SCOPE OF WORKS OF 48000 RUNNING HOURS OVERHAUL FOR PIELSTICK ENGINE N.

4
Measurement
Item Description of work Chapter / Operation Sheet
1 Liners air leak test before starting of works E1

CYLINDER HEAD (CH)

2 Removal and refitting of CH 01-05
Disassembly of all components, cleaning of CH, paint with proper
3 primer E2
Inspection, reconditioning of CH, checking for fouling and hydraulic
4 test 01-08 E3

5 Reconditioning of injectors cooling area on CH by fitting proper bush.

6 Reconditioning of gasket seating on CH & Liner 01-14
7 Checking & adjusting tappet clearance 01-01
8 Removal & refitting of exhaust valve bodies 01-02 E2
Inspection, reconditioning of exhaust valve assy, replacement of
9 sealing rings 01-03, 01-04 E4, E5, E6
10 Removal & refitting of inlet valves 01-06
11 Inspection & reconditioning of inlet valves 01-07 E9, E10, E36
12 Removal & refitting of starting valves 01-09
13 Inspection & reconditioning of starting valves 01-10
14 Inspection & reconditioning of rotating devices (rotocaps) 01-11
15 Rocking gear inspection & reconditioning 01-12 E7, E8

INJECTION
16 Removal & refitting of injection pipes 02-01
17 Removal & refitting of the injectors 02-02

8 Checking of calibration, atomization and tightness of the injectors 02-03

19 Inspection & reconditioning of injectors 02-09
20 Inspection & reconditioning of injection pumps 02-05, 02-06 E11
21 Timing adjustment (shim under injection pump body) 02-08

MOVING ELEMENTS
22 Removal & fitting of the piston-connecting rod (CR) assembly 03-02 E2
Cylinder liners and water jacket removal, liner extraction,
23 replacement of o-rings and vibration dampers 03-10 E2
24 Visual & dimensional inspection of liners 03-03 E12
25 Cylinder liners dye penetration checking E13
26 Water jacket dye penetration checking
03-06,
Service Bulletin
27 Honing of liners 480927/11.04.06
 Measurement
Item Description of work Chapter / Operation Sheet
28 Replacement of ABPR (Anti Bore Polishing Rings) E40, E41
Inspection of the protection of cylinder head tie bolts anchoring in
29 the crankcase 03-14
Inspection, overhauling of pistons
(cleaning, replacement of tie bolts if necessary, clearance
measurement between piston crown and skirt before and after
works, piston grooves, piston pin/housing, dye penetration testing , E14, E15, E16, E17,
30 replacement of o-rings) 03-09 E18, E19
31 Reconditioning of pistons 03-15
32 Replacement of piston rings 03-05 E20
33 Removal & fitting of the CR into the piston 03-07
CR inspection,
big/small end measurement record
replacement of CR tie bolts and nuts
dye penetration checking and MPI test
34 CR nuts tightening 03-08 E21, E22
35 Replacement of CR small end bushes 03-16
Replacement of CR big end bearing shells
36 clearance between crankpin and CR shell after tightening 03-17 E23, E37

CRANKCASE - BEARINGS - CRANKSHAFT

37 Casing inspection and cleaning 04-01
38 Inspection of appearing welds on crankcase 04-10
Measurements of deflection and clearances under journals (before &
39 after completion of works) 04-02 E24, E25
40 Inspection, measurement and polishing of crank pins 04-05 E26
Inspection of the bearings & replacement of the bearing shells
lubricating clearances record
41 main bearings tightening follow up 04-06 E27, E28
42 Replacement of lip seal of shaft oil seal 04-07
43 Replacement of the bearing shells of the external bearing 04-08 E29
Dismantling and mounting of counterweights
44 counterweights tightening follow up 04-09 E30
45 Safety door inspection and o-ring replacement
46 Bed plate tie bolt nuts tightening checking E31
47 Foundation tie rod nuts tightening checking E32

