Approved: Maintenance Manual Diesel Engines Abc Type 12/16Dzc

MAINTENANCE MANUAL
DIESEL ENGINES ABC TYPE 12/16DZC

Chapter 3 – Page 0/1
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Cylinder housing
APPROVED
Date:
Head of technical department
ANGLO BELGIAN CORPORATION

GHENT
WN/NT/... WN
Ed. Date Initials Changes
+ Ed. (file no.) (distr. no.)
06 19/11/2015 / / JO
File: B34_03_dd2015_11_19_Ed006_EN_Cylinder_housing ABC owns the copyright of this document. It shall not be copied or
disclosed without prior consent of ABC.
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CHAPTER 3
CYLINDER HOUSING
(Assembly 1-31)
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CONTENTS
1 CYLINDER HOUSING AND CRANKCASE ................................................................................................ 3
1.1 Description............................................................................................................................... 3
1.2 Illustration ................................................................................................................................ 4
1.3 Recapitulation of maintenance jobs ......................................................................................... 5
1.4 Spare parts ............................................................................................................................... 5
1.5 Tools ........................................................................................................................................ 5
1.6 Dismounting the cylinder liner ................................................................................................. 6
1.7 Maintaining the cylinder housing ............................................................................................. 7
1.8 Re-assembling the cylinder housing ....................................................................................... 10
2 MAIN BEARING CAPS AND SHELLS .................................................................................................... 11
2.1 Description..............................................................................................................................11
2.2 Illustrations .............................................................................................................................11
2.3 Mass ...................................................................................................................................... 12
2.4 Recapitulation of maintenance jobs ....................................................................................... 12
2.5 Spare parts ............................................................................................................................. 12
2.6 Tools .......................................................................................................................................13
2.7 Dismounting the main bearing shells ..................................................................................... 14
2.8 Dismounting the guide bearing .............................................................................................. 20
2.9 Checking the main bearing shells ........................................................................................... 21
2.10 Checking the side clearance of the thrust bearings ................................................................. 23
2.11 Remounting the bearing shells and bearing caps .................................................................... 23
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1 CYLINDER HOUSING AND CRANKCASE
1.1 DESCRIPTION
Cylinder housing
The cylinder housing is cast in GGG40. After casting, the internal tensions are removed via a thermal
stress relief process. All non-finished surfaces are protected with anti-rust epoxy paint.
The cylinder liners (26, Fig. 3.1) are placed in the bores in the upper surface of the cylinder housing. The
small collar at the top of the liner fits these bores perfectly and keeps the liners in place. The cylinder
liners are equipped with the following components:
Component Ref. Fig. 3.1 Description
Anti-polishing ring 29 Mounted at the top of the cylinder liner to avoid bore polishing.
Joint 27 Mounted under the small collar at the top of the liner to seal the
liner. This assure the tightness under the collar.
Seal O-rings 28 Mounted on the bottom of the cylinder liner. This assures the
tightness at the bottom of the liner.
Crankcase
The crankcase is casted in the cylinder housing. The sides of the case are equipped with inspection
doors, which allow you to execute maintenance on the components in the crankcase.
The crankcase contains, amongst others:
• The main bearing caps and main bearings shells
• The oil suction basket with filter and suction pipe
• Explosion relief valves (on the inspection doors)
• On one of the inspection doors, an oil fill hole with sieve and cover
• The dip stick
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1.2 ILLUSTRATION
Fig. 3.1 Exploded view cylinder housing and cylinder liner
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1.3 RECAPITULATION OF MAINTENANCE JOBS

Code Description
O2-02 Checking and, if necessary, replacing the anti-polishing ring
O2-03 Washing the cylinder housing, removing all deposits and, if necessary, repainting
the interior
O3-04 Replacing the cylinder liners
1.4 SPARE PARTS

Refer to the spare parts list of the 12/16DZC engine
1.5 TOOLS
Code Description
620.084.1100.01* Tool for mounting and dismounting the cylinder liner
620.084.1700.02* Tool for dismounting the anti-polishing ring
620.083.1600.03 Torque wrenches with sockets and accessories
*Special tool, does not come with the engine. Only supplied on request.
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1.6 DISMOUNTING THE CYLINDER LINER

