2.3.

SPARE PARTS

Fig. n° 8.4

8.2.4.

Chapter 8 Page 12 Ed. 7 E

Ref. n° 23

Description Distance washers 0.40; 0.35; 0.30; 0.25 mm

Qty/engine 4x4

TOOLS No special tools are needed.

8.2.5.

DISMANTLING OF THE TIMING GEAR (fig. 8.1 – 8.2 - 8.3 – 8.4) Required staff: 1 service man and 1 assistant. Dismantling of the timing gear can be arranged in two stages. 1. -

Dismantling of the camshaft gear wheel and guide bearing. remove the hydraulic governor and the governor gear case (chapter 5). remove the timing gear case. remove the governor case driving gear wheel. remove the screws (33) and take away the gear wheel (16). remove the hub (17), the dynamobloc (19) and the driving stub (18) as a unit by removing the screws (29 fig 8.1 – 8.2) on the stub flange and the screws (29 fig 8.1 – 8.2) on the guide bearing (23 fig. 8.1 – 8.2). Remove the oil lubricating pipe on the guide bearing. If further dismantling is necessary loose the dynamobloc (19) by following procedure: - loose all screws and remove the three with a different colour. - in their places insert some longer screws with M12 threads instead of M10. - strike slightly on the underside of the screw heads with a drift in order to free the bicones. - by means of a press, the hub can now be pushed from the driving stub to free the guide bearing.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 2.

Chapter 8 Page 13 Ed. 7 E

Further dismantling of idler gear wheels and crankshaft gear wheel.

This dismantling is only necessary in case of damage to the gear wheels proceed as nr. 1 herebove and go on: - remove the oil supply pipes to the idler gear bracket (5 fig. 8.3). - loose the screws (28 fig. 8.4) and remove the dowel pin (24 fig. 8.4) with nut (29 fig. 8.4). - take away the bracket with idler gears (9 & 11 fig. 8.3) by loosing the four screws (8 fig. 8.3) with adjusting bushes (7 fig. 8.3), the cap (6 fig. 8.3) can be removed and the shaft (12 fig. 8.3) becomes free as the gear wheels (9 & 11 fig. 8.3). Gear wheel (9 fig. 8.3) is provided with a bronze bush (10 fig. 8.3). Both gear wheels are mounted together with screws (13 fig. 8.3) and elastic pin (15 fig. 8.3) for the positionning to each other. Note: The idler gear wheels bearing bracket is provided with: - distance washers (23 fig. 8.4) for vertically adjustment - slots and a dowel pin (24 & 29 fig. 8.4) for laterally adjustment. This adjustement provides the facility to set the right gear tooth backlash between : - the crankshaft gear (1 fig. 8.4) and corresponding idler gear (11 fig. 8.3) vertically - the idler gear (9 fig. 8.3) and the camshaft driving gear (16 fig. 8.4) laterally Remove the crankshaft gear wheel (1 fig 8.3) by removing the screws (4 fig. 8.3) and the special bolts (20 fig. 8.3) with the adjusting bushes (3 fig. 8.3). This gear wheel is positionned to the crankshaft flange by the dowel pin (21 fig. 8.3). This gearwheel is composed of 2 halves and mounted to form an assembly with another two halve rings which are in 90° opposition to 2 half gears. One of this halve rings is provided with 2 threaded holes for dismounting purpose. 8.2.6.

MAINTENANCE. New gear wheels have only to be fitted in case of severe damage (broken tooth or similar) or in case of excessive wear (when it is no longer possible to adjust the clearances) Slight pitting of the faces or slight burrs on the teeth do not necessitate renewal. Any burrs should be removed with a smooth file or stone. Inspect the side faces of idler gears (9 & 11 fig. 8.3) and the inner side contact faces on the bearing bracket (5 fig. 8.3). If any roughness remove burrs and polish with fine grain emery cloth.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 8 Page 14 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.2.7.

ASSEMBLY OF THE TIMING GEAR (fig. 8.3 - 8.4 – 8.5) Required staff: 1 service man and 1 assistant. 1.

Mounting the gear wheel on the crankshaft.

Mounting of this gear wheel is a precise job and accessibility is limited: - bring the 2 half gears and the half rings together over the crankshaft tap and mount with adjusting bushes (3 fig. 8.3) and screws (4 fig. 8.3). - push the assembly against the mounting flange on the crankshaft and with the dowel pin (21 fig. 8.3/8.5) in the slot provided for. - mount the special bolts (20 fig. 8.3) through the flange, bushes and the complete assembly and tighten the nuts according to the torque table.

MARK FACE ADJUSTABLE TO CORRECT BACK LASH

PIN(22)

ELASTIC PIN(15) MARK

DOWEL PIN(21)

DOWEL PIN(21) - (MARK) - ELASTIC PIN(15) IN LINE PIN(22) IN CENTER WITH 0 MARK ON CAMSHAFTWHEEL IN LINE WITH GEAR-CASE MOUNTING FACE

Fig. 8.5 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 2.

Chapter 8 Page 15 Ed. 7 E

Mounting of the idler gear wheels.

- Assemble the idler gear wheels (9 & 11 fig. 8.3/8.5) together with screws (13 fig. 8.3) and elastic pin (15 fig. 8.3) to position each to another. - slide assembly on the shaft (12 fig. 8.3) with some oil and mount in the bearing bracket (5 fig. 8.3) with the cap (6 fig. 8.3) and screws (8 fig. 8.3) over the adjusting bushes (7 fig. 8.3). Tighten screws according to the tightening torque table in chapter General 6-8DZC. Screws (8 & 13) are to secure by LOCTITE 245 or equivalent. - Bar over the engine to bring crankpin of cylinder 1 at TDC (see reference mark on the flywheel). In this position the dowel pin (21) is at the lowest level (see fig. 8.5) or check the indication on the flywheel (see chapter injection system fig. 4.8b). - Now place the assembly bearing-bracket/idler gears to mesh with gear (1 fig. 8.3/8.5) in such a way that the mark on idler gear (11 fig. 8.3/8.5) is in the center line of the dowel pin (21 fig. 8.3/8.5). Pose under the 4 legs of the bearing bracket distance washers (23 fig. 8.4) of same tickness. Fit and tighten the four screws (28 fig. 8.4) firmly. - By means of a dial gauge with the pointer at square angle to the tooth flank measure the backlash by rocking the idler gear. Backlash is given in the table hereafter. - If not correct some distance washers must be added to increase backlash or some must be removed to reduce backlash. Bear in mind that the total tickness of the washer under each leg must be equal. Normally 1 tickness of the available washers is sufficient to do the adjustement. 3.

Mounting the camshaft gear wheel and guide bearing.

- If the hub (17 fig. 8.3), the dynamobloc (19 fig. 8.3) and the driving stub (18 fig. 8.1/8.2) have been removed as a unit together with guide bearing (23 fig. 8.1/8.2), it can be remounted again as a unit. Fit the screws (29 fig. 8.1/8.2) on the stub flange and the screws (29 fig. 8.1/8.2) on the guide bearing. Tighten the screws according to the tightening torque table (see chapter General 6-8DZC). Remount the oil lubricating pipe on the guide bearing. With a dial gauge on the shaft end, check the axial clearance; to be between 0,08/0,12 mm. - If the above parts are not removed as a unit proceed as follows: * mount the driving stub (18) on the cylinder 1 stub with screws (29 fig. 8.1/8.2) and tighten according to the tightening torque table. * slide the guide bearing (23 fig. 8.1/8.2) over the stub and position it over the two pins (one slattened (24) - one straight (26) fig. 8.1/8.2). Tighten screws on torque (see tightening torque table: chapter General 6-8DZC). * if a new guide bearing is mounted, remove the pins (24 & 26 fig. 8.1/8.2) from the cylinder housing. Push the guide bearing in the uppermost position and tighten the screws.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR

Chapter 8 Page 16 Ed. 7 E

* Probably the pin holes may not correspond any more. Proceed as follows : * bore and reem two new holes and fit the pins. * or bore and reem on a slightly greater diameter in the same holes and fit bigger pins. * To mount the hub (17 fig. 8.3) with dynamobloc (19 fig 8.3), the hub must be heated slightly on a heating plate to approx. 100/120°C. * Push and maintain the camshaft in the direction to the flywheel. Slide the hub over the stub to fit wel against the collet. Release the camshaft and let cool down. - Position the dynamobloc (19) span set and tighten the screws in several stages following the diametral opposed figure. It is most important to measure the radial and axial deviation with a dial gauge on the hub centering flange and mounting face for the camshaft gear (16 fig. 8.4). If not correct, by tightening or releasing the screws on the span set this deviation must be corrected as close as possible with: * max. radial deviation : 0,03 mm * max. axial deviation : 0,03 mm - Fit the pin (22 fig. 8.3/8.5) on the hub and place the camshaft gearwheel in such a way that the mark is in line with the gearcase mounting face (see fig 8.5). Now rotate the camshaft to bring the pin in position with the hole provided on the gear wheel (fig. 8.4/8.5). Fit the screws (33 fig. 8.3) and tighten on torque (see tightening torque table chapter General 6-8DZC). - Check all timing marks and pin positions again according to fig. 8.5 . - Adjust the backlash between idler gear (9 fig. 8.3/8.5) and camshaft gear (16 fig. 8.4/8.5) by loosening the screws (28 fig. 8.4) on the bearing bracket and by sliding it sidewards until the correct backlash is obtained. Backlash is to be measured by means of a dial gauge placed on the camshaft gear with the pointer at square angle to the tooth flank. The idler gears are blocked in position by wooden wedge. Measure by rocking the camshaft gear. Backlash is given in the table hereafter. Tighten screws (28 fig. 8.4) on torque (see tightening torque table chapter General 6-8DZC). Probably the pin holes may not correspond any more. Proceed as follows: * bore and reem a new hole and fit the pin * or bore and reem on a slightly greater diameter in the same hole and fit a bigger pin. - Remount all lubricating oil pipes for the gear lubrication. - Remount the timing gear case and the governor gear case (chapter 5). - Mount the governor and connect to the engine (chapter 5).

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

TIMING GEAR 8.2.8.

Chapter 8 Page 17 Ed. 7 E

GEARWHEEL BACKLASH TOLERANCES. See fig. 8.5 . Gearwheels

New Condition

1 & 11

0,17 to 0,28

Adjustment required > 0,5

Sens of adjustment Vertical with washers 0.40; 0.35; 0.30; 0.25 mm (23 fig. 8.4)

9 & 16

0,15 to 0,26

> 0,5

Lateral sliding of bearing bracket (5 fig. 8.3/8.5) with idler gears.

Total

0,32 to 0,54

> 1,0

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.1/60 date: 6/July/2016 Ed. 07 EN

CHAPTER 9 ENGINE DRIVEN PUMPS (Assembly 15 – 30 – 34 – 35 – 40) (41 – 45 – 50 – 51 – 151)

9.1. 9.2. 9.3. 9.4. 9.5. 9.6. 9.7. 9.8. 9.9.

PUMP GEAR CASE. ............................................................................................................... 2 FRESH WATER PUMP (H.T.- WATER PUMP). ............................................................. 16 SEA WATER PUMP. ............................................................................................................ 21 FUEL FEED PUMP (SF2/8) ................................................................................................. 30 FUEL FILTRATION ............................................................................................................ 35 LUBRICATING OIL PUMPS / PRESSURE VALVES. ................................................... 39 HAND PUMP. ........................................................................................................................ 52 THERMOSTATIC VALVE OIL CIRCUIT ...................................................................... 54 THERMOSTATIC VALVE WATER CIRCUIT ............................................................... 56

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.1.

PUMP GEAR CASE.

9.1.1.

DESCRIPTION (fig. 9.1. - 9.2. - 9.3. - 9.4.)

Ch.9 p.2/60 date: 6/July/2016 Ed. 07 EN

The pump gear case (2) is fixed to the crankcase by means of an intermediate flange (3)

The pump gear case contains : - the torsional vibration damper with elastic coupling for the pump driving gearwheel (16) - the intermediate shafts for driving the oil and the water pumps (15) - the intermediate shaft (14) for driving the water pump and the fuel feed pump The pump gear case front side is provided to support -

the fresh water pump or HT-pump the sea water pump or LT-pump the oil pumps (lubricating and scavenge in case of dry sump) the fuel feed pump a free driving available behind the cover a lubricating oil relief valve

The pump gear case front side is provided with a central bore to receive a support bearing for a secondary power take-off shaft.

To be able to reach the pump gearcase for dismounting, first following parts must be removed: -

the control box and support. the lubricating oil filters and support - lub oil piping. the water pumps and water piping. the oil pump and oil piping. the fuel feed pump with fuel piping. the secondary shaft if existing. other driving if existing.

Component

Mass (kg)

Pump gear case provided with the 4 intermediate shafts & roller bearings

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

181

Ch.9 p.3/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.1.2.

RECAPITULATION OF THE MAINTENANCE JOBS Code

Jobs

O1-06

Inspect the pump driving gear wheels in the gearcase.

O2-08

Check the gearwheels pumpcasing,.

See B34 chapter driven pumps” – case”

Renew the bearings. Visually check the gearwheels and measure the gearwheel clearances.

9.1.3.

SPARE PARTS

Fig. n°

Ref. n°

Description

Qty/engine

9.1

5

Joint (free end cover)

1

9.1

7

Joint (cover)

1

9.3

53

Seal O-ring

4

TO FORESEE AT OVERHAUL 03-06 or 48.000 Service Hours. 9.3

28

Tapered roller bearing

2 or 3

9.3

29

Tapered roller bearing

1

This table only deals with spares for pump gear case. Joints and washers for the pipes connected to it, are mentioned in the spare parts list.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Ch.9 p.4/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS Section Doorsnede AA

D

4-5

Fig. 9.1 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.5/60 date: 6/July/2016 Ed. 07 EN

36-56

39-57

B

B

A30-5 A30-4

Fig. 9.2

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.6/60 date: 6/July/2016 Ed. 07 EN

Section Doorsnede BB

A40-17 / A41-42

A40-17

Detail D

Section Doorsnede CC

Fig. 9.3

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.1.4.

Ch.9 p.7/60 date: 6/July/2016 Ed. 07 EN

TOOLS All tools hereafter are only used for roller bearing replacement except the eye bolt. Code

Jobs

*620.084.4200.01

Ram for mounting inside bearing ring diam. 34,925 mm

*620.084.4300.01

Ram for mounting inside bearing ring diam. 34,925 mm

*620.084.4400.01

Tool for mounting/dismounting distance ring diam.34,925 mm

*620.084.4500.01

Tool for mounting/dismounting distance ring diam.45,242 mm

*620.084.4600.01

Ram for mounting inside bearing ring diam. 45,242 mm

*620.084.4700.01

Ram for mounting inside bearing ring diam. 45,242 mm

*620.084.4800.01

Stop for intermediate shaft for mounting bearing d.45,242mm

*620.084.4900.01

Ram for mounting intermediate gear driving water pumps

*620.084.5100.02

Ram for mounting radial joint ring in pump casing

*620.084.9008.01

Ram for mounting outside rings of bearing diam. 34,925 mm

*620.084.9009.01

Ram for mounting outside rings of bearing diam. 45,242 mm

100.933.012.000

Lifting eye bolt.

