. i co™ WARTSILA DIESEL BOLNES NY g INSTRUCTION- AND PARTS MANUAL Engine No. Type Construction Direction of rotation: 100/500 120/500 150/600 165/600 NL WARTSILA DIESEL 0.052043, 2690 AA Kempen aan de Lak, The Neeson 200g, 2991 LO Keimpen en de Lek, Telephone C1807: 18211, Telotx 1807-19508, Tees 22499 wardcopyricuts All copyrights are reserved. No part or parts of this manual may be reproduced in any form whatsoever and no information from this book may be supplied to third parties without’ written consent of Wartsila Diesel at Krimpen aan de Lek (Holland). EXEMPTION CLAUSE: ‘These instructions and the enclosed supplements, originating from the manufacturers of parts of the engines supplied by Bolnes Motorenfabrick B.V., must be read carefully before the engine is first commissioned. They should also be studied carefully before commencing any repairs to the engine or its accessories. The text and parts of the text of all these instructions are as far as possible written as standard instructions and are adapted for the various types of engines and operating circumstances. Neither Wartsila Diesel » nor the manufacturer of certain engine components {s Itable for any errors and/or incompleteness and/or neglect in the maintenance schedule and operational schedule described ~ including first commissioning of the engine; nor is it liable for any damage - direct or indirect - resulting from any possible errors and/or incompleteness and/or neglect «CONTENTS 1-00-01 | NL 84080E1 | UNL. 150/600 Part A Part B Part C Part D Part E Part F Part ¢ Part J Part N Part P GENERAL SYSTEMS ‘TECHNICAL DATA PRESERVATION COMMISSIONING DISMANTLING, ASSEMBLY and ADJUSTMENT INSPECTION LIST for the ENGINE ABT. 500 HOURS after COMMISSIONING or after REPAIR ENGINE OPERATIONS INSTALLATION DRAWINGS ‘TROUBLE SHOOTING CONSTRUCTION DRAWINGS PARTS C) 1-00-014 \ D 7112072 I 150/600Deel A GENERAL SYSTEMS A-00-01 B4080EL NL. 150/600 A-01/A-03, A-04/A-05 A-06/A-08 A-10/A-11, An12/A-13 Ar14/A-15 A-16/A-17 Ar18/A-19 ‘A=20/A-21 An22 A=23/a-24 A-36/A-37 A=38/A-39 A-4O/A~42. An43, ory General description Starting air lube of] Cylinder cooling water Cold cooling water Fuel/ges of1 overspeed protection Alarm and protection devices Various points of desaeration, filling and draining speed control List of symbols ued in diagrams Operation of scavenging air slides Description 6-8-1. lube of1 pump monitoring unit type 502 Cranking system Diesel process Air systems A-00-01GENERAL DESCRIPTION wor-o1 | a] ZS s20sor1_ |e | NF 150/600 CHARACTERISTICS Diesel engine operation: 2-stroke with uniflow scavenging and super- charger ~ crosshead scavenger pump type Bore + 190 mm stroke 350 mm speed 600 r-p.m. Average piston speed : 7 o/s Max. continuous power : 110 kli/cylinder (150 bhp) in moderate climate J21 KW/cylinder (165 bhp) CONSTRUCTION TYPE The engines may have 2 left-handed or right~ handed construction with a clockwise or anti- clockwise direction of rotation. CONSTRUCTION : Looking at the operating side of the engine the position of the governor shows the construction (on right or left side). DIRECTION OF ROTATION : Looking at the engine towards the flywheel a clockwise direction of rotation is right and anti-clockwise left. IN-LINE ENGINE V ENGINE, Construction Direction of rotation Dismantling crankshaft TYPE CLASSIFICATION + 6 DNL 150/600 No. of cylinders In-Line engine with supercharger [-— Power in bhp oe Number of r.pem. --——_______1 CYLINDER NUMBERING IN-LINE ENGINE : The cylinders are numbered from the flywheel side. V ENGINE : The cylinders are numbered for both sides of the engine starting on the flywheel side at the operating side and continuing at the other side. A-01-01@D A-02-01 NL | 4-02-01 | GENERAL DESCRIPTION WNL | 830401 150/600 The