Required staff
One service man and one assistant
Procedure
1 Completely drain the water circuit.
2 Remove the cylinder head and the drive unit (conrod and piston). See “Chapter 1: Cylinder head”
and “Chapter 2: Drive unit”.
3 Protect the crankshaft from damage or corrosion. You can do this, for example, by inserting
strong paper in the crankcase or by taping paper to vulnerable components.
4 Extract the cylinder liner with tool 630.084.1100.01 (Fig. 3.2).
Fig. 3.2 Mounting (top) and dismounting (bottom) the cylinder liner with tool 620.084.1100.01.
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1.7 MAINTAINING THE CYLINDER HOUSING

1.7.1 Overview
Maintaining the cylinder housing includes:

1 Changing the oil (page 7)
2 Checking and cleaning the water passages (page 7)
3 Checking and replacing the cylinder liners (page 8)
4 Measuring the cylinder liners (page 9)
1.7.2 Changing the oil
Required staff
One service man
Procedure
1 Drain the oil from the engine. Proceed as follows:
a Drain the oil from the oil sump. To do so, open the oil drain cock or pump the oil out with
the pre-lubrication pump.
b Drain the oil from the oil filters. To do so, open the plug and the venting hole in the filter
house.
2 Clean the crankcase, the oil sump, the oil filling elbow and the filter cases with a brush and
gasoil. You can also use a pressure jet.
3 Dry all components with a sponge or a lint-free cloth.
4 Replace the filter elements of the lube oil filters and clean the filter cases.
5 Refill the engine with the recommended lube oil. Proceed as follows:
a Remount all the plugs and covers that you removed to drain the oil sump and oil filters.
b Fill the oil sump to the maximum level. Use the dip stick to check the oil level.
c Start the pre-lubrication pump to fill the oil pipes and vent the oil filter and the plate cooler.
You can only use the pump to vent when the engine is not in service.
6 At the next standstill of the engine, check the oil level and add some oil if necessary.
1.7.3 Checking and cleaning the water passages
Required staff
One service man
Procedure
1 Check the water passages. You can encounter the following problems:
Problem Cause
Severe corrosion Lack of anti-corrosion treatment of the water
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Problem Cause
Scale deposits Water too hard
Erosion or pitting in the wall of the cylinder • Air in the water passages, due to incorrect
liners and cylinder housing (in particular assembly or improper venting
around the water inlet and outlet)
• Lack of pressure (height expansion tank)
• Unsatisfactory water treatment
2 Clean the water passages. Proceed as follows:
a Remove all scale deposits with a steel brush, until the bare metal is visible.
b Paint the bare metal with rust proof paint, conform ABC norm 13.8/N.
1.7.4 Checking and replacing the cylinder liners
Required staff
One service man
Procedure
1 Extract the cylinder liner from the cylinder housing. See “1.6 Dismounting the cylinder liner”
(page 6).
2 Clean the collar of the cylinder liner and check it for cracks with crack detection spray (e.g.
Organol red and white). If you detect any cracks, the cylinder liner has to be replaced.
1.7.5 Honing the cylinder liners
The cylinder liners have to be honed when the piston or piston rings have to be replaced.
The surface of the cylinder liner has to be completely smooth to do so.
Required staff
One service man
Procedure
You can either hone the cylinder liner while it is on the engine or remove the cylinder liner from the
engine and hone it on a machine. Proceed as follows:
1 If you hone the cylinder liner while it is on the engine, hang a bag below the liner. This prevents
abrasives or metal particles from falling in the crankcase or the oil sump.
2 Hone the cylinder liner. If necessary, contact ABC for further information.
3 Clean the cylinder liner. Proceed as follows:
a Clean the cylinder liner with soap powder (e.g. Powder 430 M by Parco), diluted in water.
b Clean the cylinder liner with thin oil and rub it with a lint-free cloth.
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1.7.6 Measuring the cylinder liners
ALWAYS MEASURE THE CYLINDER LINERS WHILE THE LINERS ARE MOUNTED IN THE ENGINE.
Required staff
One service man
Procedure
1 Measure the inner diameter (B, Fig. 3.3) of the cylinder liner with a dial gauge. You have to
measure the diameter on three positions, each time in two directions:
Position Distance from top Description
1 75 mm Corresponds with top ring at TDC
2 375 mm Corresponds with oil scraper at BDC
3 540 mm Lowest part of cylinder liner (normally no/minimal wear)
2 Compare the results with the limits of wear. If one of the results exceeds the limit of wear, you
have to replace the liner or contact the ABC service department.
ØB Max. Max.
Dimensions Direction
(1,2,3) conicity ovality
X-X 256,000
OD 256,032
(original
dimensions) Y-Y 256,000
256,032
RL X-X 256,350
(reworking
Y-Y 256,350
limit)
LW X-X 256,500 0,05 0,1