* Special tools, not standard delivered with the engine (only delivered on request) 9.1.5.

INSPECTION OF THE PUMP DRIVING GEAR WHEELS During the overhaul of the pumps, the internal parts (gear wheels) of the pump driving case become visible and accessible. Inspect visually the gears, teeth and freedom of rotation of the roller bearings. Dismounting of the gear case is only necessary in case of damage (breakage of teeth), damaged roller bearing or exaggerated wear. This means when the flank clearance or backlash exceeds 0,35 mm. Replacement of roller bearings is recommended at maintenance interval O3-06 (48 000 service hours). Remark : Do not mix the different parts of a roller bearing set with these from another set, they are factory adjusted ! File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.1.6.

Ch.9 p.8/60 date: 6/July/2016 Ed. 07 EN

DISMOUNTING - Fig .9.1 - 9.2 – 9.3 Required staff: 1 service man. 1.

Dismounting the gear case - removing from the engine.

If the gear case is free of all mounted components and if the oil level is lowered sufficiently (wet sump), it can be dismounted: - remove all screws M20 (36,37). The gear case now rests only on the two pins (23,33). The intermediate case (3) engine must not be removed. - place the lifting eye bolt in the provided thread M12 and fix it with a rope to a crane or tackle. Bring some tension on the rope. - four holes with thread M10 are provided to push-off the gear case. - during this operation, take great care not to damage the gear wheels. - inspect the pump driving gear wheels as under 9.1.5. - if they all are in good condition and if the tapper roller bearings should not be replaced, no further dismantling is necessary. - clean the gear case from eventual sludge or deposits. 2.

Dismounting of the intermediate shaft driving water pump(s) (Fig. 9.3. - 15)

- Remove the lock nut (30), safety ring (31) and the pressing ring (24) - Remove the gear wheel (18) with a part of the roller bearing (28), the first roller row, the two outer rings and the distance ring. The second roller row is on the shaft. - With a copper drift gently knock-out the outer rings. Knock alternately on opposite diameter to avoid jamming of the ring in the bore. - The distance ring may now be removed from the gearwheel by the special tool 620.084.4400.01 - fig. 9.4 and a circlips plier.

Tool: 620.084.4400.01

Fig. 9.4 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 3.

Ch.9 p.9/60 date: 6/July/2016 Ed. 07 EN

Dismounting of the intermediate shaft driving fuel feed pump (Fig 9.3 - 14).

- Avoid the rotation of the gearwheel (17) by interposing a copper plate between gears (18) or (22) - Remove the nut (30), safety ring (31) and the pressing ring (24) - Remove the gearwheel (17) - With a copper drift knock slightly on the shaft, the first roller row becomes free, the second row is on the shaft. - With a copper drift gently knock out the outer rings. Knock alternately on opposite diameter to avoid jamming of the ring in the bore. - The distance ring may now be removed from the gear case by the special tool 620.084.4500.01 - fig.9.5 and a circlips plier.

Tool: 620.084.4500.01

Fig. 9.5 4.

Dismounting of the intermediate shaft driving sea water pump (15)

- Remove the four screws (45) and take apart the gear wheel (22) - Now proceed in the same way as for 2). 5.

Dismountng of the intermediate shaft driving oil pump (15)

- Remove the four screws (44) and take apart the gear wheel (19) - Now proceed in the same way as for 2).

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.1.7.

Ch.9 p.10/60 date: 6/July/2016 Ed. 07 EN

REPLACEMENT OF ROLLER BEARINGS Required staff: 1 service man. Clean all parts, specially the small lub oil bores! 1.

Mounting of the intermediate shafts driving oil/water pump (15)

For the two or three shafts (depending the application) the principle is identical. - Mount the second roller row with special tool 620.084.4200.01 indicated on fig 9.6 below.

Tool: 620.084.4200.01

Press or hammer

blow

Fig. 9.6 - Place the distance ring in gearwheel groove. For easy job use tool 620.084.4400.01fig.9.4. - Place the distance ring over the shaft in such a way that the gap lets an oil bore free. - Mount in the gearwheel bore the two outer bear.rings with a ram tool 620.084.9008.01 . Use a press or hammer it in carefully - see fig.9.7. - Place the gear wheel on the shaft - Mount the first roller row with the special tool 620.084.4300.01- fig.9.8. - Place the pressing ring (24) with safety ring (31) and tighten lock nut (30) according the torque table (See General 5: Tightening torques).

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.11/60 date: 6/July/2016 Ed. 07 EN

Tool: 620.084.9008.01

Press or hammer blow

Fig. 9.7 Tool: 620.084.4300.01

Press Hammer blow

Fig. 9.8 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

or

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 2.

Ch.9 p.12/60 date: 6/July/2016 Ed. 07 EN

Mounting of the intermediate shaft driving fuel feed pump (14).

- Mount the second roller row with special tool 610.084.4600.01 - fig.9.9.

Press or Hammer blow

Tool: 620.084.4600.01

Fig. 9.9 Tool: 620.084.9002.01

Press Hammer

blow

Fig. 9.10

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

or

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.13/60 date: 6/July/2016 Ed. 07 EN

- Place the distance ring in the housing (gear case) groove. For easy job, use tool 620.084.4500.01 - fig.9.5. Place the ring in the housing in such a way that the gap lets the oil bore free. - Mount in the bore the two outer rings with a ram -tool 620.084.9002.01 - See fig. 9.10. Hammer it in carefully. - Now place the shaft in the bore and stop it with tool 620.084.4800.01 provided for. At the other end of the shaft a ram - tool 620.084.4700.01 - fig.9.11 is used to hammer in the first roller row of the bearing. Do not forget to place first the distance ring over the shaft.

Tool: 620.084.4800.01

hammer blow

Press or

Tool: 620.084.4700.01

Fig. 9.11 - Place the gearwheel (17) with tool 620.084.4900.01 - fig. 9.12 . Tool: 620.084.4900.01

Press or hammer blow

Fig. 9.12 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Ch.9 p.14/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

- Smear the shaft and the bore with grease Shell Alvania R or equivalent - Place the radial oil seal (50) with a ram - tool 620.084.5100.02 - fig.9.13 . Push it in by hand and by knocking with the hand on the ram. If necessary knock only slightly with a hammer on the ram.

Tool: 620.084.5100.02

Push in or hammer slightly

Fig. 9.13 9.1.8.

MOUNTING THE GEAR CASE ON THE ENGINE - Fig.9.1 - 9.2 - 9.3 Required staff: 1 service man and 1 assistant. Clean all parts, especially clear the contact surfaces from all rests of Silastic (Silicon Sealant). 1.

Mounting on the engine.

- Place the lifting eye bolt in the provided thread M12 and fix it with a rope to a crane or tackle. - Measure the backlash clearance between the gear teeth flanks (see table with values hereafter) - Smear the mounting face of the gear case with Loctite 574. - Present the gear case over the two pins (23) and (33) and push it against the mounting face of the intermediate plate (3). - Measure the backlash between the central gear (16 – Fig 9.1) and gears (17 & 19 Fig 9.1). Minimum required backlash approx. 0,10 mm. If on one side too much and File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.15/60 date: 6/July/2016 Ed. 07 EN

the other side too less backlash is measured, the pump gear case can be pulled upwards or downwards depending the case, to equalize somewhat the backlash. - Tighten the gear case with the screws (36, 37). Tighten them all around according to the torque table. 2.

Normal backlash.

Backlash is in principle not adjustable. Small changes are only possible by: - pulling the gear case over the pins (upwards or downwards). - pulling the pumps laterally in their housings. The backlash is measured by miniature dial gauge or puppitaster. Place the pointer at square angle on.a tooth flank and move the gearwheel by hand; the other wheels of the system must be kept standstill. It is advisable. to measure over about 4 places around the gearwheel. Since it is very difficult, due to accessibility, to measure backlash with the pump mounted, it is advisable to do it when the gear case stands still apart from the engine, the pumps being mounted temporarily. Backlash tolerances (ref. to fig. 9.1 till 9.3 for gear numbers) Gearwheels 16/17

Backlash tol. (mm) 0.10 to 0.22

17/18

0.09 to 0.19

18/HT-pump (A40-17)

0.09 to 0.19

17/22

0.09 to 0.19

21/LT-pump (A40-17 / A41-42)

0.10 to 0.20

16/19

0.10 to 0.22

20/luboil pump (A30-4)

0.09 to 0.19

20/scavenge pump (A30-5)

0.09 to 0.19

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.2.

FRESH WATER PUMP (H.T.- WATER PUMP).

9.2.1.

DESCRIPTION (Fig. 9.14 (a,b) )

Ch.9 p.16/60 date: 6/July/2016 Ed. 07 EN

The fresh water pump is a centrifugal pump driven from the crankshaft by a gear train and flanged on the pump driving gear case. The fresh water pump keeps the H.T. water in circulation over the engine i.e. over cylinder housing, cylinder heads, turbocharger and heat exchanger. The pump is not self-priming; consequently it must be provided with the necessary vent plugs. For the same reason the HT-circuit must be adequately vented to avoid any air trap. The pump consists of: -

a shaft (21) with taper dubble roller bearing (25). a driving gear (17) a blade wheel (6) fixed on the shaft with a fixing nut (8) and lock ring (7) water tightness is assured by a mechanical shaft seal (14) and a rotary shaft seal (15) the rotating assembly is mounted in the body (1) and provided with cover (4) which includes the bearing housing. - bearing lubrication is assured by oil projections from the gear case. Component

Mass (kg)

Fresh water pump complete 6-8DZC

9.2.2.

33.6

RECAPITULATION OF THE MAINTENANCE JOBS Code O1-03

Jobs Overhaul of the seawater pump, softwater pump. Check the anodes in the cooling water circuit and renew if necessary.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Ch.9 p.17/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.2.3.

9.2.4.

SPARE PARTS Fig. n°

Ref. n°

Description

Qty/pump

9.15

14

Mechanical shaft seal

1

9.15

7

Lock ring

1

9.15

13

Distance washer

1

9.15

25

Double row tapper roller bearing

1

9.15

15

Rotary shaft seal

1

9.15

3

Seal O-ring

1

9.15

16

Seal O-ring

1

9.15

11

Joint

1

TOOLS Code 620.083.9002.01

Description. Tool for removing fresh water pump Pliers for circlip with straight jaws for inner diameter

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Ch.9 p.18/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE MANUAL DZC ENGINES

A Suction side

Zungzijde

I

X

Section A-A

Doorsnede A-A

A

Perszijde

Delivery side

Direction of rotation

Draaizin

ENGINE DRIVEN PUMPS

Fig. 9.14 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.19/60 date: 6/July/2016 Ed. 07 EN

Tool: 620.083.9002.01

Fig. 9.15 9.2.5.

DISMANTLING OF THE PUMP (fig.9.14 and 9.15) Required staff: 1 service man. 1. -

2.

Removing from the engine. Drain the fresh water circuit. Drain the water from the pump with drain cock (28). Disconnect the flanges from suction and pressure pipes. Remove the screws (2) securing the pump on the gearcase and take apart the pump as a unit. Special press screws M14 tool 620.083.9002.01 can be provided for this purpose. Dismantling the pump.

- Remove the cover (4) by unscrewing screws (12) - Place the complete pump in a vice by fixing the gearwheel between the jaws using protection pads in soft material. Unlock the ring (7) and remove the fixing nut (8) by using a wrench (key size 30) through the pressure bore (outlet). Be carefull this nut is a left tightening nut, for unscrewing turn clockwise! - Further unscrew (counter clockwise) the blade wheel (6) from the pump shaft (21). - Unlock the lip of ring (19) from off the 2 nuts (20) and loosen the nuts. Followed by removing the pump gear (17), doing this by slightly ticking the gear free with a plastic or wooden hammer. Remove the inner pressing ring (18). - Next unscrew the screws (23) and remove the pressing ring (24). - Now to remove the shaft (21) with the bearing (25), one must tick with a wooden hamer on the shaft from the pump side to the gear side. Tick until the shaft is clear. - When the shaft with the bearing is removed, the mechanical seal (14) and rotary shaft seal (15) may be removed from the body (1). - For renewal of the taper roller bearing, To remove the bearing one can use a press for removing the bearing from the shaft. File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.20/60 date: 6/July/2016 Ed. 07 EN

- In case a new taper roller bearing (25) must be fitted, do not forget to install the inner spacer ring of the bearing for the exact axial clearance. 9.2.6.

INSPECTION OF PARTS Check if the following parts are in good condition - The impeller and its fixing onto the shaft with fixingnut. Slight cavitation signs at the roots of the blades are acceptable. If some material is missing at the blades, rendering it less stronger then it is recommended to change the blade wheel, also in case of other damage. - The taper dubble roller bearing. - The gear wheel. Damaged seals must be renewed. When such a complete dismantling occurs, renewal of shaft seals (14 & 15) is highly recommended.

9.2.7.

ASSEMBLY Required staff: 1 service man. 1.

Assembling the pump

- The procedure is the reverse of the dismantling procedure - If the blade wheel has been renewed after assembly, the clearance X must be measured. Value: 0,3 to 0,7 mm. This distance, if not correct, can be modified by means of the distance washer (13) between the body (1) and the cover (4). - Tighten the nuts (20) according to the torque table and secure with a new lock ring securing the 2 nuts. The upper side and only the upper side of the lock nut (=nut side) must be greased in with Molykote. - Screw on the blade wheel (6) turning clockwise and tighten according to the torque table. Use for this LOCTITE nr.245. - Install lockring (7) and tighten nut (8) according to the torque table. Attention this nut is a left turned nut therefore tightening must be done turning counterclockwise. Use for this LOCTITE nr.270. - For all threads carefully search for the beginning of the thread avoiding damage to the thread. 2.

Fitting on the engine

- Mount in reverse order from removing. Take care not to damage the gearwheels by introducing the pump into the gear case. - After remounting on the engine, the flank teeth clearance must be checked. See table under 9.1.8 (Backlash tolerances table). - Connect the water piping and check for tightness. File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.3.

SEA WATER PUMP.

9.3.1.

DESCRIPTION (fig. 9.16 & 9.17)

Ch.9 p.21/60 date: 6/July/2016 Ed. 07 EN

The sea water pump is a self priming rotary pump, driven from the crankshaft by a gear train and flanged on the pump driving gear case. The sea water pump provides the cooling water for the charge air cooler, the lub oil cooler and the heat exchanger (fresh water cooler).

The pump consists of: - a shaft (12) with roller bearings(14 and 18). - a driving gear (42) - an impeller (27) with distance ring (26) and two port plates (25), one at each side of the impeller. The impeller is fixed on the shaft with a key (5), a nut (3) with washer (4). - water tightness is assured by mechanical seal with contact ring (23) and a rotary seal (20) and a water thrower (21). - the rotating assembly is mounted in a bearing housing (13) and in two half bodies (1 and 7), sealed together with a seal-O-ring (6) and a V-clamp system with nuts and bolts(34). - lubrication by oil supply from the engine - the presence side is provided with a pressure relief valve Component Sea water pump complete for 6DZC

Mass (kg) 70.4

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.3.2.