BOLNES " engine is built up of a number of components, the most important of which are described below: FRAME : The engine frame is made entirely of steel plate with the exception of the vertical frame plates in the crankshaft area which are wade of cast steel. The construction 1s designed such that once the detachable columns on the open side of the frame plate have been removed the crankshaft can be removed sideways. ‘The entire frame is annealed, after welding but before machining, to reduce stresses to a minimum. CRANKSHAFT The crankshaft consists of flanged shafts, crank pieces and intermediate shafts connected by shrink connections The construction of the crankshaft makes it possible for both ends of the shaft to take full engine power. BEARINGS ‘The crankshaft and connecting rods have thinshell bearings with a steel base. This steel base is covered with en adhesive layer to which a further layer of lead bronze with emergency running properties is applied. The top layer is a thin layer of Babbit with a galvanically applied zinc coating. ‘The connecting rod is drilled hollow for lube ofl for the lubrication of crosshead pin and cooling of working piston. CONNECTING ROD CROSSHEAD SCAVENGING AIR PISTON This is made of highquality castiron, cast in one piece. It is a cylinder- type crosshead snd works as a scavenger pump in series with the supercharger. The annealed and machined crosshead pin is fixed with bolts to the connecting rod and is installed in the thinvalled bearing bush. This is secured in the scavenging air piston. ‘The piston rod is drilled hollow for lube ofl for cooling of working piston. PISTON RODGENERAL DESCRIPTION 4-03-01 | NL 84030E1 | VNL. 150/600 WORKING PISTON CYLINDER LINER CYLINDER HEAD CAMSHAFT + The forged steel working piston has a basin ehaped top which, together with the similar form of the cylinder head, forms the “lens” shaped combustion chamber. The internal shape of the piston, together with the top of the piston rod, forms the chamber through which the lube of1 flows. The lube oil cools the piston wall be~ hind the piston rings and then the top of the piston. The cast iron, porous, chrome plated cylinder liner has tangentially drilled air inlet ports, which provide a good air vortex in the cylinder. The cylinder head consists of two parts made of high quality castiron. The starting air valve, indicator tap and both injectors are fitted to the bottom part of the cylinder head. The exhaust valve is centrally positioned with regard to the combustion chamber. The valve seat is exchangeable The entire machined, smooth camshaft has cams for exhaust valve and fuel pump for each cylinder. The cams are individually, hydraulically adjustable. The camshaft is driven by the crankshaft via a tensionable roller chain. 4-03-01iD a 4-04-01 | SYSTEMS STARTING AIR wnt | 8206081 150/600 A. Main air valve B. Pilot sir velve in fuel pump block . Starting air valve in cylinder head D, Exhaust valve in cylinder head E. Working piston G. Roller guide in camshaft support H. Fuel ofl cam K, Safety valve ‘The servo component of the main air valve may be operated pneumatically or electrically as well as manually. When the servo component is operated the main air valve opens and the entire starting air system is pressurized. The starting alr presses the plunger of the pilot air valve on the roller guide so that the fuel cam also commands the valve. When the working piston has just passed the T.D.C. the fuel of1 cam has lifted the pilot air valve far enough to allow starting air to flow to the servo part of the starting valve. This valve opens and allows starting air into the cylinder. The starting afr pushes the working piston downwards and the engine starts. Before the exhaust valve opens, the fuel