(limit of wear) Y-Y 256,500 0,05. 0,1
Fig. 3.3 Measuring positions and limits of wear
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1.8 RE-ASSEMBLING THE CYLINDER HOUSING

Required staff
Procedure
1 Remount all components in reverse order from dismounting. You have to remount:
• The cylinder heads
• The drive units
• The crankshaft and the vibration damper
• The timing gear
• The pump gear case and the pumps
A LOT OF COMPONENTS HAVE TO BE MOUNTED WITH LOCTITE 574 (E.G. COVERS, OIL PAN, OIL SUMP,
FLYWHEEL SIDE COVERS, GEAR CASE INTERMEDIATE FLANGE, PUP GEAR CASE, TIMING GEAR CASE…).
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2 MAIN BEARING CAPS AND SHELLS
2.1 DESCRIPTION
Main bearing caps
The intermediate bearing caps (3, Fig. 3.4) and guide bearing cap (2, Fig. 3.4) are placed on the
crankcase with studs (5, Fig. 3.4) and nuts (6, Fig. 3.4). The nuts are tightened hydraulically.
Main bearing shells

Each main bearing cap contains two half bearing shells: an upper (2, Fig. 3.5) and a lower (1, Fig. 3.5)
bearing shell. The shells are positioned by lips and grooves, provided in the shells.
The shells are identical for all bearings, including the guide and the middle bearing. The guide bearing
has two half thrust bearings (3, Fig. 3.5), which line up the crankshaft horizontally.
2.2 ILLUSTRATIONS
Fig. 3.4 Exploded view main bearing caps
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Fig. 3.5 Exploded view main bearing shells
2.3 MASS
Component Ref. Mass (kg)
Lower half bearing shell 1, Fig. 3.5 1,37
Upper half bearing shell 2, Fig. 3.5 1,17
Half thrust bearing 3, Fig. 3.5 0,9
2.4 RECAPITULATION OF MAINTENANCE JOBS

Code Description
O2-05 Checking the condition of the main bearings (incl. axial bearing) and – if necessary
– replacing the bearings.
O3-01 Replacing the main bearings and the axial bearing.
2.5 SPARE PARTS

Component Ref. # 12DZC # 16DZC
Lower half bearing shell 1, Fig. 3.5 8 10
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Component Ref. # 12DZC # 16DZC

Upper half bearing shell 2, Fig. 3.5 8 10
Half thrust bearing 3, Fig. 3.5 2 2
2.6 TOOLS
Code Description
630.084.1500.01 Hydraulic tensioning tool with hand pump, to loosen and tighten the bearing cap
bolts. Hydraulic surface of tensioning tool has to be 7333 mm².
630.083.7600.01 Pen dismounting tool for bearing shells  20
630.083.7700.01 Pen dismounting tool for bearing shells  10
630.083.9011.01 Assembling gauge main bearing shells
630.083.9005.01 Tool for dismounting bearing caps
WITH THE TENSIONING TOOL, YOU CAN APPLY PRESSURE TO THE BEARING CAP BOLTS. AS A RESULT,
THE BOLTS ARE LENGTHENED AND YOU CAN FURTHER TIGHTEN THE BEARING CAP NUTS. THE AMOUNT
OF PRESSURE THAT YOU APPLY TO THE BOLTS DETERMINES HOW FAR YOU CAN TIGHTEN THE NUTS.
THE TIGHTENING PRESSURE THUS INDIRECTLY CORRESPONDS WITH A CERTAIN TIGHTENING FORCE.
IT IS VERY IMPORTANT THAT THE HYDRAULIC SURFACE OF YOUR TENSIONING TOOL IS 7333 MM². IF
NOT, THE TIGHTENING PRESSURES THAT ARE LISTED IN THIS MANUAL WILL NOT RESULT IN THE
CORRECT TIGHTENING FORCE. YOU WILL THEN UNDER- OR OVERTIGHTEN THE BEARING CAP BOLTS.
ALWAYS TIGHTEN THE TWO BEARING CAP BOLTS AT THE SAME TIME. TO DO SO, CONNECT THE TWO
TENSIONING TOOLS TO THE SAME HAND PUMP.
For more detailed instructions on the use and maintenance of the hand pump, refer to the
instruction booklet of the pump itself. It can be provided to you by the ABC service
department.
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2.7 DISMOUNTING THE MAIN BEARING SHELLS