TIMING GEAR - CAMSHAFT - BARRING GEAR

48 Visual inspection of cams and tappet rollers 05-01
49 Timing gear backlash measurements 05-02 E33
50 Checking of camshaft gearwheel springs 05-03
51 Removal and fitting of rocker arm push rods 05-04
52 Inspection of inlet and exhaust tappets and rollers 05-05 E34
Inspection / replacement of camshaft bearings
53 lubricating clearances record 05-06 E35
54 Barring gear inspection and overhaul 05-07
 Measurement
Item Description of work Chapter / Operation Sheet
55 Removal and fitting of the timing gears 05-08
56 Replacement of oil seals between the valve gear casings 05-10

COUPLING - VIBRATION DAMPER

57 Overhauling of the vibration damper, replacement of springs 06-01, 06-02

FLUID SYSTEMS
Inspection, cleaning of filters of starting electrovalves. Changing if
58 necessary 07-01
59 Inspection, overhauling of main starting air valve 07-02
60 Oil circuit gasket replacement
61 Fresh water circuit gasket replacement
62 Fuel oil circuit gasket replacement
63 Flexible hoses replacement
Overhauling of oil and water thermostatic valves, change of
64 thermostatic elements

65 Overhauling main water jacket pipes (chemical cleaning , restoring)

SUPERCHARGING
66 Air coolers overhaul (2 pieces) (cleaning, hydraulic test)
Replacement of the expansion bellows and overhauling of the
67 exhaust manifolds 08-01

GOVERNING - OVERSPEED - SAFETY - WIRING SYSTEM

68 Electronic overspeed test 09-01
Inspection of resilient links and replacement of ball joints on cross
69 linkage 09-03
70 Adjustment of control linkage 09-04
Inspection of the hydraulic governor control and replacement of
71 governor bearings 09-06 E38
Inspection of the stop jack and the fuel rack limitation jack on
72 starting 09-07

73 Preparation - Engine cleaning

74 Trials
Service Bulletin
75 Running in 482287/23.11.2001 E42
76 2-days endurance period after completion of running in
 SCOPE OF WORKS OF 48000 RUNNING HOURS OVERHAUL FOR PIELSTICK ENGINE N.
Measurement
Item Description of work Chapter / Operation Sheet
1 Liners air leak test before starting of works E1

CYLINDER HEAD (CH)

2 Removal and refitting of CH 01-05
Disassembly of all components, cleaning of CH, paint with proper
3 primer E2
Inspection, reconditioning of CH, checking for fouling and hydraulic
4 test 01-08 E3

5 Reconditioning of injectors cooling area on CH by fitting proper bush.

6 Reconditioning of gasket seating on CH & Liner 01-14
7 Checking & adjusting tappet clearance 01-01
8 Removal & refitting of exhaust valve bodies 01-02 E2
Inspection, reconditioning of exhaust valve assy, replacement of
9 sealing rings 01-03, 01-04 E4, E5, E6
10 Removal & refitting of inlet valves 01-06
11 Inspection & reconditioning of inlet valves 01-07 E9, E10, E36
12 Removal & refitting of starting valves 01-09
13 Inspection & reconditioning of starting valves 01-10
14 Inspection & reconditioning of rotating devices (rotocaps) 01-11
15 Rocking gear inspection & reconditioning 01-12 E7, E8

INJECTION
16 Removal & refitting of injection pipes 02-01
17 Removal & refitting of the injectors 02-02

8 Checking of calibration, atomization and tightness of the injectors 02-03

19 Inspection & reconditioning of injectors 02-09
20 Inspection & reconditioning of injection pumps 02-05, 02-06 E11
21 Timing adjustment (shim under injection pump body) 02-08