Ch.9 p.22/60 date: 6/July/2016 Ed. 07 EN

RECAPITULATION OF THE MAINTENANCE JOBS Code

Jobs

M1-03

Clean water filters if provided.

O1-03

Overhaul of the seawater pump, softwater pump. Check the anodes in the cooling water circuit and renew if necessary.

9.3.3.

SPARE PARTS Fig. n°

Ref. n°

Description

Qty/pump

9.15

6

Seal O-ring

1

9.15

9

Tab washer

4

9.15

14

Roller bearing

1

9.15

15

Locking washer

1

9.15

18

Roller bearing

1

9.15

19

Seal collar

1

9.15

20

Rotary shaft oil seal

1

9.15

21

Water thrower

1

9.15

23

Mechanical seal with contact ring

1

9.15

24

Seal spacer

1

9.15

30

Shim 0.25 (as required)

1

9.15

31

Shim 0.35 (as required)

1

9.15

38

Tab washer

1

9.15

48

Seal O-ring

1

9.15

49

Seal O-ring

1

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

X

X

ENGINE DRIVEN PUMPS

Ch.9 p.23/60 date: 6/July/2016 Ed. 07 EN

Fig. 9.16 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.3.4.

Ch.9 p.24/60 date: 6/July/2016 Ed. 07 EN

TOOLS Code

Description.

*620.084.9015.01

Assembly cone for mechanical seal.

*620.084.5200.01

Tool for dismounting the impellor Pliers for circlip with straight jaws for inner diameter

* Special tool, not standard delivered with the engine (only delivered on request). 9.3.5.

DISMANTLING OF THE PUMP (fig.9.16) Required staff: 1 service man. 1.

On the engine.

Inspection and replacement of the impeller is possible with the pump remaining on the engine. - Shut-off the sea water supply and drain-off the water with cock (44). - On the non-drive end half body (1), disconnect the V-clamp halves (40) from the installation piping. - Disconnect the V-clamp halves (34) between the two half bodies and remove the non-drive end half body (1). - Remove split pen (2) and unscrew the nut (3), remove the washer (4) and place the special tool 620.084.5200.01 to remove the impeller (Fig.9.17). Extraction holes are provided in the impeller (M10).

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.25/60 date: 6/July/2016 Ed. 07 EN

Tool 620.084.5200.01

Fig. 9.17 2.

Removing the complete pump from the engine.

- Shut-off the sea water supply and drain-off the water from the circuit and the pump. Drain cock (44). - Disconnect the 2 V-clamp halves (40) from the installation piping on the two half bodies (1& 7). Disconnect the lub oil supply pipe. If no assistance is available, mind the weight! Attach a rope around the pump at two places and hang on a tackle. Put some tension on the rope. - Remove the screws (45) on the adaptor (41) and take apart as a unit by using the tackle.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 3.

Ch.9 p.26/60 date: 6/July/2016 Ed. 07 EN

Dismantling of the pump.

- The gearwheel (42) is mounted with a dynanobloc. Bicone clamping set (43). Remove the 10 screws on the set. Instead of the remaining two of another color, put two screws M8 and tighten them equally in order to release the bicones. Take apart the gear and the clamping set. - Remove the impeller as described under point 1. - Remove the distance ring (26) and the seal spacer (24) with shims (30 and 31) if available. - Unscrew the four nuts (10) and remove the drive end half body (7) with port plate (25) - Remove the adaptor(41) from the bearing housing(13) after removing the self locked nuts (47) - Now the mechanical seal with contact ring (23) and the rotary shaft oil seal (20) with water thrower (21) are free for eventual replacement. - If roller bearings (14 and 18) need to be replaced, further dismantling is necessary. Remove the screws (39), the lock nut (16) with locking washer (15) and take apart the seal housing (37) and spacer (35). - Press on the drive-end of the shaft until the inner race of the roller bearings (18) is clear of the bearing housing (13). If no press available, a soft hammer may be used to withdraw the shaft (12). - Remove the roller bearing (18) and collar (19) from the shaft using an extractor or a press. - Re-insert the shaft from the non-drive-end and press out the roller bearing (14). Remove it from the shaft. - Withdraw the outer race of the roller bearing (14) from the housing (13) with a pully extractor. 9.3.6.

ASSEMBLING OF THE PUMP (fig.9.16) Required staff: 1 service man. 1.

The pump-assembly.

- Thoroughly clean all components - Press the outer race of the roller bearing (18) into the housing (13). - Press the location roller bearing (14) on the shaft, insert the shaft from the drive end and press in. - Press seal collar (35) on the shaft. - Side the inner race of the bearing (18) on to the shaft and press home. - Secure the bearing by fitting circlip (17), use appropriate pliers tool. - To fit the seal collar (19), clean the shaft (12) and the bore of the collar with a degreaser like “Ultra clean” (Innotec) or equivalent. Dry by air. Apply a thin bead of Loctite 641 to the leading edge of collar bore and shaft. Fit the seal collar with a twisting action to ensure good Loctite distribution. Allow Loctite to cure about 4 hours before running the pump. File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS -

-

-

Ch.9 p.27/60 date: 6/July/2016 Ed. 07 EN

Press the seal (20) into the housing (13) ensuring the spring faces the bearing. Push the water thrower (21) on to the shaft against the seal collar (19). Fit seal housing (37) with screws (39) and tab washers (38). Fit locking washer (15) and lock nut (16). Tighten nuts and bend down a tab on the washer into a slot in the nut. To fit contact ring of the mechanical seal (23), clean the contact ring housing. Slightly wet the housing with a solution of 3 % detergent (Oltec Clean 9100 (IAS)) and carefully enter the ring into the housing. Re-assemble the drive end body (7) to the bearing housing (13). Tighten nuts (10) and press down tab on tab washers(9). Clean the shaft, using an adequate degreaser like “Ultra clean” (Innotec) or equivalent to eliminate all trace of grease and dirt. Slightly wet the shaft and the mechanical seal (23) with a solution of 3 % detergent (Oltec Clean 9100 (IAS)). For old seawater pumps which have no mounting chamfer on the shaft for the mechanical seal, also wet the therefore to use mounting tool 620.084.9015.01 (see Fig. 9.18) . Do not use grease. Surfaces on contact, ring and mechanical seal must be free from dirt and grease! Push the seal (23) over the shaft, for old type of seawater pump without chamfer use assembly cone tool code 620.084.9015.01 to protect the seal face (Fig. 9.18). Push the port plate (25) home into the body. On the back, lugs are provided to fit into slots on the body. Slide the seal spacer (24) on the shaft against the mechanical seal (23). Tool 620.084.9015.01

Fig. 9.18 Note: Tool only to be used with old type see water pump without chamfer on shaft.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 2.

Ch.9 p.28/60 date: 6/July/2016 Ed. 07 EN

Impellor and port plates.

- Place the shims (30/31) on the shaft. These shims are important as they relatively locate the impeller (27) to the port plates (25). The clearance X measured on each side must be within 0,18 to 0,23 mm. - How measuring the clearance: * Because the width of the distance ring (26) is greater then the impeller width + twice the side clearance (X + X ), so the impeller is automatically centered once the correct clearance is obtained on one side, this of course assuming the parts are not worn. - The easiest way to check clearance is to mount the impeller with a known value for the shim thickness in order that the impeller runs free from the drive end port plate. - Then place the distance ring (26) over the impeller and measure the clearance with a feeler gauges and a ruler placed on the distance ring. Now, calculate the thickness to add or to substract to obtain the prescribed clearance of 0,18 to 0,23 mm and consequently make the choice for the shims if needed. - If correct, continue the assembly. - Insert key (5) in the key way on the shaft. Press the impeller (27) on the shaft. - Assemble the washer (4) and nut (3) until the impeller is fully home. Tighten nut (3) according to the torque table. Do not forget to install the split pen (2) for locking and securing the nut on the shaft. - Place the seal-O-ring (6) on the distance ring (26) and press the ring into the drive end body (7). Place port plate (25) into the non-drive end body (1). Ensure that the lugs go into the slots in the body and press over distance ring. - Lock the body halves with the V-clamp. 3.

Fitting on the engine.

- Mount in reverse order from dismounting. Take care not to damage the gear wheels by introducing the pump into the gear case. The best way for this purpose is to attach the pump, hanging it horizontally with a rope fixed to a tackle. - After remounting on the engine, the flank teeth clearance must be checked. See table under point 9.1.8. . - Connect the V-clamp halves to the installation piping and check for tightness.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.3.7.

Ch.9 p.29/60 date: 6/July/2016 Ed. 07 EN

STARTING UP / LUBRICATION - Open the sea water supply. If the pump is under water level by opening, the vent plugs and air can be removed. - If not, fill the pump with water; the pump will continue to self prime at all subsequent starts. Bleed the complete system. - The pump is lubricated with engine oil. A pipe connection is provided for.

9.3.8.

PRESSURE RELIEF VALVE - The pressure side is provided with a pressure relief valve to avoid overpressures if operating against closed valve. - The pressure on the relief valve is set at 3 bar. - The maintenance of this valve consists to check if no leakage occurs at pressure below the setting point, if setting point is correct and to check if no leakage occurs after closing again. - If leakage occurs, valve must be lapped with the seat.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.4.

FUEL FEED PUMP (SF2/8)

9.4.1.

DESCRIPTION - (Fig. 9.19 - 20)

Ch.9 p.30/60 date: 6/July/2016 Ed. 07 EN

The purpose of this engine driven pump is to provide the fuel injection pumps with the necessary fuel amount under a determined pressure. The pressure is regulated in the system by relief valve(s). The pump is driven from an intermediate gearwheel in the pump gear case over a flexible coupling. The pump is of the gear type.

Fig. 9.19

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.31/60 date: 6/July/2016 Ed. 07 EN

Intermediate shaft driving waterpumps (Sect.015 code 620.015.9013.07)

(See page 1)

Fig. 9.20 Component Fuel feed pump complete SF2/8

Mass (kg) 7.25

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Ch.9 p.32/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.4.2.

RECAPITULATION OF THE MAINTENANCE JOBS Code

Jobs Overhaul the oil and fuel feed pump.

O2-11

Replace the fuel feed pump connection and sealings.

9.4.3.

9.4.4.

SPARE PARTS

Fig. n°

Ref. n°

Description

Qty/pump

9.19

8

Rotary shaft seal

1

9.19

10

Seal O-ring

1

9.19

18

Joint

1

9.19

21

Flexible coupling

1

TOOLS No special tools are needed for.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.4.5.

Ch.9 p.33/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE If the fuel used by the pump is free from dirt and water, the fuel feed pump does not normally require maintenance. However, at the given maintenance interval, it is recommended to check : - the flexible coupling (21) - the pump for leakage at seal-O-rings (18, 10) and at the rotary shaft seal (8). Required staff: 1 service man 1.

Removing from the engine.

- Unscrew the four screws (24) and take off the complete pump. - Inspect the flexible coupling (21). Look if the synthetic coupling part is in good condition. Signs of wear are evident if material dust is present in the adaptor (22 – Fig 9.20). - Inspect the rotary shaft seal (27 - Fig 9.20). If no leakage, replacement is not necessary. The adaptor (22) is also provided with a leakage indicating hole. 2.

Replacing the flexible coupling.

- The coupling must be replaced as a unit, i.e. a primary hub, coupling part in synthetic material, a secondary hub and the keys (5 - fig 9.19 and 26 - fig 9.20). - Remove the adaptor (22 - fig 9.20) from the engine by removing the screws (25 – fig 9.20). - Remove now the hubs respectively from driving shaft and pump shaft. - Inspect the key and key grooves. Replace damaged keys. - Put a new flexible coupling and remount. 3.

Replacing the rotary shaft seal (8) and ball bearing (7). (Fig. 9.19)

- Remove as mentioned under point 2 hereabove. - Remove the key (5) from the shaft. - Remove set nuts (14) and remove cover (2) together with the ball bearing (7), rotary shaft seal (8) and 2 circlips. (9) - Remove the first circlips (9) from the cover (2) with a circlips plier. - Remove the rotary shaft seal (8) from out of the cover. - Remove the 2nd circlips (9) with a circlips plier. - Remove, from the pump side, the bearing (7) using a threaded rod and nut or a copper drift knocking only on the center of the bearing. - If there is dirt to be seen, clean the housing using an adequate degreaser like “Ultra Clean” (Innotec) or equivalent. Dry by air. - Reinstall cover (2) to the body (1) together with the gears. Doing this making sure that the O-ring is adequately in place. Tighten nuts (14). File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.34/60 date: 6/July/2016 Ed. 07 EN

- Place a new ball bearing over the shaft. Use for this an adequate bearing mounting drift. Do not use grease! Tick the bearing until it is fully against the back of the chamber. - Mount the first circlips (9) using a circlips plier. Also degrease. - To mount the rotary shaft seal (8). It must be mounted with the open side towards the bearing. To mount, do NOT USE GREASE. Carefully put the seal over the shaft. - Carefully place the second circlips (9) 9.4.6.

ASSEMBLY Required staff: 1 service man. - If the seal O-rings or other joints are subject to leakage, they must be renewed. - Keep all parts clear. - Remount in reverse order from dismantling.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.5.

FUEL FILTRATION

9.5.1.

DUPLEX FUEL FILTER

Ch.9 p.35/60 date: 6/July/2016 Ed. 07 EN

Description: The filters are designed to filter fuel from particulate matter and thus to provide clean fuel oil to the engine.

Component Duplex fuel filter

Mass dry (kg)

Mass wet (kg)

16

20

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.36/60 date: 6/July/2016 Ed. 07 EN

Working principle: In general the fuel is passed through a filter vessel containing a filter element which filters the fuel. The filer is designed to enable continuous use by incorporating a standby filter vessel which can be brought into operation by actuating the changeover so the contaminated filter can be replace during operation of the engine at the required mainentance interval. Recapitulation of maintenance job: Code

Jobs

C1-04

Drain off any water from the day fuel tank and/or the water separator. (in fuel line)

M2-03

Check if renewal of the elements of the fuel filters is necessary. Frequence of renewal depends on quality of the fuel and possible contamination of the filter element.

M3-01

Renew elements of the fuel filters.

Maintenance See Operating Manual chapter “General Directives”. Changing filter elements See Operating Manual chapter “General Directives”.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.5.2.

Ch.9 p.37/60 date: 6/July/2016 Ed. 07 EN

FUEL FILTER/WATER SEPARATOR

WARNING When servicing the separator and/or maintenance on fuel lines, no glowing objects, open lights and or discharging equipment may be present which can cause fire hazard. Also the engine is considered as a hot surface so therefor no service may be done to fuel related engine/installation parts until the engine is completely cooled down to prevent fire hazard. Always use adequate PPE’s (personal protective equipment) like fuel resistant gloves, protective goggles and full cover facial protection. Description: The fuel filter/water separator operates by a three stage system, filtering out all harmful solid particles and liquid impurities which are heavier than diesel fuel that would otherwise cause engine problems. Working principle: - First stage: Separation of foreign solids and of liquid impurities by centrifugal action. - Second stage: Very small particles rise within the fuel to the top of the conical insert and collect on its sloping surfaces. In time these fractions build up and gradually sink to join the impurities separated in the first stage. - Third stage: Fine filtering of the fuel in the filter element (3). Maintenance: The separator needs to be checked daily for accumulated water and dirt in the bowl and if necessary drained off.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.38/60 date: 6/July/2016 6-7 Ed. 07 EN

Attention: Do this only when engine has fully stopped. Change filter element: Unscrew the tightening screw of the separator. For changing of the filter element (3) it should be steadily rotated while being carefully withdrawn from the housing. The new element is inserted by reversing this procedure. After changing the element, always check compression seal (2) and cover seal (1) and change if necessary. It is not necessary to airbleed the system after draining water and dirt or after changing the element.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.6.