2.7.1 Overview
1 Loosening the bearing cap nuts (page 14)

2 Removing the bearing cap and the lower bearing shell (page 19)
3 Removing the upper bearing shell (page 20)
2.7.2 Loosening the bearing cap nuts
Required staff
Procedure
To dismount the bearing shells, you have to loosen the bearing cap nuts with the hydraulic tool
630.084.1500.01. The tool consists of:
• A bridge, a hydraulic cell and a pulling nut (Fig. 3.6). These parts have to be mounted on the
bearing cap studs.
• A hand pump. You use this pump to apply pressure to the bearing cap studs.
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A B C Ref. Description
A Bridge
B Hydraulic cell
C C Pulling nut
Fig. 3.6 Components hydraulic tensioning tool
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Proceed as follows to loosen the bearing cap nuts:

1 Unscrew the side bolts M27 (Fig. 3.7) of the main bearing caps (fixing torque: 1350 Nm). Make
sure you do not lose the washers.
Fig. 3.7 Side bolts M27
2 Mount the components of the hydraulic tensioning tool on the two bearing cap studs. Proceed
as follows:
a Put the bridge and the hydraulic piston on the bearing cap stud. Make sure the opening of
the bridge is at the front, so you can reach the turning holes in the bearing cap nut.
b Screw the pulling nut on the bearing cap stud, as far as possible. Then, screw the pulling nut
3/4th of a turn back.
Fig. 3.8 Opening in bridge and turning holes in conrod nut
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3 Connect the oil lines to the hydraulic cells of the tensioning tools and to the pressure connectors
on the hand pump.
A
A
B B
C C
Fig. 3.9 Connections on hydraulic cells and on hand pump
Ref. Description Ref. Description

Position of opening in bridge (to
A Connection on hydraulic cell C
loosen/tighten conrod nut)
B Closing plug hydraulic cell D Two connections on hand pump
THE OIL LINES ARE FILLED WITH OIL. THEY ARE EQUIPPED WITH SELF-CLOSING COUPLINGS TO KEEP
THE OIL FROM SPILLING. BE CAREFUL NOT THE DAMAGE THE OIL LINES. KEEP THEM AWAY FROM
SHARP OBJECTS AT ALL TIMES.
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4 Put the hand pump in position A (PUMP) and start pumping (Fig. 3.10). Stop when the pressure
is 1090 bar. For a hydraulic surface of 7333 m², this corresponds with 800 kN.
5 Loosen the bearing cap nuts. To do so, put a small bar in one of the turning holes and turn the
nut (Fig. 3.11).
6 Slowly turn the lever of the hand pump towards position B (RELEASE) to lower the pressure (Fig.
3.10). Stop when all pressure is off (0 bar on the manometer).
Fig. 3.10 Hand pump positions Fig. 3.11 Turning the conrod nuts
7 Remove all components of the tensioning tools from both bearing cap studs.
8 Further screw off the bearing cap nuts by hand. Remarks:
• Screw off both nuts simultaneously, so the bearing cap lowers evenly.
• Stop when you see the side thread at each side of the main bearing cap.
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2.7.3 Removing the bearing cap and the lower bearing shell
Required staff
Illustration
Fig. 3.12 Dismounting bearing cap
Ref. Description Ref. Description

A Dismounting pen  10 D Plate for dismounting bearing cap
(630.083.7700.01) (630.083.9005.01)
B Dismounting pen  20 E Bolts to hold plates (100.102.027.060)