cam has turned to such an extent that the pilot air valve has shut off the air supply and vented the servo part of the starting valve so that this valve closes. If the operation of the main air valve is interrupted this valve will Close and the entire starting air system is vented. A safety valve, set at 36 bar, is fitted at the end of the starting air line. This valve prevents the pressure in the system for any reason whatsoever, from becoming too high. It is essential that there is no moisture whatsoever in the starting air to prevent engine damage and breakdowns in the starting air systen. It is therefore also essential that sufficient condense traps are placed in the supply line to the main air valve in the correct positions, and that these are drained regularly. A-04-O1ML VL. A-05-01 8206071 150/600 A-05-01A-06-01 e4o80rl x ‘NL 150/600 A-06-01SYSTEMS ao7-o1 | | ZN LUBE OTL BOLNES 84080E1 | NL XT 150/600 A. Lube of1 pump H. Auxiliary lube of] pump B. Check valve J. Hand pump (. Thermostatic valve K. Cylinder lubricator D. Lube of1 cooler L. Float control E, Duplex filter M. Filter G. Overflow relief valve N. O41 reservoir. ‘The basic diagram is described here; refer to the drawings in part G for the actual system. ‘The engine lubrication consists of the following four systems: Circulation lube ofl for the moving parts and piston cooling. Cylinder lubrication. = Supercharger lubrication. = Governor lubrication. CIRCULATION LUBE OTL For lube ofl qualities, see part B-06. The engine driven lube ofl pump is of the gear wheel type. ‘This pump draws the lube ofl from the engine sump and pumps it through the check valve, the thermostatic valve, the lube ofl cooler and the duplex filter to the main lube of1 pipe in the crankcase. From here it {s distributed to the various moving parts. To cool the piston the lube ofl is pumped from the crankshaft bearing, through the bore in the crankshaft, the channel in the connecting rod, the crosshead and the channel in the piston rod, to the piston. In the hollow part of the piston the lube oil first cools the piston wall near the piston ring, thea the top of the piston and then flows through the pipe in the piston rod and the crosshead back to the engine crankcase. ‘The output of the lube of] pump at maximum operating speed is much more than the volume needed for lubricating and cooling the engine. The adjustable control/overflow relief valve controls the lubricating- ofl pressure in the engine system. Only the volume of of1 which goes to the engine system first passes through a filter (duplex configuration). Adjust the lube ofl pressure at the following engine running conditions (for correct adjustment values refer to B-08): ~ Engine runs at full speed. Lube of] at operating temperature. Pressure difference across duplex filter as low as possible, i.e. clean filter. Lube of1 flows through only one element of duplex filter. Lube of1 pump's built-in relief valve is closed. ‘The safety relief valve built into the lube ofl pump will not open during normal running conditions of the engine but only when the system pressure exceeds a certain value, for instance when starting a cold engine or 1f one of the pipes is blocked. The set value of this relief valve is about 0.5 - 1 bar higher than the setting of overflow relief valve G. The lube of1 temperature is controlled by a thermostatic valve, which keeps the temperature of the lube oil leaving the engine at a constant value. The thermostatic valve is installed behind the ube of1 pump and before the lube of1 cooler. A07-01NL | 4-08-01 | systems LUBE OTL SYSTEMS ‘WNL | 8408081 150/600 ‘The duplex filter is fitted behind the lube ofl cooler and parallel to the overflow valve. The filter has wire filter elements with a nominal mesh