LUBRICATING OIL PUMPS / PRESSURE VALVES.

9.6.1.

DESCRIPTION (Fig.9.21 & 9.22)

Ch.9 p.39/60 date: 6/July/2016 Ed. 07 EN

In case of dry sump application (most M-versions) two oil pumps are provided (Fig.9.21): a lubricating oil pump and a scavenge oil pump. The lubricating oil pump takes the oil from the service oil tank and feeds it to the engine under pressure. The scavenge oil pump removes the returned oil from the crankcase and pumps it to the service oil tank. Both pumps have the same internal construction, but are provided with a different gearwheel in order to drive the scavenge pump at higher speed than the lubricating oil pump. In case of wet sump application, only a lubricating oil pump is provided (Fig.9.22). The lubricating oil pump is provided with a pressure relief valve and on the pump pressure side a pressure regulating valve is foreseen with oil discharge back to the crankcase (pump gear case). Oil pumps are gear driven from the crankshaft gear over intermediate gears and driving gears (4 & 5). The pumps are flanged on the pump gear case.

Component

Mass (kg)

Lubricating oil pump complete with gear wheel

37.2

Scavenge oil pump complete with gear wheel

36.5

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.6.2.

Ch.9 p.40/60 date: 6/July/2016 Ed. 07 EN

RECAPITULATION OF THE MAINTENANCE JOBS Code

Jobs Overhaul the oil and fuel feed pump.

O2-11

Replace the fuel feed pump connection and sealings. Perform an overhaul of the oil by-pass valve.

O2-19

9.6.3.

9.6.4.

SPARE PARTS Fig. n°

Ref. n°

Description

Dry sump

Wet sump

9.21

12

Joint

1

1

9.21

13

Square joint

1

-

9.21

14

Square joint

6

3

9.21

32

Seal O-ring

2

1

9.23

3

Bush

4

8

9.26

10

Joint

1

1

9.27

6

Joint

1

1

TOOLS Code 620.084.9011.01

Description. Tool for removing oil pump bush

620.084.9012.01

Tool for fitting oil pump bush

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.6.5.

Ch.9 p.41/60 date: 6/July/2016 Ed. 07 EN

DISMANTLING Required staff: 1 serviceman. 1.

Removing from the engine (Fig.9.21/9.22)

- Shut off valves in oil circuit. Be sure that the oil level in crankcase is sufficiently low to avoid oil spillage. - Removing the scavenge oil pump (dry sump) * Remove the nuts (27) on inlet bend (7). * Remove the nuts (30) on pump flange. * Remove the bolts (21&26) on between flange (1) and pressure bend (9) * Remove the pipe connection to the hand pump on bend (9). * Take the pump apart f rom the gear case and remove the inlet bend and the pressure bend if necessary. Take care not to damage the teeth on the gear wheel. - Removing the lubricating oil pump ( dry sump and wet sump) : * Disconnect and remove the oil piping between pump pressure bend (9) and pressure regulating valve. * Proceed further in the same way as for the scavenge pump.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

Pressure

relief valve

Fig. 9.21

AA Door snede Coups

Scavenge oil pump

X

A

B

B

620.030.1100.05 620.030.2100.05

31-39

A

620.030.1300.02

Lubricationg oil pump

regulating valve

Pressure

620.030.1200.01

Zichl volgens pijt Vue sutvant fleche

Door snede Coups

X

BB

620.030.1300.02

ENGINE DRIVEN PUMPS

Ch.9 p.42/60 date: 6/July/2016 Ed. 07 EN

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

Fig. 9.22 2.

Dismantling the oil pump (Fig.9.23) File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Pressure relief valve

31-39

Lumbricating oil pump

Pressure regulating valve

ENGINE DRIVEN PUMPS

Ch.9 p.43/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.44/60 date: 6/July/2016 Ed. 07 EN

- Remove the cover or the pressure relief valve at the non drive end - Unscrew and remove the eight screws (7) and release the bearing body by means of the two press holes M10. - Remove the gear wheel from the shaft - Now the pump gears (4 & 5) are available for removing.

Fig. 9.23 3.

Inspection.

- Clean all parts - Inspect the gear, the pump body and bearing body for damage. Replacement is only necessary in case of breakdown of gears (broken teeth) a heavy and deep scoring on the gear side faces or body thrust faces. - Measure the clearance between the bushes and the shaft. When the limit of wear is exceeded, the bushes must be renewed. O.D. Shaft (mm)

L.W. Bush (mounted mm)

Max. clearance new (mm)

Clearance between shaft and bush (mm)

39.959 to 39.975

40.058 to 40.016

0.10

0.10

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 4.

Ch.9 p.45/60 date: 6/July/2016 Ed. 07 EN

Renewal of bearing bushes (Fig.9.23/9.24/9.25)

- Use tool 620.084.9012.01 to press out the two bushes from the bearing body and the one near the drive gear. - To remove the remaining bush. By means of a saw-blade, saw through the bush sidealong the oil grooves. Once the bush is cut through, the stress is released and the bush can be hooked out. - All bushes are identical. Introduce the new bushes using tool 620.084.9011.01 to press them home. - The bushes must be fitted in such a way that * the oil grooves are adjacent to each other * the bush is 3,5 to 4,5 mm beneath the side faces

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS Tool 620.084.9011.01

Tool 620.084.9012.01

Press in.

Press out.

Ch.9 p.46/60 date: 6/July/2016 Ed. 07 EN

Position of the oil grooves

Fig. 9.24 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.47/60 date: 6/July/2016 Ed. 07 EN

Tool 620.084.9012.01

Tool 620.084.9011.01

Press out.

Press in.

Positions of the oil grooves

Fig. 9.25 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 5.

Ch.9 p.48/60 date: 6/July/2016 Ed. 07 EN

Inspection of pressure regulating valve (Fig.9.26)

The pressure regulating valve consists of a body (l), a piston (2), a spring(3) and an adjusting system (4,8,9). The piston travel is controlled by the engine oil pressure with a connecting pipe. Oil tightness is assured by the cap nut(6) and seal-O-ring(10). The inspection consists to remove the spring and piston: -

Remove the cap nut To keep the initial setting, do not touch the screw(8) and nut (9). Unscrew the plug (5), bearing in mind the initial spring force. Remove the spring carrier(4), the spring(3) and the piston (2). The piston (2) is provided with an extraction threaded hole M8. Broken spring or damage requires replacement. If the piston shows some scuffing or scoring marks, it must be polished with fine emergy cloth and carefully cleaned afterwards. In any fact, the piston must slide freely in the body.

Pressure adjustment is made with running engine at speed above 500 rpm and with luboil at service temperature (near 70/75°C). Loose nut (9); turn clockwise screw(8) to increase oil pressure; turn anti-clockwise screw (8) to reduce oil pressure. The values for the oil pressures are given in chapter General 6-8DZC - part 2.8 – Pressures – Luboil pressure (enterance motor), depending nominal speed of the engine. The value is to be read from the control panel of the engine.

Oil pressure engine entrance engine

Remark: The oil pressure at idle speed cannot be adjusted, because it is the result of the margin between the total pump flow and the lubricating flow for a given speed.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.49/60 date: 6/July/2016 Ed. 07 EN

Fig. 9.26 6.

Inspection of pressure relief valve (Fig.9.27)

The lubricating oil pump is provided with a pressure relief valve. The function of this valve is to avoid over pressures during starting with cold oil and in case of malfunction of the pressure regulating valve. It consists of a body (l) bolted on the bearing body of the oil pump, a valve or piston (2), a spring (3) and a pressure setting system (4&5). Oil tightness is assured by seal-Oring (6). The inspection consists to remove valve and spring: - Remove plug (5) bearing in mind the initial spring force - Broken spring or damage requires replacement. - If the valve shows some scuffing or scoring marks, it must be polished with fine emery cloth and carefully cleaned afterwards. In any fact, the valve must slide freely in the body. Pressure is factory set at 7 +/- 0,7 bar and is a result of the spring force.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.50/60 date: 6/July/2016 Ed. 07 EN

Fig. 9.27

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.6.6.

Ch.9 p.51/60 date: 6/July/2016 Ed. 07 EN

ASSEMBLING Required staff: 1 serviceman. 1.

Mounting the oil pump (Fig.9.23)

- Clean carefully the sealing surfaces on pump body (l) and bearing body (2). Degrease with an adequate degreaser like Ultra Clean (Innotec) or equivalent. - Slide the pump gears in the body. Oil the bushes and shaft ends. - Smear the sealing surfaces with a film of Loctite 549. - Mount together and fix with the screws (7). These parts are positioned with pins (6&8). Allow loctite to cure. - Check if the pump is running freely. - Mount the driving gearwheel and fix nut on torque according torque table. The gear backlash or tooth flank clearance of the pump gears is between 0,75mm and 0,85mm. 2.

Pressure regulating valve (Fig.9.26)

- - Remount in reverse order from dismantling. - - Check if the oil connection (oil pipe) is free; it is recommended to clean it and to blow it through with dry air. 3.

Pressure relieve valve (Fig.9.27)

- Remount in reverse order from dismantling. - Seal mounting face with Loctite 549. - Pressure testing after assembly is recommended. 4.

Fitting or mounting the oil pump on the engine (Fig.9.21 / Fig.9.22)

- Renew all joints. Renew the jeal-O-ring (32). - Remount in reverse order from dismantling. Take care not to damage the gearwheels by introducing the pump into the gearcase. - After re-mounting on the engine, the flank teeth clearances must be checked, see table under 9.1.8. (Backlash tolerances table). - Connect oil piping and check for tightness when running the engine.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.7.

HAND PUMP.

9.7.1.

DESCRIPTION (Fig.9.28)

Ch.9 p.52/60 date: 6/July/2016 Ed. 07 EN

9-13

The hand pump is a semi-rotary pump. It is mainly used for filling up the oil circuit before the engine is started. Depending upon the settings of a three-way plug cock(7) and a square ball valve (5) the intake can take place from the service oil tank or from the crankcase. The output can be fed to the engine lubrication circuit or to the service oil tank.

Fig. 9.28 File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.7.2.

Ch.9 p.53/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE There is no specific maintenance.

9.7.3.

SPARE PARTS There are no specific spare parts.

9.7.4.

TOOLS No special tools are needed.

9.7.5.

ASSEMBLY The hand pump is fixed to the pump driving gear case by a distance screw (3) and nut (11).

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Ch.9 p.54/60 date: 6/July/2016 Ed. 07 EN

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.8.

THERMOSTATIC VALVE OIL CIRCUIT

9.8.1.

DESCRIPTION (Fig 9.29) The thermostatic oil valve is a 3-way valve that regulates the oil temperature of the engine by passing a regulated portion of the oil flow by the oil cooler. The temperature control is created by the expansion of a wax element which is highly sensitive to temperature changes. Large forces are created by the warming/expansion of the micture which in turn acts upon the sliding valve, thus regulating the flow. The diagram below shows the valve actuation in diverting mode at start and cooling positions. C

Cold position

Hot position

Bypass

B Outlet/ cooler

A

Fig. 9.29 Component

Mass (kg)

Thermostatic oil valve

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

18

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.8.2.

Ch.9 p.55/60 date: 6/July/2016 Ed. 07 EN

RECAPITULATION OF THE MAINTENANCE JOBS Code M5-02

Jobs Check the alarm and security devices (overspeed, thermostats and pressostats, overload limiter and microswitch for load indication) for correct function and operation.

O2-15

Overhaul of the HT, LT and oil thermostatic valve. Thermostatic elements need to be renewed.

9.8.3.

SPARE PARTS We refer to the spare parts manual.

9.8.4.

TOOLS No special tools are needed.

9.8.5.

MAINTENANCE In order to service the thermostatic valve, the valve needs to be removed from the installation. To remove the temperature element (4) from the assembly, ensure that the fluid system is drained and depressurized. Remove the valve from the system. Separate the body parts (1) and lift out the elements assembly (4). Inspect both the element assembly and the seat for wear and damage. Check that the element is fully closed. It is advisable to replace all gaskets (5) and O-rings (3 & 4) with new parts before reassembly. Lubricating the O-rings (3 & 4) lightly with grease like CERAN WR2 (Total) or equivalent before re-installing the element, the cage and cover. Attention: Hazardous liquids For use refer to safety prescription card. On re-assembly the housing bolts should be tightened on the torques to be found in the tightening torque table. (See Chapter General table 5) Ensure no air is trapped around the valve when the system is recommisioned.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.9.

Ch.9 p.56/60 date: 6/July/2016 Ed. 07 EN

THERMOSTATIC VALVE WATER CIRCUIT The thermostatic water valve is a 3-way valve that regulates the water (coolant) temperature of the engine by passing a regulated portion of the coolant by the pipe/plate cooler. The temperature control is created by the expansion of a wax element which is highly sensitive to temperature changes. Large forces are created by the warming/expansion of the micture which in turn acts upon the sliding valve, thus regulating the flow. 3 Types used according to type of engine: - Thermostatic valve water temperature engine outlet 80°C - Thermostatic valve water temperature engine outlet 85°C - Thermostatic valve water temperature inlet air cooler 43°C

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.9.1.

Ch.9 p.57/60 date: 6/July/2016 Ed. 07 EN

THERMOSTATIC VALVE 80°C and 85°C (Behr-Thomson)

9.9.1.1. DESCRIPTION (Fig. 9.30)

Fig. 9.30 Component

Mass (kg)

Thermostatic water valve

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

19,9

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.58/60 date: 6/July/2016 Ed. 07 EN

9.9.1.2. RECAPITULATION OF THE MAINTENANCE JOBS

Code M5-02

Jobs Check the alarm and security devices (overspeed, thermostats and pressostats, overload limiter and microswitch for load indication) for correct function and operation.

O2-15

Overhaul of the HT, LT and oil thermostatic valve. Thermostatic elements need to be renewed.

9.9.1.3. SPARE PARTS See spare parts manual sectie 045. 9.9.1.4. MAINTENANCE Replacement of wax-element: - Loosen the 3 cylinderhead screws (13) and draw out the cover (5). - Draw out the thermo-element (2) with a set of pliers. - Replace the element with exactly the same element with exactly the same start-toopen temperature. - When the element is fully in place. The cover can be replaced. Do not forget to mount also Seal-O-ring (8). - Tighten the 3 cylinderhead screws (13). 9.9.1.5. EMERGENCY In case of control failure, the valve can be operated by hand. If the valve is malfunctioning the flow of the coolant to the cooling element can be re-established by turning the stud (7) inward about 5 turns after loosening the countering nut (15). It is strongly recommended to send the unit to the manufacturer for repair.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS 9.9.2.