(630.083.9011.01)
C Tool for remounting bearing shells Iron wires to hold plates

(630.083.9011.01)
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Procedure
1 Mount a plate 630.083.9005.01 at each side of the bearing cap. Fix the plates with bolts
100.102.027.060.
2 Put an iron wire through each plate. These wires will help you to keep the bearing cap upright
while lowering it.
3 While holding the bearing cap, further screw off the bearing cap nuts.
4 Lower the bearing into the carter. Make sure the bearing cap stays in upright position. You can
also use two tackles to hold and lower the bearing.
Result: Once you lowered the bearing cap, you can take out the lower bearing shell.
2.7.4 Removing the upper bearing shell
1 Slide the bearing cap to the side, onto the carter supports.
2 Rotate the crankshaft until you can see an oil bore in the crankshaft and mount the dismounting
pen  20 or  10 in the bore.
3 Turn the crankshaft clockwise (seen from the flywheel side).
Result: The upper half bearing shell starts to come out.
4 Turn the upper half bearing shell to remove it from the engine.
2.8 DISMOUNTING THE GUIDE BEARING

Required staff
Procedure
The guide bearing is the second bearing, counted from the flywheel side. Proceed as follows to
dismount it:
1 Remove the bearing cap as described in “2.7.2 Loosening the bearing cap nuts” (page 14) and
“2.7.3 Removing the bearing cap and the lower bearing shell” (page 19).
DO NOT REMOVE THE STOPS (4, FIG. 3.5) FORM THE BEARING CAP OF THE GUIDE BEARING. THEY ARE
MOUNTED AT A SPECIFIC DISTANCE (18 MM) ABOVE THE MOUNTING SURFACE OF THE BEARING.
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2 Push the crankshaft to the left with a crowbar (Fig. 3.13) and take out the right thrust bearing.
ALWAYS PLACE THE CROWBAR ON THE COUNTERWEIGHTS OF THE CRANKSHAFT, NEVER ON A CRANK
WEB OR ANOTHER PART OF THE CRANKSHAFT.
Fig. 3.13 Pushing crankshaft aside
3 Take hold of the half bearing shell and rotate it to remove it from the engine.
4 Push the crankshaft to the right with a crowbar (Fig. 3.13) and take out the left thrust bearing.
5 Take hold of the half bearing shell and rotate it to remove it from the engine.
2.9 CHECKING THE MAIN BEARING SHELLS

2.9.1 Overview
You have to check the main bearing shells to see if they have to be replaced. You have to execute the
following checks:
1 Measuring the clearance between the crankshaft and the main bearing shells (page 22)
2 Visually checking the main bearing shells (page 22)
YOU ALSO HAVE TO REPLACE THE BEARING SHELLS EVERY 48000 RUNNING HOURS (OVERHAUL O3-
01). BESIDES, ABC RECOMMENDS TO REPLACE THE SHELLS EACH TIME YOU REMOVED A BEARING CAP.
ALWAYS REPLACE THE UPPER AND THE LOWER BEARING SHELL AT THE SAME TIME, ALSO IF ONLY ONE
OF THE SHELLS DISPLAYS WEAR.
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2.9.2 Measuring the clearance between the crankshaft and the main bearing shells
Required staff
One service man
Procedure
1 Loosen the bearing cap nuts and lower the bearing cap with the lower bearing shell. See:
• 2.7.2 Loosening the bearing cap nuts (page 14)
• 2.7.3Removing the bearing cap and the lower bearing shell (page 19)
2 Put a Plastigage strip in the lower bearing shell.
You can obtain Plastigage strips directly from the Perfect Circle Corporation or from local
Perfect Circle distributors.
3 Remount the bearing cap with the lower bearing shell. You have to tighten the bearing cap bolts
hydraulically. See:
• 2.11.5 Remounting the lower bearing shells (page 25).
• 2.11.6 Tightening the bearing cap nuts (page 27)
4 Remove the bearing cap.
5 Based on the Plastigage scale, check the clearance between the crankshaft and the bearing
shells. The clearance has to be between 0,22 and 0,32 mm.
6 Do the following if the clearance is not between 0,22 and 0,32 mm:
a Replace the bearing shells and recheck the clearance.
b If the clearance is still not correct, you can ask ABC to rework the crankshaft and mount
undersize bearing shells. Contact the ABC service department for more information.
2.9.3 Visually checking the main bearing shells
Required staff
One service man
Procedure
1 Clean the main bearing shells with a soft cloth and closely check the anti-friction coating of the
shell.
2 Replace the bearing shell if the anti-friction coating is loose or shows severe damage (severe
scratches or a lot of grooves).
You do not have to replace the bearing shell in case of slight wear, minor roughness or
slight cavitation around the oil bore and the sittings of the location lugs.
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2.10 CHECKING THE SIDE CLEARANCE OF THE THRUST BEARINGS