MOVING ELEMENTS
22 Removal & fitting of the piston-connecting rod (CR) assembly 03-02 E2
Cylinder liners and water jacket removal, liner extraction,
23 replacement of o-rings and vibration dampers 03-10 E2
24 Visual & dimensional inspection of liners 03-03 E12
25 Cylinder liners dye penetration checking E13
26 Water jacket dye penetration checking
03-06,
Service Bulletin
27 Honing of liners 480927/11.04.06
 Measurement
Item Description of work Chapter / Operation Sheet
28 -
Inspection of the protection of cylinder head tie bolts anchoring in
29 the crankcase 03-14
Inspection, overhauling of pistons
(cleaning, replacement of tie bolts if necessary, clearance
measurement between piston crown and skirt before and after
works, piston grooves, piston pin/housing, dye penetration testing , E14, E15, E16, E17,
30 replacement of o-rings) 03-09 E18, E19
31 Reconditioning of pistons 03-15
32 Replacement of piston rings 03-05 E20
33 Removal & fitting of the CR into the piston 03-07
CR inspection,
big/small end measurement record
replacement of CR tie bolts and nuts
dye penetration checking and MPI test
34 CR nuts tightening 03-08 E21, E22
35 Replacement of CR small end bushes 03-16
Replacement of CR big end bearing shells
36 clearance between crankpin and CR shell after tightening 03-17 E23, E37

CRANKCASE - BEARINGS - CRANKSHAFT

37 Casing inspection and cleaning 04-01
38 Inspection of appearing welds on crankcase 04-10
Measurements of deflection and clearances under journals (before &
39 after completion of works) 04-02 E24, E25
40 Inspection, measurement and polishing of crank pins 04-05 E26
Inspection of the bearings & replacement of the bearing shells
lubricating clearances record
41 main bearings tightening follow up 04-06 E27, E28
42 Replacement of lip seal of shaft oil seal 04-07
43 Replacement of the bearing shells of the external bearing 04-08 E29
Dismantling and mounting of counterweights
44 counterweights tightening follow up 04-09 E30
45 Safety door inspection and o-ring replacement
46 Bed plate tie bolt nuts tightening checking E31
47 Foundation tie rod nuts tightening checking E32

TIMING GEAR - CAMSHAFT - BARRING GEAR

48 Visual inspection of cams and tappet rollers 05-01
49 Timing gear backlash measurements 05-02 E33
50 Checking of camshaft gearwheel springs 05-03
51 Removal and fitting of rocker arm push rods 05-04
52 Inspection of inlet and exhaust tappets and rollers 05-05 E34
Inspection / replacement of camshaft bearings
53 lubricating clearances record 05-06 E35
54 Barring gear inspection and overhaul 05-07
 Measurement
Item Description of work Chapter / Operation Sheet
55 Removal and fitting of the timing gears 05-08
56 Replacement of oil seals between the valve gear casings 05-10

COUPLING - VIBRATION DAMPER

57 Overhauling of the vibration damper, replacement of springs 06-01, 06-02

FLUID SYSTEMS
Inspection, cleaning of filters of starting electrovalves. Changing if
58 necessary 07-01
59 Inspection, overhauling of main starting air valve 07-02
60 Oil circuit gasket replacement
61 Fresh water circuit gasket replacement
62 Fuel oil circuit gasket replacement
63 Flexible hoses replacement
Overhauling of oil and water thermostatic valves, change of
64 thermostatic elements

65 Overhauling main water jacket pipes (chemical cleaning , restoring)

SUPERCHARGING
66 Air coolers overhaul (2 pieces) (cleaning, hydraulic test)
Replacement of the expansion bellows and overhauling of the
67 exhaust manifolds 08-01

GOVERNING - OVERSPEED - SAFETY - WIRING SYSTEM

68 Electronic overspeed test 09-01
Inspection of resilient links and replacement of ball joints on cross
69 linkage 09-03
70 Adjustment of control linkage 09-04
Inspection of the hydraulic governor control and replacement of
71 governor bearings 09-06 E38
Inspection of the stop jack and the fuel rack limitation jack on
72 starting 09-07

73 Preparation - Engine cleaning

74 Trials
Service Bulletin
75 Running in 482287/23.11.2001 E42
76 2-days endurance period after completion of running in