Ch.9 p.59/60 date: 6/July/2016 Ed. 07 EN

THERMOSTATIC VALVE 43°C (Thermoreg)

9.9.2.1. DESCRIPTION (Fig.9.31)

8-9-10

Fig. 9.31 Component

Mass (kg)

Thermostatic water valve

19,4

9.9.2.2. RECAPITULATION OF THE MAINTENANCE JOBS

Code M5-02

Jobs Check the alarm and security devices (overspeed, thermostats and pressostats, overload limiter and microswitch for load indication) for correct function and operation.

O2-15

Overhaul of the HT, LT and oil thermostatic valve. Thermostatic elements need to be renewed.

9.9.2.3. SPARE PARTS See spare parts manual section 045.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

ENGINE DRIVEN PUMPS

Ch.9 p.60/60 date: 6/July/2016 Ed. 07 EN

9.9.2.4. MAINTENANCE - The valves will operate in any position but must be installed with the ports in the correct position. (See Operation Manual: Chapter : Service and supervision of the engine at service) - Stresses from the supporting pipework should be kept to a minimum in accordance with good working practices. - Regularly inspect for wear and corrosion as part of a planned preventative maintenance programme. (See maintenance M5-02) - Care should be taken in handling the valves because of the weight and it should be recognized that the valve body will be at the same wordkihng temperature of the fluid flowing through it and thus could cause burns when engine has turned. - The valve must be suitably isolated from the system pressure and proved to have no pressure within it before any maintenance is carried out. Remark: Always use adequate personal protective equipment (PPE) to carry out maintenance or service.

File: B24_09_dd2016_07_06_Ed008_EN_Engine_Driven_pumps ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

CHAPTER 10 STARTING SYSTEM (Assembly 62 - 64 - 75)

10.1. 10.2. 10.3. 10.4.

PNEUMATIC STARTING ON CYLINDERS ...................................................................... 1 AUTOMATIC STOP DEVICE ............................................................................................. 14 COMPRESSED AIR RECEIVER. ....................................................................................... 19 CYLINDERHEAD STARTING VALVE ............................................................................ 23

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM 10.1.

Chapter 10 Page 1 Ed. 7 E

PNEUMATIC STARTING ON CYLINDERS

10.1.1. DESCRIPTION (Fig. 10.1, 10.2, 10.3, 10.4 & 10.5) Starting of the engine is achieved by directing compressed air sequentially to the cylinders over a non-return starting valve (3 – fig 10.1 & 10.2). The air applies force to the pistons and sets in motion the crankshaft. The compressed air comes forth from the air recievers filled at 30 bar and is fed to the cylinders over a water-separator (fig 10.6), an oil-lubricator (fig 10.7) and a main starting valve (fig 10.4 & 10.5) which can be acted manually (lever) or automatically (solenoid valve) at a distance. From the main air line, over a derivation, air pressure is reduced to 10 bar by a pressure reducing valve (33 – fig 10.3) and directed to the air distributor (1 – fig 10.1 & 2 – fig 10.2), to the starting device (fig 10.10) and sequentially to the non-return starting valve one on each cylinder. When the crankshaft is turned, the fuel is injected at high pressure by the injection pump and ignites the considered cylinder on its compression stroke and starts the engine. 10.1.2. RECAPITULATION OF THE MAINTENANCE JOBS Code M1-01

Jobs Fill automatic lubricator on the starting air pipe.

M1-02

Drain water from the compressed air receivers and water separator filter (starting air line).

M3-03

Check functioning of the automatic lubricator for the starting air.

O1-09

Renew the water separator filter

O2-13

Overhaul of main starting air valve

10.1.3. SPARE PARTS Fig. n°

Ref. n°

Description Common spare parts

Qty(6DZC) Qty(8DZC)

10.4

30

Valve body

1

1

10.4

33

Electro magnetic coil

1

1

10.1.4. TOOLS ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

″W″ ″Y″

″Y″

No special tools are required.

6DZC - Fig. 10.1

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 10 Page 2 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

″Y″

″Y″

STARTING SYSTEM

8DZC - Fig. 10.2 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 10 Page 3 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 4 Ed. 7 E

Zicht vlg. Pijl ″Y″ Vue acc. to arrow ″Y″

″Z″

195 tot C,L. motor (S2) 195 to C,L. engine (S2)

1073,5 tot C,L. motor (S2) 1073,5 to C,L. engine (S2)

″X″

Fig. 10.3 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Fig.10.4

Fig.10.5

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 10 Page 5 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 6 Ed. 7 E

10.1.1. WATER SEPARATOR (Fig. 10.6)

Fig.10.6 In addition to condensate, the compressed air produced by the compressor also contains residues from the pipes, such as chips or rust particles, which can impair the proper functioning of pneumatically controlled cylinders, valves, etc. Therefore the air needs to be filtered and is filtered to 50µm. (=filter rate) Maintenance: * Drain off condensate regularly by opening the manual drain valve (8). * Clean the sintered metal filter (5) (if dirty). Cleaning: 1.

Disconnect the unit from the compressed air supply.

2.

Unscrew the bowl (2), loosen the fixing nut (7) of the sintered metal filter.

3.

Remove baffle plate (6) with shim (9).

4.

Remove the filter insert (5) clean it as follows: a)

Wash the filter insert with solvent and blow through it from the inside to the outside. ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM b) 5.

Chapter 10 Page 7 Ed. 7 E

Dry the filter insert with compressed air. Fit the sintered metal filter again and screw the bowl (2) back on.

Renewing the filter: 1. Follow the same procedure for cleaning the filter up to and including step 3. 2.

Remove the filter insert (5) and replace it.

3.

Reassemble all components.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 8 Ed. 7 E

10.1.2. AUTOMATIC LUBRICATOR (Fig. 10.7) To lubricate all pneumatic control equipment such as cylinders, valves ext. , an automatic lubricator is installed in the air starting system. Lubrication is by means of the creation of an airborne fog or mist that passes downstream to lubricate compressed air equipment.

Fig.10.7 Oil consumption: At an air flow of qv=1000 l/min approx.. 1-2 drops/min Bowl volume= max. 125cm³ Recommended lubrication: SAE 10 to max. SAE 20 / HL25 DIN 51524 – ISO VG 32 to ISO VG55/40°C Compressor oil is normally suitable for this application. ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 9 Ed. 7 E

It is possible to fill the lubricator unit whilst under pressure by means of the oil dip stick. Slowly unscrew the dip stick relieving the bowl pressure. When the pressure has been completely vented, take away the stick and fill the bowl with oil. Check the height for the oil on the dipstick.

ATTENTION When receiving a lubricator from the factory, serviced or new, the following instructions must be followed: The bowl must be filled an adequate height (see the height on the dipstick) with an recommended oil lubricant. Special attention must be given to screw (5). When the lubricator is delivered, the screw is completely screwed in. In order to become a good lubrication of the compressed air, this screw must be loosened 1/4 of a turn. Check if the oil is effectively being consumed (see oil level diminishing). Verifies and controls: * Every 15 days, check oil level * Every 6 mounths or every 1000 working hours; check the correct working of the device and eventual leakage. * Every year disassemble the lubricator and clean its parts using only water and soap or similar neutral cleaning agents. Take care when cleaning polycarbonate bowls with TRICHLOOR based agents such as Benzol, Aceton and all fluids which contain plasticizer, should not be used under any circumstances. Warnings: * Do not disassemble the bowl when the lubricator is under pressure. * Do not install close to hot parts. Max. working temperature 50°C. * Avoid shocks and vibrations. * Always turn off the mains air supply when removing, servicing or dismantling. Note: Operation, maintenance and disassembly can only be done by authorized and skilled personel. Incorrect use can be dangerous for persons or other devices.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 10 Page 10 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM 10.1.3. MAINTENANCE 10.1.4. SERVICE AND ADJUSTMENT OF THE DISTRIBUTOR (Fig. 10.8) 6DZ A

TOP

Borgen met LOCTITE 510 Seoling with LOCTITE 510 Borgen met LOCTITE 222

A

Seoling with LOCTITE 222

8DZ A

TOP

Borgen met LOCTITE 510 Seoling with LOCTITE 510 Borgen met LOCTITE 222

A

Seoling with LOCTITE 222

Fig.10.8 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 11 Ed. 7 E

Procedure: - Remove the central air supply pipe (20 – Fig 10.2) and connecting cover (2). - Bring the crankshaft into the position “START CYL. 1” to be found on the inside of the flywheel and that is indicated with indication tool 620.083.1900.01 (this point is 22° à 23° after TDC in expansion stroke) (See Fig 4.8 a & b) Another way to become the position of “START CYL. 1” is by calculating the curve distance “A” on the circumference of the installed flywheel: - Take attention to the direction of rotation of the engine counter-clockwise (A) or clockwise (K) for location of this point. See fig 4.8b for the location of “START CYL. 1” - For example calculation using standard flywheel Ø 950 mm. Circumference of flywheel (mm) : π D = π x 950 = 2984 mm Curve distance per degree(mm/°): (π D / 360°) = 2984/360° = 8,29mm/° Example calculation curve distance “START CYL.1”: “START CYL.1”= 22° à 23° after TDC in expansion stroke Curve distance “START CYL.1” after TDC on the circumference of the flywheel : 22° à 23° x 8,29mm/° = 182,38 à 190.67 mm - Following this, the position of the distributor disc (3) needs to be checked. The position of the distributor disc depends on the firing order of the engine and number of cylinders. The position of the distributor must be as in following indicative tables.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 12 Ed. 7 E

6DZ : Direction of Rotation Counter – Clockwise (A) : 1-2-4-6-5-3

6DZ : Direction of Rotation Clockwise (K) : 1-3-5-6-4-2

TOP

TOP

The position of the sleeve in the distributor disc The position of the sleeve in the distributor disc must be in such a way that cylinder No.1 is just must be in such a way that cylinder No.1 is just starting and cylinder No.3 is just being closed. starting and cylinder No.2 is just being closed.

8DZ : Direction of Rotation Counter – Clockwise (A) : 1-4-7-3-8-5-2-6

8DZ : Direction of Rotation Clockwise (K) : 1-6-2-5-8-3-7-4

TOP

TOP

The position of the sleeve in the distributor disc The position of the sleeve in the distributor disc must be in such a way that cylinder No.1 is just must be in such a way that cylinder No.1 is just starting and cylinder No.6 is just being closed. starting and cylinder No.4 is just being closed. ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 13 Ed. 7 E

- If the position of the distributor is not correct, the position needs to be corrected. Therefor unlock the locking washer (8) and remove nut (7). - Place a new locking washer (8) and slightly tighten nut (7). - Adjust the distributor as indicated above for the type of engine. Hand tighten nut (7). - Remove carefully shaft (4) together with the distributor disc (3) out of the air distributor. - Place the shaft in a vice and tighten only on the flat surfaces of the shaft. Make sure to use aluminium or soft metal tighteners which do not damage the shaft during tightening. - Tighten nut (7) firmly and lock the locking disc (8) as indicated on fig. 10.8 . Attention: Make sure the distributor disc has not changed position during tightening and locking. - Remount the adjusted distributor onto the engine. - Re-install cover (2) and air pipe (20). - Start the engine.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM 10.2.

Chapter 10 Page 14 Ed. 7 E

AUTOMATIC STOP DEVICE

10.2.1. DESCRIPTION (fig. 10.9) The stop device is consisting of a body (1) containing a hydraulic piston (2) and a pneumatic piston (10). At stop position, both pistons are pushed down by a piston rod (4) and springs (5). At the upper end the piston rod by a pin (A13-12) and a slot is linked to the stop handle provided in the rod. Function: 1.

Starting:

When the starting electro-valve is operated, air at 10 bar is fed under the pneumatic piston (10) pushing the complete system upwards in order to release the racks on the fuel injection pumps. In the meantime, during starting, oil pressure is built up and gives action to: - the hydraulic piston (2) to keep it in upper position - the pneumatic piston (10) to push it down at rest, a throttle (34 - fig 10.3) in the air supply arranges a slow return to rest. 2.

Running:

Until the oil pressure is above a minimum allowed limit, the piston rod (4) remains upwards and due to the slot, gives free action to the control spindle and fuel racks under control of the governor. Component Automatic stop device assembly

Mass (kg) 8

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 10 Page 15 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

Stop position

Running

Air supply

Lub oil supply

A75-13

A13-20

STARTING SYSTEM

Fig. 10.9 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

11-13

9-16

11-13

10-16

STARTING SYSTEM

Chapter 10 Page 16 Ed. 7 E

Fig. 10.10 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 17 Ed. 7 E

10.2.2. RECAPITULATION OF THE MAINTENANCE JOBS

Code O1-10

Jobs Overhaul of hydraulic stop cylinder.

10.2.3. SPARE PARTS

Fig. n° 10.9

Ref. n° 14

Description Seal O-ring

Qty/engine 2

10.2.4. TOOLS No special tools are needed. 10.2.5. MAINTENANCE No specific maintenance is required. Only a regular lubrication of the piston rod and stop handle shaft and pin is necessary. However the free movement of the rod must be checked during starting and stopping. Hesitation in the movement can indicate some jamming of the pistons, the rod or the springs. Occasionally some internal corrosion can occur. Dismantling: Required staff : 1 service man - Disconnect the oil and air piping. Check the pipes internally for rust or water. Blow through with dry, clean compressed air. - Remove the fixation screws (A75-13) and remove the assembly from the engine. - Remove the locating screw (12) and loose the lock nut (9) - Record the position of the spring adjusting screw (8) in regard to the upper face of the spring housing (3). Loose the adjusting screw (8) until there is no more tension on the springs (5). - Remove the nuts (13) and take apart the parts (3, 4, 5, 6, 7, 8 & 9) - Remove the hydraulic piston (2). Two threads M8 are provided for. - Remove the screws (15) ;take apart the cover (11) and remove the pneumatic piston (10). One thread M8 is provided for.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 18 Ed. 7 E

Maintenance: Required staff : 1 service man - Clean all parts thoroughly. If the pistons show signs of scoring of jamming, polish them with fine polishing-cloth. Check the free movement in the housing. Check also the free movement of the piston rod, if necessary polish with fine polishing-cloth. - If there is corrosion on the springs it is advisable to replace them. - Clean the oil groove in the body, the oil leak return hole and connection Assembly: Required staff : 1 service man - remount in reverse order from dismantling. - Rub the faces of spring carrier (2x (6)) and intermediate carrier (7) in with molykote during assembly. - replace the seal-O-rings (14) and fit the new ones with CERAN WR2 (Total) or equivalent. - the lower cover (11) is mounted with Loctite 549 to assure sealing. Avoid Loctite introduction into the cylinder in order not to stick the piston (10). 10.2.6. ADJUSTMENT If parts have been replaced and the relative position of the adjusting screw (8) is unknown, adjusting is necessary. - Connect the oil supply line (M14) to an oil supply foreseen with a pressure gauge with scale up to 6 bar. - Increase the pressure up to 4 bar approx. The piston rod must move to its uppermost position. - Close the oil supply and let the pressure fall-off. The piston-rod must go down now, once a pressure of 1,4/1,5 bar is reached. - If the piston rod (4) is falling down at: * a pressure above 1,4/1,5 bar, decrease the spring pressure by unscrewing the adjusting screw (8) * a pressure below 1,4/1,5 bar, increase the spring pressure - Once the correct pressure is obtained, turn the piston rod in such a way as to put the locating screw (12) in the corresponding groove - Block the lock nut (9) - Mount on the engine and connect oil and air supply and oil leak pipe. - Check if the pin (A13-20) can move freely in the slot of the piston rod (4).