Required staff
One service man
Procedure
1 Put a dial gauge on the thrust bearing.
2 Push the thrust bearing to the right with a crowbar and set the dial gauge to 0.
3 Push the thrust bearing to the left with a crowbar and read the side clearance from the dial
gauge.
4 Compare the clearance with the limits of wear:
Original dimensions (mm) Limit of wear (mm)
0,12 - 0,27 0,12 – 0,30
5 If the clearance is larger than 0,30 mm, replace the thrust bearings and remeasure the clearance.
6 If the clearance is still larger than 0,30 mm, replace the normal thrust bearings by oversized
thrust bearings. Contact the ABC service department for more information.
WHEN YOU MEASURE THE CLEARANCE ON THE THRUST BEARINGS, WE STRONGLY RECOMMEND THAT
YOU ALSO MEASURE THE CRANKSHAFT DEFLECTION. SEE “CHAPTER 7: CRANKSHAFT”.
2.11 REMOUNTING THE BEARING SHELLS AND BEARING CAPS

2.11.1 Overview
Remounting the bearing shells and bearing caps includes:

1 Remounting the bearing cap studs (page 23)
2 Remounting the thrust bearings (page 24)
3 Remounting the upper bearing shells (page 24)
4 Remounting the lower bearing shells (page 25)
5 Tightening the bearing cap nuts (page 27)
6 Marking the bearing cap studs and nuts (page 31)
2.11.2 Remounting the bearing cap studs
Required staff
Procedure
1 If necessary, remount the bearing cap studs. Tighten them with a torque wrench to 200 Nm.
Normally, however, you did not have to remove the studs.
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2.11.3 Remounting the thrust bearings
Required staff
One service man
Procedure
Remount the two half thrust bearings, with the bronze and tapered side towards the crank web.
Proceed as follows:
1 Push the crankshaft to the left with a crowbar (Fig. 3.13).
ALWAYS PLACE THE CROWBAR ON THE COUNTERWEIGHTS OF THE CRANKSHAFT, NEVER ON A CRANK
WEB OR ANOTHER PART OF THE CRANKSHAFT.
2 Put the half bearing shell in the right side of the thrust bearing and rotate it to slide it in place.
3 Push the crankshaft to the right with a crowbar.
4 Put the half bearing shell in the left side of the thrust bearing and rotate it to slide it in place.
2.11.4 Remounting the upper bearing shells
Required staff
One service man
Procedure
To remount the upper bearing shell, you use tool 630.083.9011.01. Proceed as follows:
1 Place the upper bearing shell in tool 630.083.9011.01. Make sure that the location lug of the
bearing sits in the groove of the tool.
2 Turn the crankshaft until the dismounting pen ( 20 or  10).
3 Mount the tool with the bearing shell over the bearing cap studs. Fix the bolts by hand.
4 Turn the crankshaft counterclockwise (as seen from the flywheel side).
Result: The crankshaft pushes the upper bearing in place.
5 Remove tool 630.083.9011.01 and remove the dismounting pen from the crankshaft.
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630.083.9011.01
Fig. 3.14 Tool 630.083.9011.01
2.11.5 Remounting the lower bearing shells
Required staff
One service man
Procedure
1 Put the lower bearing shell in the bearing cap. Make sure that the location lug of the bearing sits
in the groove of the bearing cap.
MAKE SURE YOU REMOUNT THE BEARING CAP IN THE SAME POSITION AS BEFORE:
• THE NUMBER ON THE BEARING CAP HAS TO CORRESPOND WITH THE NUMBER ON THE
CYLINDER HOUSING. THE NUMBERING STARTS AT THE FLYWHEEL SIDE, FROM 0.
• THE MARK ON THE BEARING CAP HAS TO BE AT BANK A