of 20 um as well as magnets. This filter ensures continuous cleaning of the lube oil before it flows into the engine A hand pump is included in the system to pre-lubricate the engine before starting. The additional connection on the hand pump can be used to empty the engine's crankcase. The valve behind the hand pump must be closed while the engine runs to prevent the hand pump from being danaged. An electrically driven auxiliary pump can be included in the lube of1 system. This pump also has a check valve behind the puup and a relief valve. The lube of1 system also contains the following components : = Venting and draining devices on cooler and filters. = Pressure gauges. ~ Thermometers. ~ Combined pressostat/thermostet switch to warn for either the low lube of1 pressure and/or high lube ofl temperature. CYLINDER LUBRICATION For lube of1 qualities, see part B-06. ‘The cylinder lubricator driven by the engine camshaft has it's own reservoir. An accurately adjusted volume of lube ofl is punped by the lubricator from this reservoir to both lubricating points in each eylinder lining. A floater valve and a high placed ofl reservoir ensure that this reservoir 1s always full at a constant level which is well above the plunger drive. There is a filter between the ofl reservoir and the level switch to protect the cylinder lubricating equipment. The cylinder lubricator can be operated manually so that pre~lubrication is possible when the engine is not running. The following, though not shown, are present in this system : = Level switch to warn for lube ofl level in lubricator. = Proving switch to warn when the lubricator stops, because of defective drive (not standard for in-line engines). LUBRICATING SUPERCHARGER * LUBRICATING HYDRAULIC GOVERNOR * Both the supercharger and the governor have their own lube oil system with a built-in reservoir. This level must always be checked when the engine is not running, and Must be between the two marks. * Refer to the appropriate instruction manuals in part H for the correct type of lube ofl, the operation and maintenance of these systems. 4-08-01NL | 4-10-01 | sysTems CYLINDER COOLING WATER SYSTEM vst | 84080E1 4-10-01 150/600 A. Cooling water pump E. De-geration connection on cylinder head B. Check valve G. Inspection glass in de-aeration line C. Thermostatic valve H. Expansion tank D. Cooling water cooler K. Auxiliary cooling water pump ‘The basic diagram is described here. Refer to the drawing in part G appropriate for the installation. The description explains : - the system. ~ de~aerating the cooling water space in the cylinder head. SYSTEM The engine driven centrifugel pump pumps the cooling water - via a check valve, @ thermostatic valve and @ cooler - to the engine. In the engine the cooling water removes heat from cylinders, cylinder heads and the supercharger after which it flows back to the suction side of the pump via the main cooling water return line. The thermostatic valve keeps the cooling water return temperature of the engine constant. Any air or gas bubbles may leave the cooling water in the expansion tank. The system also has the following components : ~ Various thermometers. = Pressure gauge. - Thermostatic switch as an alarm for high cooling water temperature In addition to an auxiliary pump the system may also include other equipment which removes heat from the cooling water. Principly this equipment should be installed between the thermostatic valve and the cooler because then the temperature across the engine is not affected. Always consult BOLNES about such additions. Refer to part B07 for cooling water treatment.oN NY ML vNL A-11-01 g4080T1 150/600 ar11-01150/600 4° YY Dsvsrens aio: | a | Zo COLD COOLING WATER SYSTEM BOLNES 84080E1 | VNL XY wy 