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM 10.3.

Chapter 10 Page 19 Ed. 7 E

COMPRESSED AIR RECEIVER.

10.3.1. DESCRIPTION (fig.10.2.) A compressed air receiver is provided with each engine for starting purpose. The air receiver is filled-up with air, delivered by an air compressor in the installation. The nominal air pressure is 30 bar. The air receiver is provided with the receiver itself (29) and with the valve housing (1) or head. At the lower point, there is a water draining valve (43). The valve housing (1) contains the filling valve assembly with handwheel (4) and the starting valve assembly with handwheel (4). Furthermore there is a pressure gauge (38) with manometer valve (39) and an overpressure relief valve (63). The head is mounted on the receiver by means of studs (30) and nuts (34). Sealing is assured by joint (37). Standard capacities: 125 l - 200 l - 2x125 l - 2x200 l. Component Complete receiver 125 l

Mass (kg) 184

Complete receiver 200 l

226

Complete receiver set of 2 x 125 l

385

Complete receiver set of 2 x 200 l

442

10.3.2. RECAPITULATION OF THE MAINTENANCE JOBS No specific maintenance. Code M1-02

Jobs Drain water of the compressed air receivers..

Remark: According classification societies for ships or other security institutions, the air receivers are subjected to regular pressure testing and inspection and setting test of the pressure relief valve. 10.3.3. SPARE PARTS (fig. 10.2 & 10.3) See spare parts manuel.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 20 Ed. 7 E

10.3.4. TOOLS No special tools are needed. 10.3.5. MAINTENANCE Refer to the Operating Manual – Chapter 5 for a regular water draining of the receivers. However some remarks can be formulated: - before dismantling the valve housing from the receiver, be sure that all air is blown off and that there is no pressure anymore. - the internal wall of the receiver is coated with a special corrosion resistant coating! During cleaning do not use sharp objects to avoid piercing the coating. - the valve housing is mounted with studs and nuts (30 + 34). The torque on the nuts is 400 - 420 Nm (40 - 42 kgm). By removing the valve housing the joint (37) fig.10.6. must be renewed.

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Filling handwheel

Starting handwheel

Fig. 10.11 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 10 Page 21 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

AssemblySect. Sect.064 064 Assembly

STARTING SYSTEM

Fig. 10.12 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 10 Page 22 Ed. 7 E

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM 10.4.

Chapter 10 Page 23 Ed. 7 E

Cylinderhead starting valve

10.4.1.1. DESCRIPTION The non-return starting valve enters compressed air of 30 bar into the cylinders to start the engine. For a more detailed description of the starting process and the role of the starting air valve, see “Pneumatic starting on cylinders” (page 4). 10.4.2. ILLUSTRATION

Assembly 620.062.1200.01 Starting air valve

Fig. 10.13 10.4.3. MASS Non-return starting valve

2,33 kg

10.4.4. RECAPITULATION OF MAINTENANCE JOBS Code O1-01

Jobs Overhaul of the main starting valve.

O2-01

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 24 Ed. 7 E

10.4.5. SPARE PARTS Refer to the spare parts list of the 6/8DZC engine. 10.4.6. TOOLS No special tools required. 10.4.7. MAINTAINING AND REPLACING THE MAIN STARTING VALVE 10.4.7.1. Overview Maintaining the main starting valve includes: 1

Replacing the main starting valve

2

Disassembling the main starting valve

3

Cleaning the components

4

Assembling the main starting valve

10.4.7.2. Replacing the main starting valve Required staff One service man Procedure 1

Shut off the air supply from the compressed air bottles.

2 Disconnect the main air collector pipe and pilot-air-pipe from the main starting valve. 3

Dismount the main starting valve from the cylinder head.

4

Replace the removed valve by a revised or new valve.

5

Connect the main air collector pipe and pilot-air-pipe to the main starting valve.

Fig. 10.14

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 25 Ed. 7 E

10.4.7.3. Disassembling the main starting valve Required staff One service man Procedure 1 Remove lock nut (5) to dismount intermediate pinion (8) and the brazed ring nipple (1) with seal O-rings (15). 2 Mount the starting valve housing (3) in a bank screw with plug (6) facing upwards so you can remove plug (6) and sealing ring (10). 3 Secure with a screwdriver in the bottom groove, the valve (2) against rotation and loosen hexagon nuts (16). 4

Dismount seal O-ring (14) and piston (4).

5

Dismount sealing ring (11)., spring (9) and sealing ring (12).

6 Disassemble valve (2) from valve seat (7) and sealing ring (13). The valve is now completely disassembled. 10.4.7.4. Cleaning the components Blast the following components to remove all grease and dust. Use a blast medium that does not corrode the surface of the components (blast medium for valves): - starting valve housing (3) - lock nut (5) - intermediate pinion (8) - brazed ring nipple (1) - plug (6) - valve (2) Use sanding paper 400 to clean the piston (4) and valve seat (7). All rubber and copper seals must be replaced by new ones. 10.4.7.5. Assembling the main starting valve Required staff One service man Procedure 1 Apply grinding paste on valve (2) and mount valve seat (7) with sealing ring (13) over valve (2). 2

Grind in the valve (2) and remove redundant paste.

3 Mount valve seat (7) with valve (2) in starting valve housing (3) and place sealing ring (12). 4

Mount sealing ring (11)., spring (9) and seal O-ring (14) ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

STARTING SYSTEM

Chapter 10 Page 26 Ed. 7 E

5 Mount the starting valve housing (3) in a bank screw and install hexagon nuts (16) (Fig. 10.14). Use Loctite 243 to secure the nuts. 6

Mount plug (6) and sealing ring (10).

7 Mount the seal O-ring (15) in the brazed ring nipple (1) and install the nipple over the valve housing (3). Attention: ON THE INSIDE OF THE BRAZED RING NIPPLE (1) ONE SIDE IS FLAT, THE OTHER SIDE IS CONVEX. MOUNT THE NIPPLE WITH THE FLAT SIDE AGAINST THE HEXAGON PART OF THE VALVE HOUSING (3). 8 Mount seal O-ring (15), intermediate pinion (8) and lock nut (5) over the valve housing (3).

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 1/22 Ed. 08- 14/07/2017 – EN Turbocharger

CHAPTER 11 TURBOCHARGER (Assembly 20-21)

File:

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 2/22 Ed. 08- 14/07/2017 – EN Turbocharger

CONTENTS 1

File:

TURBOCHARGER ........................................................................................................................... 3 1.1

Description............................................................................................................................... 3

1.2

Mass ........................................................................................................................................ 4

1.3

Illustrations .............................................................................................................................. 4

1.4

Recapitulation of maintenance jobs ......................................................................................... 9

1.5

Spare parts ............................................................................................................................... 9

1.6

Tools ...................................................................................................................................... 10

1.7

Dismounting and remounting the turbocharger ..................................................................... 10

1.8

Dismounting and remounting the silencer or the air intake housing ....................................... 12

1.9

Blocking the turbocharger impeller .........................................................................................13

1.10

Maintaining the turbocharger ................................................................................................ 14

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 3/22 Ed. 08- 14/07/2017 – EN Turbocharger

1

TURBOCHARGER

1.1

DESCRIPTION The turbocharger increases the engine’s efficiency and power output by sending compressed air to the cylinders. As this compressed air contains a lot of oxygen, it allows you to inject and combust extra fuel in the cylinders. As a result, you get a higher output at the same rotational speed. The turbocharger consists of two major components, i.e. a turbine and a compressor: Component Turbine (1, Fig. 11.1 & Fig. 11.2)

Description The turbine uses the engine’s exhaust gasses to drive the compressor of the turbocharger. It works as follows: 1

The exhaust manifolds on the cylinders collect the exhaust gasses and take them to the gas inlet housing of the turbocharger.

2

Via the gas inlet housing, the exhaust gasses enter the turbine. In the turbine, they bump into the blades of the turbine wheel and the wheel starts turning.

3

As the turbine wheel is connected to the compressor wheel, the compressor wheel starts turning as well and air is sucked into the compressor.

Once their job is done, the exhaust gasses leave the turbocharger turbine. On their way out, they pass an exhaust cone, an expansion compensator and the silencer. Compressor

The compressor sends compressed air to the cylinders. It works as follows:

(2, Fig. 11.1 & Fig. 11.2)

1

When the compressor wheel starts turning, the compressor sucks in air from the air filter (3, Fig. 11.1 and Fig. 11.2) and compresses it.

2

The compressed air is sent to the cylinders, via the air cooler. The air cooler cools the air and increases its density. The denser the air is, the more oxygen it contains and the larger its impact on the power output of the engine will be.

In between the turbine and the compressor, there is a bearing housing that contains the shafts and bearings of the turbocharger gearwheels. These turbocharger bearings are lubricated by the lube oil of the engine and the bearing housing is cooled by the engine’s cooling circuit.

The air circuit is equipped with endoscope keyholes, which allow you to check the inside of the circuit (see Fig. 11.4, Fig. 11.5 and Fig. 11.6).

For more detailed information on the turbocharger (working, technical specifications…), refer to KBB’s instruction manual.

File:

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 4/22 Ed. 08- 14/07/2017 – EN Turbocharger

1.2

MASS Component

1.3

Complete turbocharger M40 (KBB)

260

Silencer

35

Air intake housing

12

ILLUSTRATIONS

Fig. 11.1

Turbocharger 6/8DZC TKV

Ref.

File:

Mass (kg)

Fig. 11.2

Turbocharger 12/16DZC TKV

Description

1

Turbine

2

Compressor

3

Air filter

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 5/22 Ed. 08- 14/07/2017 – EN Turbocharger

Fig. 11.3

File:

Turbocharger and support 12/16DZC

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 6/22 Ed. 08- 14/07/2017 – EN Turbocharger

C

A

D

B

C

A

D B

Fig. 11.4

Endoscope keyholes 6/8DZC

Ref.

File:

Description

A

Endoscope keyhole before air cooler

B

Endoscope keyhole after air cooler

C

Endoscope keyhole exhaust

D

Endoscope keyhole air collector

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 7/22 Ed. 08- 14/07/2017 – EN Turbocharger

Presentation with air intake cone

Presentation with air filter

C A

Fig. 11.5

B

Endoscope keyholes 12/16DZC

Ref.

File:

Description

A

Endoscope keyhole before air cooler

B

Endoscope keyhole after air cooler

C

Endoscope keyhole exhaust

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 8/22 Ed. 08- 14/07/2017 – EN Turbocharger

A

Fig. 11.6

Endoscope keyholes

Ref. A

File:

Description Endoscope keyhole air collector

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 9/22 Ed. 08- 14/07/2017 – EN Turbocharger

1.4

RECAPITULATION OF MAINTENANCE JOBS The maintenance intervals in the maintenance program are averages. They have to be adjusted according to local conditions and the specific configurations of the engine.

ALL DEFECTS, HOW INSIGNIFICANT THEY MIGHT SEEM, HAVE TO BE REPAIRED AS SOON AS POSSIBLE. IF NOT, THEY CAN CAUSE MAJOR DAMAGES TO THE TURBOCHARGER AND TO THE ENGINE IN GENERAL.

Code

Description

C1-07*

Cleaning of the turbocharger compressor by water injection

M6-04*

Checking and - if necessary - cleaning the air intake circuit and compressor wheel

M6-05*

Checking and - if necessary - cleaning the exhaust gas circuit

O1-08 O2-10**

Complete overhaul of the turbocharger

O3-05

Checking and - if necessary - replacing isolation of exhaust pipe

*Maintenance interval depends on the environment (air pollution, engine room ventilation, water quality). **For engines with frequent load changes, complete overhaul is recommended at 12000 hours.

1.5

SPARE PARTS Code 620.082.2200.07

File:

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

Description Maintenance set for turbocharger KBB M40

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 10/22 Ed. 08- 14/07/2017 – EN Turbocharger

1.6

TOOLS Code 620.084.6300.02

Description Tool set for turbocharger KBB M40 Open-end wrench A/F 13 (for blocking the turbocharger) Blocking device (for blocking the turbocharger)

1.7

DISMOUNTING AND REMOUNTING THE TURBOCHARGER You only have to dismount the entire turbocharger for a thorough inspection. To execute the regular maintenance checks and tasks described under “1.10 Maintaining the turbocharger” (page 14), you only have to dismount parts of the turbocharger. Required staff One service man Dismounting the turbocharger THE BEARING HOUSING (20, FIG. 11.7) HAS THREADED HOLES THAT CAN BE EQUIPPED WITH EYE BOLTS. NEVER USE THESE EYE BOLTS TO LIFT THE ENTIRE TURBOCHARGER, ONLY USE THEM TO LIFT THE BEARING HOUSING.

1

Remove the covers from the turbine inlet housing (21, Fig. 11.7).

2

Disconnect the exhaust gas piping from the turbine inlet housing (21, Fig. 11.7) and the turbine outlet housing (23, Fig. 11.7). Be careful not to damage the gaskets.

3

Disconnect all the pipes from the compressor housing (25, Fig. 11.7). Dismount the pipes if necessary.

4

Drain the lube oil and cooling water from the turbocharger.

5

Disconnect the cooling water inlet, the cooling water outlet, the lube oil inlet and the lube oil outlet.

6

Disconnect the water and air pipes that you use to clean the compressor.

7

Attach the ropes to the turbocharger:

8

File:

•

Attach one rope to the flange between the silencer (28, Fig. 11.7) and the compressor housing (25, Fig. 11.7).

•

Attach the other rope to the flange between the turbine inlet housing (21, Fig. 11.7) and the turbine outlet housing (23, Fig. 11.7).

Attach both ropes to the hoist, hoist the turbocharger and put it on a wooden surface (e.g. a wooden pallet). Make sure the turbocharger does not tip.

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 11/22 Ed. 08- 14/07/2017 – EN Turbocharger

Fig. 11.7

Dismounting the turbocharger

Remounting the turbocharger

File:

1

Attach two ropes to the turbocharger, as described in step 7 of “Dismounting the turbocharger” (page 10).

2

Attach both ropes to the hoist, lift the turbocharger and place it on the engine block.