MOUNTING THE BEARING CAP INCORRECTLY CAN CAUSE SERIOUS DAMAGE TO THE ENGINE.
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Bank B
Flywheel
Bank A
Fig. 3.15 Numbers on bearing caps and cylinder housing (underside view of engine)
Fig. 3.16 Marks on bearing caps and cylinder housing
2 Check if the intermediate rings (4, Fig. 3.4) are in place and remount them if necessary.
3 Put the bearing cap with the lower bearing shell over the bearing cap studs.
4 Manually screw on the bearing cap nuts.
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MAKE SURE YOU REMOUNT THE BEARING NUTS IN THE SAME POSITION AS BEFORE. ALL STUDS AND
NUTS ARE MARKED WITH A CYLINDER NUMBER AND BANK LETTER. IF YOU ARE MOUNTING NEW STUDS
AND NUTS, YOU HAVE TO MARK THEM AFTER YOU MOUNTED THEM. SEE “2.11.7 MARKING THE
BEARING CAP STUDS AND NUTS” (PAGE 31).
2.11.6 Tightening the bearing cap nuts
1 Mount the hydraulic tensioning tool on the bearing studs as described in step 2 of
“2.7.2 Loosening the bearing cap nuts” (page 14). Make sure the marking hole of the bridge sits
in the middle of the bearing cap nut (Fig. 3.17).
Fig. 3.17 Marking hole
2 Connect the oil lines to the hydraulic cells and to the hand pump as described in step 3 of
“2.7.2 Loosening the bearing cap nuts” (page 14).
3 Tighten the nuts to 150 bar. Proceed as follows:
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a Put the hand pump in position A (PUMP) and start pumping (Fig. 3.18). Stop when the
pressure is 150 bar. For a hydraulic surface of 7333 m², this corresponds with 110 kN.
b Keep the pressure at 150 bar for at least 20 seconds. If the pressure drops, pump again to
keep it at 150 bar.
If you accidently raised the pressure too much, lower it by slowly turning the lever of the
hand pump towards position B (RELEASE). When you reached the 150 bar, put the lever back
on position A (PUMP) and keep the pressure at 150 bar for at least 20 seconds.
c After 20 seconds, tighten the bearing cap nuts until they sit against the bearing cap. To
tighten the nuts, put a small bar in one of the turning holes and turn the nut.
d If you mount new nuts, mark the position of the nut with a center punch. You can do this
through the hole in the bridge of the tensioning tool (Fig. 3.19).
Fig. 3.18 Hand pump positions Fig. 3.19 Marking bearing cap nut
4 Tighten the nuts to 1090 bar. For a hydraulic surface of 7333 m², this corresponds with 800 kN.
You do this the same way you tightened the nuts to 150 bar.
If you are mounting new nuts, mark the nuts after you tightened them.
5 Slowly turn the lever of the hand pump towards position B (RELEASE) to lower the pressure (Fig.
3.18). Stop when all pressure is off (0 bar on the manometer).
6 Remove all components of the tensioning tools from both bearing cap studs.
7 If you mounted new bearing cap nuts, check the rotation angel of the nuts. Proceed as follows:
a Measure the rotation angle between both marks on the conrod nut with a tape measure
(Fig. 3.20). The rotation angle has to be between 301° and 313°, which corresponds with a
distance of 28 to 35 mm.
b If the rotation angle is not correct, contact the ABC service department.
MAINTENANCE MANUAL
Ed. 06- 19/11/2015 – EN
Cylinder housing
Fig. 3.20 Measuring rotation angle
8 Mount the bolts M27. Proceed as follows:

a Put the washers over the bolts and mount them in the cylinder housing (Fig. 3.21).
b Pretighten the bolts with a torque wrench to 650 Nm.
c Definitively tighten the bolts with a torque wrench to 1350 Nm.
Fig. 3.21 Bolts and washers
Ref. Description
A Bolt M27 (refer to spare parts list)
MAINTENANCE MANUAL
Ed. 06- 19/11/2015 – EN
Cylinder housing
B Washer (refer to spare parts list)
THE THEORETICAL STRETCH OF THE BEARING CAP BOLTS IS 1,6 ± 0,1 MM. YOU CAN THUS ALSO
MEASURE THE STRETCH TO CHECK IF THE BOLTS ARE TIGHTENED CORRECTLY.
MAINTENANCE MANUAL
Ed. 06- 19/11/2015 – EN
Cylinder housing
2.11.7 Marking the bearing cap studs and nuts
Required staff
One service man
Procedure
All bearing cap studs and nuts have to be marked, so you can keep the correct studs and nuts together.
If you mounted new studs and nuts, you have to mark them yourself:
• Mark the studs and nuts on the head (Fig. 3.22) so the marks are visible when the bearing cap
studs and nuts are mounted.
• Mark each stud and nut with its bank letter (A or B) and bearing number (0-9, starting from the
flywheel side). You find an overview of all marks in the table below.
Bearing
Bank
0 1 2 3 4 5 6 7 8 9
A A0 A1 A2 A3 A4 A5 A6 A7 A8 A9
B B0 B1 B2 B3 B4 B5 B6 B7 B8 B9
Fig. 3.22 Marks on studs and nuts