150/600 Uelliatalel abate B. Thermoscatic control valve b. tube oft cooler ies eadrart osotaanwater 0,065 | 0,25 70,010 height of piston rings 5,00 ~97030 piston ring opening megsure under 0,9 3,5 slanted slot 45 pleton ting opening measure right 09 3,0 Fight angled slot angled CRANKSHAFT with BEARINGS connecting rod bearings a - 0,014 diameter crankpin VDNL 16s 9°Oh8 0,043 diameter crankpin DNL 155 83 crankshaft bearings - 0,014 dianeter crankshaft VDNL 170 Ooh 0,043 @iameter crankshaft DNL 13s T'Oe3 width over axial me 0,30 | 2 bearing VON -0,15 wath axial bearing om, | go OH 030 | see crankshaft crankshaft deflections deflections protocol 0,07 * Check clearance with a new ring. ** Serious damage or wear, where the bronze leyer in the loaded bearing half is visible over 30% of the cfrcumferance regardless of the width. Renew bearing halves as set. ‘*k* Renew when chrome layer is worn through.TECHNICAL DATA NO GO- SIZES Code 8-02-02/85010E1 150/600 sizes in om clearance in um CAMSHAFT new new no 80 0 shaft dianeter 60 sore 0,05 0,30 40,049 bearing diameter 60 3030 EXHAUST VALVE and ROCKER exhaust valve spindle 25 70108 diameter 0,06 0,06 re exhaust valve guide 95 £0,020 diameter 0,007 bearing bush diameter 3570408 in valve lever 0 0,09 0,3 0,03 shaft dianeter valve lever Se Hig oe SCAVENGING AIR PISTON and SCAVENGING AIR PISTON LINER diameter scavenging air 260 $0,032 0,35 a piston liner ° Bite tae Giameter scavenging ait 260-010 piston under rings 70,12 height of groove in 3 10,01 scavenging air piston -0,01 a Gice height of scavenging air a 0,060 piston ring -0,075 scavenging ait ring opening 1 a bearing bush diameter 95. 70,05 * crossheads 40,03 A a diameter crosshead pin 9s 70,08 ~0,07 hardness of crosshead pin Re 60 ~ 63 * Check clearance with a new ring. ‘** Serious damage or wear, where the bronze layer in the loaded bearing half is visible over 30% of the circumference regardless of the with of the wear. Renew bearing halves as set.TECHNICAL DATA soxor | m| ‘TORQUE VALUES BOLNES 84080E1 | VNL 4 \ 150/600 For bolt connections attention should be paid to the following points: PREPARATION: = Check threed. = Lubricate bolts, which will be heated, with copper-molykote. = Do not use grease or oil when Loctite is applied. = Gil bearing surfaces and threads lightly and check smooth screwing when torque wrench or hydraulic tensioning tools are used. ‘TIGHTENING: ~ Tighten bolt connections, fitted on moving parts, by using a torque wrench, and the specified torque value. - = Tighten cylinder head bolts and staybolts by using hydraulic tensioning tools. Refer to part D-36/D-37 or the use of hydraulic tensioning tools. SUMMARY of CENERAL TORQUE VALUES Allen screws and hexagonal bolts Maximum torque for 8.G material M6 10 N.m ( 1.0 kgf.m) M8 23 N.m ( 2.3 kgf.m) M10 45 Nom ( 4.5 kgf.m) M12 76 Nom ( 7.6 kgf-m) M16 168 N.m (16.8 kgf.m) M 20 324 Nom (32.4 kgf.m) M24 560 Nem (56.0 kgf-m) SUMURY of DEVIATING TORQUE VALUES concernin, Torque - EW 10.2 kef-m) 165/600 Securing aut injector Tio Nim (1° “eve ig0/e00 Securing nut gland against injector holder 40 N.m (4 kgf.m) Securing bolt crosshead pin and connecting rod 400 Nem (40 kgf.m) Securing nut of cover behind camshaft (V-engine) 45 Nem ( 4.5 kgf. Securing nut connecting rod cover 324 Nom (32.4 kgf, Cheek the torque tension at 90% of the specified torque values. SUMMARY of HYDRAULIC TENSION CYLINDER PRESSURES stud Pressure in cylinder Torque * Cylinderhead (cam-profile sealing) 460 bar see D-06-01B Cylinderhead ("O"-ring sealing} 450 bar 1150 Nm Staybolts ONl-engines . 670 bar Staybolts VDNL-engines 600 bar x Only to be used in emergencies. 3-03-01@ NL | B-04-01 | TECHNICAL DATA LOCKING and SEALS vw | 8408021 150/600 Type of Description of assembling Joctite 373 Under camshaft bearing. 