3

Remount and reconnect all components. Proceed as follows: a

Remount the bolts at the foot of the turbocharger and tighten them.

b

Reconnect the exhaust gas piping to the turbine inlet housing (21, Fig. 11.2) and the turbine outlet housing (23, Fig. 11.2). Put molybdenum sulphide lubricant on the connecting bolts of the exhaust gas pipes before you remount them.

c

Remount the covers on the turbine inlet housing (21, Fig. 11.2).

d

Reconnect all pipes to the compressor housing (25, Fig. 11.2). Remount the pipes if you had to take them off to dismount the turbocharger.

e

Reconnect the cooling water inlet, the cooling water outlet, the lube oil inlet and the lube oil outlet.

f

Reconnect the water and the air pipes that you use to clean the compressor.

4

Tighten the bolts at the foot of the turbocharger and in all the pipe connections.

5

Check if the turbocharger is free of stresses and forces. If not, the pipe connections will not fit properly. If necessary, reconnect the pipes.

6

Resupply the turbocharger with lube oil and cooling water. Check all the pipe connections for leaks and tighten the connections when necessary. Make sure to use the correct gaskets.

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 12/22 Ed. 08- 14/07/2017 – EN Turbocharger

1.8

DISMOUNTING AND REMOUNTING THE SILENCER OR THE AIR INTAKE HOUSING Required staff One service man Dismounting the silencer or the air intake housing 1

Remove the stud bolt joints (C, Fig. 11.8), the hexagon nut (D, Fig. 11.8) and the toothed washer (E, Fig. 11.8) from the compressor housing.

2

Slide the silencer (A, Fig. 11.8) or the air intake housing (B, Fig. 11.8) from the compressor housing.

3

Place the silencer or the air intake housing on a wooden surface (e.g. a wooden pallet).

Remounting the silencer or the air intake housing 1

Slide the silencer (B, Fig. 11.8) or the air intake housing (A, Fig. 11.8) on the compressor housing.

2

Put the hexagon nuts (D, Fig. 11.8) and the toothed washer (E, Fig. 11.8) on the bolts (C, Fig. 11.8) in the compressor housing flange. Tighten the bolts and the nuts.

Ref. A

B

Description

A

Air intake housing

B

Silencer

C

Stud bolt joint M8

D

Hexagon nut M8

E

Toothed washer M8

C, D, E Fig. 11.8

File:

Dismounting and remounting the silencer

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 13/22 Ed. 08- 14/07/2017 – EN Turbocharger

1.9

BLOCKING THE TURBOCHARGER IMPELLER IT IS ONLY ALLOWED TO BLOCK THE TURBOCHARGER IMPELLER IF THE TURBOCHARGER IS DEFECTIVE AND YOU HAVE TO RUN THE ENGINE ANYWAY.

Required staff One service man Procedure 1

If possible, open the air manifold on the engine so the engine can take air in through the turbocharger and the air manifold.

2

Put the blocking device on the compressor impeller. Make sure the cutouts in the blocking device hold the impeller blades (Fig. 11.9).

3

Fix the blocking device with the stud bolts of the compressor housing and tighten them firmly (Fig. 11.9).

4

Cut off the oil supply to the turbocharger by mounting a blank flange on the oil supply. You do not have to cut off the cooling water.

5

Close the open intake ports to prevent foreign matter from entering the turbocharger.

A Ref.

Description

A

Bolt M8 for fixing blocking device

B

Blocking device

C

Impeller

B C

A

Fig. 11.9

File:

Blocking the turbocharger

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 14/22 Ed. 08- 14/07/2017 – EN Turbocharger

1.10

MAINTAINING THE TURBOCHARGER

1.10.1 Overview Maintaining the turbocharger includes: 1

Cleaning the compressor by water injection (C1-07) (page 14)

2

Checking the air intake circuit (M6-06) (page 14)

3

Checking the exhaust gas circuit (M6-07) (page 14)

4

Cleaning the silencer (page 15)

5

Cleaning the magnetic filter (every 500 hours of operation) (page 17)

6

Replacing the turbocharger insulation (O3-06 or O3-07) (page 18)

1.10.2 Cleaning the compressor by water injection (C1-07) Refer to the operating manual.

1.10.3 Checking the air intake circuit (M6-06) Required staff One service man Procedure 1

Check the air circuit before the air cooler (air intake side). Remarks:

•

Use an endoscope to check the air cooler entrance and the air circuit coming from the turbo (see Fig. 11.4 and Fig. 11.5 on page 6 and 7).

•

Check the cleanliness of the components (no dirt in the cooler), check the straightness of the lamella and check for hazardous particles.

2

Check the air circuit after the air cooler. Put an endoscope through the endoscope keyhole after the air cooler (see Fig. 11.4 and Fig. 11.5). Check also the interior of the air circuit. Put an endoscope through the endoscope keyhole at the end of the air collector (see Fig. 11.4 and Fig. 11.6 on page 6 and 8).

3

If there is an obstruction in the air circuit, you have to disassemble and clean the circuit. Clean all components with a detergent (e.g. IAS Oltec Clean 9100) or a bio-degreaser.

1.10.4 Checking the exhaust gas circuit (M6-07) Required staff One service man Procedure 1

File:

Put an endoscope through the endoscope keyholes before the turbocharger turbine (see Fig. 11.4 and Fig. 11.5) and check the interior of the exhaust gas circuit.

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 15/22 Ed. 08- 14/07/2017 – EN Turbocharger

2

If there is an obstruction in the exhaust circuit, you have to disassemble the circuit and remove the obstruction. If necessary, ABC can execute a thorough sand-blasting cleaning.

1.10.5 Cleaning the silencer Required staff One service man Procedure You can check and clean the silencer while it is mounted on the turbocharger. Proceed as follows: 1

Open the tension strips and remove them (A, Fig. 11.10).

2

Pull the filter mat (B, Fig. 11.10) over the silencer (F, Fig. 11.10). Leave the punched plate (C, Fig. 11.10) on the silencer.

3

Clean the filter mat. Proceed as follows:

4

a

Put the filter mat in a clean liquid (diesel fuel, perchlorethylene) for 10 minutes.

b

Rinse the filter mat with the liquid and clean the outside of the mat with a soft brush.

c

Stub out the filter mat and dry it well.

Check if the felt filter is dirty and clean it if necessary. Proceed as follows: a

Loosen the three bolts of the punched plate and remove the plate from the silencer.

b

Clean the felt filter with a brush and remove any oil contamination with diesel fuel. Never use water to clean the felt filter.

If the felt coatings of the silencer are very dirty, you have to dismount the silencer and replace the felt coatings. See “1.8 Dismounting and remounting the silencer or the air intake housing” (page 11).

5

File:

Remount the punched plate and the dried filter mat. Press the punched plate down at the side and fix it with the three hex screw and spring washers (Fig. 11.11)

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 16/22 Ed. 08- 14/07/2017 – EN Turbocharger

•

NEVER USE A P3-SOLUTION OR TRICHLOROETHYLENE TO CLEAN THE SILENCER COMPONENTS. WHEN USING ANOTHER LIQUID THEN THE ONES MENTIONED IN THE PROCEDURE, ALWAYS CHECK THE COMPATIBILITY WITH THE FILTER MATERIAL.

•

WHEN WORKING WITH THE CLEANING LIQUID, TAKE INTO ACCOUNT THE SAFETY REGULATIONS (HANDLING OF HAZARDOUS, VOLATILE AND COMBUSTIBLE SOLVENT) AND FIRE PROTECTION REGULATIONS (DIN 14096).

•

IN CASE OF SHIP OPERATION, TAKE INTO ACCOUNT THE REGULATIONS OF THE CLASSIFICATION SOCIETIES WITH REGARD TO CLEANING LIQUIDS.

A B

Ref.

C

Description

A

Tension strip

B

Filter mat (fleece)

C

Punched plate

D

Screw plug (M10)

E

Felt coatings

F

Silencer

D

E F

File:

Fig. 11.10

Checking and cleaning the silencer

Fig. 11.11

Hex screws and spring washers of punched plate

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 17/22 Ed. 08- 14/07/2017 – EN Turbocharger

1.10.6 Cleaning the magnetic filter (every 500 hours of operation) Required staff One service man Procedure 1

Remove the hex bolts M8 (C, Fig. 11.12) and remove the cover (A, Fig. 11.12).

2

Remove the magnetic filter column (B, Fig. 11.12).

3

Clean the filter in clean diesel fuel and blow it out with compressed air.

4

Remount the magnetic filter column (B, Fig. 11.12).

5

Remount the cover (A, Fig. 11.12). Fix it with the hex bolts M8 (C, Fig. 11.12) and the locking washers.

C

Ref.

Description

A B

Fig. 11.12

File:

A

Cover

B

Magnetic filter column

C

Hexagon head bolt

Magnetic filter

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 18/22 Ed. 08- 14/07/2017 – EN Turbocharger

1.10.7 Replacing the turbocharger insulation (O3-06 or O3-07) Required staff One service man Procedure Due to thermal stress and expansion, the insulation on some parts of the turbocharger can crack and come off. The insulation on the following components has to be replaced: Component

Fig.

Exhaust manifold(s)

Dismount the exhaust manifold(s) and send them to the ABC service department.

Fig. 11.13

Turbocharger inlet

Dismount the turbocharger and send it to the ABC service department.

Fig. 11.14 Fig. 11.18 Fig. 11.19

Turbine

The insulation on the turbine is different for standard engines (Fig. 11.15 and Fig. 11.20) and engines with classification (Fig. 11.16 and Fig. 11.21), but both types of insulation have to be replaced. You can replace this insulation yourself.

Fig. 11.15 Fig. 11.16 Fig. 11.20 Fig. 11.21

Expansion bellow (only for engines with classification)

Engines with classification have insulation on the expansion bellows. You can replace this insulation yourself.

Fig. 11.17 Fig. 11.22

Fig. 11.13

File:

Procedure

Insulation exhaust manifold

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 19/22 Ed. 08- 14/07/2017 – EN Turbocharger

File:

Fig. 11.14

Turbocharger inlet insulation 6/8DZC

Fig. 11.15

Turbine insulation standard engines 6/8DZC

Fig. 11.17

Insulation expansion bellow 6/8DZC (only for engine with classification)

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

Fig. 11.16

Turbine insulation engine with classification 6/8DZC

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 20/22 Ed. 08- 14/07/2017 – EN Turbocharger

File:

Fig. 11.18

Turbocharger inlet 12/16DZC TKV

Fig. 11.19

Turbocharger inlets 12/16DZC TKP

Fig. 11.20

Turbine insulation standard engines 12/16DZC

Fig. 11.21

Turbine insulation engine with classification 12/16DZC

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 21/22 Ed. 08- 14/07/2017 – EN Turbocharger

Fig. 11.22

File:

Insulation expansion bellow 12/16DZC (only for engine with classification)

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DIESEL ENGINES ABC TYPE 6/8/12/16DZC Chapter 11 – Page 22/22 Ed. 08- 14/07/2017 – EN Turbocharger

File:

B24_11_dd2017_07_14_Ed008_EN_Turbocharger

ABC owns the copyright of this document. It shall not be copied or disclosed without prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.1/19 date: 13/July/2016 Ed. 06 EN

CHAPTER 12 COOLERS (Assembly 23 – 36)

12.1. 12.2. 12.3. 12.4.

OIL COOLERS ........................................................................................................................ 2 PIPE COOLER ......................................................................................................................... 2 PLATE COOLER..................................................................................................................... 7 CHARGE AIR COOLER. ..................................................................................................... 14

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS 12.1.

Ch.12 p.2/19 date: 13/July/2016 Ed. 06 EN

OIL COOLERS In regard to the application or to the necessity for a certain engine type, we have the choise between 2 different oil coolers, namely pipe coolers and plate coolers. (We refer to the Operation Manual or to the Description and Applications Manual).

12.2.

PIPE COOLER

12.2.1. DESCRIPTION (fig. 12.1) In installations where there is no sea water circuit or another open water circuit, the oil cooler is included in the LT-circuit in case of a radiator, a bun cooler, a keel cooler or a general cooling circuit or in the HT-circuit in case of single cooling circuit. The oil cooler consists of: - a cooler tube assembly or tube stack (1) mounted in a steel cylindrical envelope. - the free ends are provided with covers (2) & (10) on which flanges for the water circuit connection are provided. The covers contain also the protective anodes (3), 2 anodes per cooler. - the assembly is sealed by precision o-rings (6) or (7) and joints (5) - the cooling water is flowing through the pipes and the lub oil is circulating around the tubes and the flow is directed by means of baffles in polypropylene. - the envelope is provided with the connection flanges at oil side. Cooler type Z-OK-267-1-8/12 Z-OK-267-1-9/13,5 Z-OK-267-1-10/15 Z-OK-267-1-12/18 Z-OK-267-1-14/21 Z-OK-267-1-16/24

Mass (kg) 190 215 230 270 300 350

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

Soft water Soft water

ZEHT VLG PUL VIEW ACC ARROW

DOOR SHEDE SECTION

Zort water

DOOR SHEDE SECTION

Zort water

COOLERS

Ch.12 p.3/19 date: 13/July/2016 Ed. 06 EN

Fig. 12.1 File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Ch.12 p.4/19 date: 13/July/2016 Ed. 06 EN

MAINTENANCE MANUAL DZC ENGINES

COOLERS 12.2.2. RECAPITULATION OF THE MAINTENANCE JOBS Code M4-02

Jobs Check the quality of the cooling water, adjust the water treatment if necessary

O1-07(*)

Visually inspect the pipe oil cooler and clean if necessary

* Depends on the environment (air pollution, engine room ventilation, water quality) 12.2.3. SPARE PARTS Fig. n° 12.1

Ref. n° 5

Description

12.1

6

Precision O-ring

2

12.1

8

Precision O-ring

5

12.1

11

Joint (fresh water flanges)

2

12.1

12

Joint (oil flanges)

2

12.1

3

Anode

2

12.1

9

Screw

2

Joint

Qty/engine 2

Remark: The spare parts for the coolers may be ordered by repair set containing items 5, 6, 11 & 12 . (620.082.4100.01) 12.2.4. TOOLS No special tools are needed.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.5/19 date: 13/July/2016 Ed. 06 EN

12.2.5. MAINTENANCE (fig. 12.1) Staff required: 1 service man and 1 assistant. 1.

Dismantling.

For a good access for cleaning the internal tubes, it is necessary to remove the covers. If the upper half clamps of the cooler supports are removed, the cooler can remain on the engine. - drain both the water and oil system by removing the plugs. - disconnect the water piping at free end side (installation piping or engine piping) and remove the cover. - disconnect the oil piping at the flanges. - disconnect the water piping at flywheel side. - slide the oil cooler somewhat away on the supports. - remove the cover at flywheel side. - now the tubes are fully accessible for cleaning. 2.

Cleaning / Inspection.