Approved: Maintenance Manual Diesel Engines Abc Type 12/16Dzc

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MAINTENANCE MANUAL

DIESEL ENGINES ABC TYPE 12/16DZC

Head of technical department

ANGLO BELGIAN CORPORATION

1 CYLINDER HOUSING AND CRANKCASE

Fig. 3.1 Exploded view cylinder housing and cylinder liner

1.3 RECAPITULATION OF MAINTENANCE JOBS

O3-04 Replacing the cylinder liners

1.4 SPARE PARTS

620.084.1700.02* Tool for dismounting the anti-polishing ring

620.083.1600.03 Torque wrenches with sockets and accessories

1.6 DISMOUNTING THE CYLINDER LINER

1.7 MAINTAINING THE CYLINDER HOUSING

Maintaining the cylinder housing includes:

1.7.2 Changing the oil

1.7.3 Checking and cleaning the water passages

1.7.4 Checking and replacing the cylinder liners

1.7.5 Honing the cylinder liners

1.7.6 Measuring the cylinder liners

2 375 mm Corresponds with oil scraper at BDC

3 540 mm Lowest part of cylinder liner (normally no/minimal wear)

LW X-X 256,500 0,05 0,1

Fig. 3.3 Measuring positions and limits of wear

1.8 RE-ASSEMBLING THE CYLINDER HOUSING

2 MAIN BEARING CAPS AND SHELLS

Main bearing shells

Fig. 3.4 Exploded view main bearing caps

Fig. 3.5 Exploded view main bearing shells

Upper half bearing shell 2, Fig. 3.5 1,17

Half thrust bearing 3, Fig. 3.5 0,9

2.4 RECAPITULATION OF MAINTENANCE JOBS

2.5 SPARE PARTS

Component Ref. # 12DZC # 16DZC

Half thrust bearing 3, Fig. 3.5 2 2

630.083.7600.01 Pen dismounting tool for bearing shells  20

630.083.7700.01 Pen dismounting tool for bearing shells  10

630.083.9011.01 Assembling gauge main bearing shells

630.083.9005.01 Tool for dismounting bearing caps

2.7 DISMOUNTING THE MAIN BEARING SHELLS

1 Loosening the bearing cap nuts (page 14)

2.7.2 Loosening the bearing cap nuts

Fig. 3.6 Components hydraulic tensioning tool

Proceed as follows to loosen the bearing cap nuts:

Fig. 3.7 Side bolts M27

Fig. 3.8 Opening in bridge and turning holes in conrod nut

Fig. 3.9 Connections on hydraulic cells and on hand pump

Ref. Description Ref. Description

B Closing plug hydraulic cell D Two connections on hand pump

Fig. 3.12 Dismounting bearing cap

Ref. Description Ref. Description

B Dismounting pen  20 E Bolts to hold plates (100.102.027.060)

C Tool for remounting bearing shells Iron wires to hold plates

2.7.4 Removing the upper bearing shell

2.8 DISMOUNTING THE GUIDE BEARING

Fig. 3.13 Pushing crankshaft aside

2.9 CHECKING THE MAIN BEARING SHELLS

2.9.3 Visually checking the main bearing shells

2.10 CHECKING THE SIDE CLEARANCE OF THE THRUST BEARINGS

2.11 REMOUNTING THE BEARING SHELLS AND BEARING CAPS

Remounting the bearing shells and bearing caps includes:

2.11.2 Remounting the bearing cap studs

2.11.3 Remounting the thrust bearings

2.11.4 Remounting the upper bearing shells