The cooler consists of 2 sides: the water side and the oil side. Each side must be cleaned separately. Water side: - Close off at one end the cooler by means of a steel plate with a joint. - The water side of the cooler can be cleaned by a product like Silicene (SID Benelux) or a equivalent product. -

-

-

-

Attention: Hazardous liquids, for use refer to safety prescription card Poor the product, using the appropriate concentration with water, into the water side of the cooler. Be careful when gas is produced by the product, no open flames may be in the vicinity because of probable flammable gas. Make use of necessary PPE like chemical resistant mouth cover and chemical resistant gloves. Do this in open air or if not else possible in a well ventilated room. After the product has worked out and no gas is any more produced, the product can be drained. Collect the product in a chemical resistant jug and dispose of the product in an environmental friendly manner following local/international laws. After this, rense the water side of the cooler thoroughly with water. Clean the interior of the tubes with a barrel-brush. If there are any hard deposits in the tubes a long thin pipe can be used to push carefully remaining deposits out of the cooling pipes. Do this with the utmost care without damaging the tubes and/or cooler itself. Thoroughly inspect the tubes for signs of corrosion or erosion, particularly in the vicinity of the water inlet. These signs give on early warning of leaking tubes.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.6/19 date: 13/July/2016 Ed. 06 EN

- Examine the protective coating of the covers. If there are signs of cracking or blistering, the cover must be renewed or new coating must be applied by a specialized company. - Examine the protection anode(s). Its renewal is essential if it is corroded for 50%. - Rince the tubes with clear water. Oil side: - In order to clean the oil side of the cooler, all the covers need to be removed. - When the covers are removed the tube stack (1) is visible. Press out the tube stack with a press which evenly presses over the complete side surface of the tube stack. - When the tube stack is out of the cooler, the oil side can be cleaned by using a degreaser like Ultra Clean (Innotec) or a equivalent product. Attention: Hazardous liquids, for use refer to safety prescription card - After degreasing, dry the pipes and surfaces by air or clean compressed air. - Replace all replacement components to be found in repair set 620.082.4100.01 . - Re-assemble the cooler by pressing the tube stack back into the cooler by means of the same press used previously, pressing on the complete surface of the tube stack. Do this with utmost care. Remark: Complete dismantling is generally not necessary because the oil side remains sufficiently clean. If complete dismounting seems to be needed, the tube stack is to be removed from the steel envelope by appropriate tools. 3.

Assembly.

- Renew all joints and precision O-rings. - Renew anode(s) if needed. - Proceed in the reverse order of the dismantling procedure. 4.

Note.

When the cooler has been reassembled on the engine, the air must be allowed to escape while the system is being refilled. Shortly after the engine has been started, it is advisable to expel any air again.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS 12.3.

Ch.12 p.7/19 date: 13/July/2016 Ed. 06 EN

PLATE COOLER

12.3.1. DESCRIPTION (Fig. 12.2, 12.3 & 12.4) The plate heat exchanger consists of a pack of individual plates (2, 4, 5 and 6), which are gathered till one pack using gaskets (3) & (9). The connections are situated at the bottom of the pack. The plate pack is build using pressure plates (1 and 10).

Fig. 12.2 File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.8/19 date: 13/July/2016 Ed. 06 EN

The plate pack consist out of 4 types of plate: - Endplate type II (2): The function of this plate is to position the pack against the frame. This endplate (2) is directly connected with the connections. This plate needs a square joint around the inlets for sealing purposes. - Channel plates (4): These plates are direct behind the first plate. It are 4-hole plates with a normal joint (3). The plates are mounted alternating up and down. - Endplate I (5): This plate is mounted between the channel-plates and the transition plate (6). - Transition plate (6): This plate is mounted between the end plate I (5) and the pressure plate (1), and is placed to make draining of the water possible by using plugs (17). Cooler complete plate cooler (empty)

Mass (kg) depending engine application

When a plate pack is made out of several plates, the openings in the corners are forming collectors through which the water or oil can flow between the plates. Because of the joint arrangement and the alternating placement of plates “A” and “B” (Fig 12.3), the two fluids are running alternating into the passages. The warm medium gives its energy to the cold one during the passage through the heat exchanger. The temperature of the warmer medium drops, while the temperature of the colder medium is increased.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.9/19 date: 13/July/2016 Ed. 06 EN

Fig. 12.3 12.3.2. RECAPITULATION OF THE MAINTENANCE JOBS Code M4-02

Jobs Check the quality of the cooling water, adjust the water treatment if necessary

O2-18(*)

Completely clean the oil plate cooler.

* Depends on the environment (air pollution, engine room ventilation, water quality) 12.3.3. SPARE PARTS Advise the spare parts list to determine the exact parts. 12.3.4. TOOLS Code 620.084.1800.02

Description Tool for the mounting and dismantling of the plate cooler

To avoid hand injuries owing to sharp edges, protective gloves should always be worn when handling plates and protective sheets.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.10/19 date: 13/July/2016 Ed. 06 EN

12.3.5. MAINTENANCE 12.3.5.1. Dismantling the heat exchanger Mounting of the platecooler happens by means of extended studs, after pressing the plates the studs are replaced by shorter ones. Make sure that the extended studs are mounted before dismantling the heat exchanger. - If the heat exchanger is hot, wait until it has cooled down to about 40° C before opening.

Fig. 12.4 -

Drain the plate heat exchanger. Mark the plate assembly on the outside by a diagonal line or mark the plates in order. Grease the threads with a thin film of grease. Measure and note down the dimension “A”.

- Count the number of plates. To avoid hand injuries owing to sharp edges, protective gloves should always be worn when handling plates and protective sheets.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.11/19 date: 13/July/2016 Ed. 06 EN

- Loosen the bolts (12) and remove them. - Open the plate pack by letting the pressure plate (9) glide on the carrying bar. 12.3.5.2. Cleaning of the plate cooler: 1.

Regular cleaning:

The interval of the maintenance program depends on the used cooling water and of the heating load. Normally, it is not necessary to open the heat exchanger for regular cleaning (except an intermadiate control of plates and joints). There is a possibility to clean the plate cooler with the special equipment “Cleaning in Place” CIP, using chemical cleaning agents. Information concerning the equipment and cleaning products can be obtained with the ABC service department. 2.

Thoroughly cleaning:

During the thoroughly cleaning the accent is upon the control of every seperate part of the heat exchanger. This control is to determine a possible chemical and mechanical corrosion of the seperated components. During this cleaning, the next procedure must be followed taking care of the required quantities in regard to the degree of deposits as specified below: - For following media: - Calcium carbonate chemical cleaning using ammonia, nitric acid - Concentration max. 4%, temperature max. 60° C (140° F) - Oil resideus chemical cleaning by means of a paraffinic naphta-based solvent

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.12/19 date: 13/July/2016 Ed. 06 EN

Cleaning: - Open the heat exchanger - Remove the gaskets - Clean with a soft brush and running water - Rinse with water using a high pressure hose - Dry with a cloth and wipe with clean water

Fig. 12.5 Remark: Never use hydrochloric acid with stainless steel plates. Water of more than 330 ppm Cl may not be used for the preparation of cleaning solutions. Gaskets in EPDM rubber qualities swell in these media. Contact time should be limited to 30 minutes.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS 3.

Ch.12 p.13/19 date: 13/July/2016 Ed. 06 EN

Mounting of the heat exchanger:

-

Check that all the sealing surfaces are clean. Brush the threads of the bolts clean, using a steel wire brush. Lubricate the threads with a thin layer of grease. Attach gaskets to the plates and chack that all the gaskets are properly attached. If the gasket is wrongly positioned, it will show by the fact that it rises out of the gasket groove or that it is positioned outside the groove. - Insert the plates with the herring bone pattern positioned in alternate directions and with the gaskets turned towards the frame plate.

- Count and check the numer of plates. - Place the bolts (14), guidance bar (12), locking washer (13 & 16), guidances (11) and nut (15) and greas the threads with a thin layer of grease. - Press the plate assembly together and tighten the bolts alternately and diagonally. Be careful so that the frame plate and the pressure plate are always in parallel. - The dimension “A” can be calculated as next. N=number of plates in the plate assembly A= x N The real dimension “A” may never be less. - If the plates are correctly asembled, the edges form a “honeycomb” pattern.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS 12.4.

Ch.12 p.14/19 date: 13/July/2016 Ed. 06 EN

CHARGE AIR COOLER.

12.4.1. DESCRIPTION (Fig.12.6 & 12.7)

Fig. 12.6 File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.15/19 date: 13/July/2016 Ed. 06 EN

Fig. 12.7 The charge air cooler consists of: - a cast iron frame (1) containing the cooling block - a top closing cover (2) and a bottom cover with flanges (3), for connection to the water circuit. The joints (5)(6) ensure the water tightness. The covers are internally coated with corrosion resistant coating. Cooling water is flowing in the tubes of the cooling block and air between the tubes which are provided with a multitude of cooling fins. Cooler type Cooler complete

Mass (kg) 232

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Ch.12 p.16/19 date: 13/July/2016 Ed. 06 EN

MAINTENANCE MANUAL DZC ENGINES

COOLERS 12.4.2. RECAPITULATION OF THE MAINTENANCE JOBS

Code M1-05

Jobs Check free passage blow off hole on air cooler, if provided.

M6-07(*)

Check he differential pressure of the air cooler and clean if necessary

O2-23*

Complete cleaning the charge air cooler

* Depends on the environment (air pollution, engine room ventilation, water quality) 12.4.3. SPARE PARTS

Fig. n° 12.6

Ref. n° 6

Description Joint (water flanges)

Qty/engine 2

12.7

5

Joint

1

12.7

6

Joint

1

12.7

14

Joint (air flanges)

2

12.4.4. TOOLS No special tools are needed.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

Ch.12 p.17/19 date: 13/July/2016 Ed. 06 EN

12.4.5. MAINTENANCE (Fig.12.6 & 12.7) 12.4.5.1. Pressure drop charge air cooler. Generally prescripted the charge air cooler must be completely cleaned when the initial pressure drop of the air cooler (newly build engine) has been increased by 50%. A pressure drop that is double the original value must be considered as an absolute working limit for the engine. 12.4.5.2. Complete cleaning of the charge air cooler. Staff required : 1 service man and 1 assistant (in case the cooler is removed apart from the engine) 1.

Dismantling.

To have good access to the tubes internally for cleaning, it is necessary to remove the covers. The air cooler may remain on the engine. -

drain the water circuit - plugs (4) disconnect the cooling water piping at the flanges remove the covers (2) and (3). in order to clean thouroughly the air side it is preferable to take the cooler away from the engine. - disconnect the funnel inlet cooler (see fig. 11.2 chapter 11). - loose the cooler fixation screws. - slide the cooler to flywheel side to render free the funnel outlet cooler from the air receiver or manifold. Remove funnel from cooler (see fig.11.1. chapter 11). 2.

Cleaning / Inspection.

The cooler can be cleanened by means of a ultrasone cleaner at ABC. ABC advises cleaning in the factory. When this is not possible the cooler can be cleaned manually. The cooler consists of 2 sides; the water side and the air side. Water side: - Close off at one end the cooler by means the cover plate (2) with joint (5). - The water side of the cooler can be cleaned by a product like Silicene (SID Benelux) or a equivalent product. Attention: Hazardous liquids, for use refer to safety prescription card - Poor the product, using the appropriate concentration with water, into the water side of the cooler. - Be careful when gas is produced by the product, no open flames may be in the vicinity because of probable flammable gas. Make use of necessary PPE like File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS

-

-

-

-

Ch.12 p.18/19 date: 13/July/2016 Ed. 06 EN

chemical resistant mouth cover and chemical resistant gloves. Do this in open air or if not else possible in a well ventilated room. After the product has worked out and no gas is any more produced, the product can be drained. Collect the product in a chemical resistant jug and dispose of the product in an environmental friendly manner following local/international laws. After this, rense the water side of the cooler thoroughly with water. Clean the interior of the tubes with a barrel-brush. If there are any hard deposits in the tubes a long thin pipe can be used to push carefully remaining deposits out of the cooling pipes. Do this with the utmost care without damaging the tubes and/or cooler itself. Thoroughly inspect the tubes for signs of corrosion or erosion, particularly in the vicinity of the water inlet. These signs give on early warning of leaking tubes. Examine the protective coating of the covers. If there are signs of cracking or blistering, the cover must be renewed or new coating must be applied by a specialized company. Examine the protection anode(s). Its renewal is essential if it is corroded for 50%. Rince the tubes with clear water.

Air side: - The cooler can be cleaned chemically using a product like Oltec Clean 9100 (IAS), or another product for cleaning engine components. - Remove all covers of the cooler. - Submerge the cooler, preferably using a tackle with sufficient lifting capacity (see. Cooler mass 12.4.1), into a bath with the product using the appropriate concentration with water. Do this procedure at least in a well ventilated room. -

Attention: Hazardous liquids, for use refer to safety prescription card Leave the cooler as long as necessary into the product mix. Lift/take out the cooler using appropriate personal protective equipment like chemical resistant gloves. Dry the cooler with compressed air or also clear water can be used. When the cooler can’t be cleaned by the previous procedure, the air side can also be cleaned by using a degreaser like “Ultra Clean” (Innotec), gas-oil or white spirit. Clean the air sides in both directions.

Remark: * Care must be taken not to subject the tube block to temperatures above 120°C * High water pressure cleaning is to be avoided, because the cooling fins may be damaged or bended, which can disturb the air flow.

File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES

COOLERS 3. -

Ch.12 p.19/19 date: 13/July/2016 Ed. 06 EN

Assembly. renew screws and washers if needed. proceed in the reverse order of the dismantling procedure. renew all joints and seal-O-rings on funnels (see spare parts by chapter 11) proceed in the reverse order of the dismantling procedure we recommend that, after assembly, the charge air cooler should be subjected to a water pressure test.

4.

Water pressure test.

Required staff One service man Procedure - Mount the cover (2, Fig. 12.7) with the joint (5, Fig. 12.7) on the air cooler to close off one side of the cover. Also mount all necessary plugs and seals in the cover and the air cooler. - Place the air cooler vertically on its covered side and fill it completely with water (up to the top of the cooler). - Close off the air side with sealing plates and the standard air cooler gaskets. Use one sealing plate with an air pressure connection. - Put the air cooler under a pressure of 7 bar and check all tubes for leaks. There is a leak when air or air bubbles come out of the tube. - Do one of the following: If...

Do the following...

There are no leaks

You can stop the test and remove all testing components.

There are leaks

• •

Mark all the leaking tubes and remove the testing components. Seal the tube with a conical, red copper plugs. Mount the plugs with Loctite 275.

You cannot have more than three plugged tubes in an air cooler. If there are more leaking tubes in the air cooler, the tube block has to be repaired or replaced. 5.

Note.

When the cooler has been reinstalled on the engine, the air must be allowed to escape while the system is being refilled. Shortly after the engine has been started, it is advisable to expel any air again. File: B24_12_dd2017_07_14_Ed007_EN_Coolers ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

CHAPTER 13 TECHNICAL SPECIFICATIONS PRODUCTS

13.1.

SPECIFICATIONS OF PAINT .............................................................................................. 1 ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

MAINTENANCE MANUAL DZC ENGINES.

TECHNICAL SPECIFICATIONS PRODUCTS 13.1.

SPECIFICATIONS OF PAINT

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 13 Pag 1 Ed. 5 E

MAINTENANCE MANUAL DZC ENGINES.

TECHNICAL SPECIFICATIONS PRODUCTS

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 13 Pag 2 Ed. 5 E

MAINTENANCE MANUAL DZC ENGINES.

TECHNICAL SPECIFICATIONS PRODUCTS

ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC.

Chapter 13 Pag 3 Ed. 5 E