241 Fastening bolts scavenging air liner. 241 Fastening bolts for bearingcap camshaft. 2a Fastening bolts camshaft bracket. 241, Fastening bolts fuel pump bracket. 307/ Steel bush in fuel rack fuel pump bracket. 242 Studs for fastening sealing bush holder. 572 Intermediate lengthening piece and end cover Lube of1 pump. 241 cylinder studs 572 Nipple in floatvalve. 572 Fastening lube oil pressure line in cylinder lubricator. 572,, Coupling in cylinderhead. IS04Ey, "O"=ring under cap for cylinderhead. TSO4E’ Rubberplate for overflow valve. 549 Scavenging air liner. 572 Securing sealing part of SPV-valve. 572 All fastening plugs and couplings. 573 Center partitions sealing bush holder 9.6.03018.0 INSTRUCTIONS for USING LOCTITE: = degrease components with loctite superclean 706 (no thinner etc.) ~ allow degresing agent to evaporate = apply loctite to both surfaces ~ fit components and observe curing time loctite type clearance in mm curing time 241 0.15 15 minutes 3 hours 572q 0.6 3 hours 12. hours 307 0.3 30 minutes 6 hours ISO4E - 20 seconds —_3 hours 549 0.6 6 hours 24 hours. 573 O.1 immediately after fitting * Note: Activator T only to be used with Loctite type 307. Before applying loctite, one of the parts should be pre-treated with activator T. Then should be stopped for abt. 3 minutes (solvent in activator should evaporate at first). ISO4E One of the surfaces to be glued, should be greased lightly. This should be pressed during 10 seconds.cN N74 3-05-01 wt | 3-05-01 | TECHNICAL DATA FUEL QUALITIES vw | 8206081 150/600 SUMMARY OF FUEL CODES Classification | Trade name Corresponds moat closely to specification* ASTM | BS 2869/70 | DIN Automotive D 975-73 |ClassA1 |— gas oil Grade 1-D Industrial D 975-73. {Class A2 | 51601-75 yeeatien (marine) Grade 2-D aie gas ofl Marine diesel -— Class Bl = | -— fuel distillate Diesel fuels |Marine diesel D 975-73 | Class B2 | 51603-76 with small fuel blended Grade 4-p Heizél L amounts of : \_ eet a eeeidae Light diesel | Class B 2 Fuel | 30 mm/s D 396-73 fuel Inter- | Quality 5 - [-— nediate | Cltsht) | 2 60 un?/s Class B 51603-76 fuel eet cae Hei2dl u pee 100 mm?/s [fet | p 396-73 ae fuel oils Quality 5 al |-— (heavy) 2, | (TFO) j 120 m?/s ~ \- fuel | 180 mn”/s Class F - fuel ; 7 420 mn”/s Heavy fuel fuel or Class ¢ ~ These fuel Marine oils do not fuel comply with (Fo) the maximum : 1 acceptable 600 m/s united |p 396-73 | Class H | s1603-76 values fuel states | Quality 6 |Heizol s Bunker | be | international deliveries to ships. ‘The of1 companies adhere to British Standard specifications for ** an extra requirement is a viscosity of max. 7 am’/e at 50 °c. #44 Residual fuels are indicated by stating their viscosity in an”/s at 50 °c.TECHNICAL DATA B-05-02 FUEL QUALITIES 8408021 VL 150/600 Standard BOLNES engines can run on distillate fuels without any problem. ‘This includes: - Marine gas oil Class A 2. - Marine diesel fuel distillate Class B 1. Part A-14/A-15 describes the basic diagram and the treatment of the type of fuel. The standard BOLNES engine can also run on marine diesel fuel blend Glass B 2 but it is essential to adapt the fuel treatment. @ ‘The heavy ofl type BOLNES engines can run on residual fuel. The following maximum acceptable values are given for this type of fuel = Viscosity at 50 °c 180 mn?/s - Density at 15 °c 0.99 ke/1 = Water (after separation) 0.1 % vol = Sulphur 3.5. % vol = Ash content 0.05 % vol = Vanadium 200 ppm = conradson Carbon Residue 10 %mass ~ Viscosity during injection 11 : 12.5 am’/s Note : ‘The values listed above do not guarantee good ignition quality. The sodium content must always be lower than 25 % of the vanadium content - even when there is less than 200 ppm vanadium. B-05-02NL | 8-06-01 | TECHNICAL DATA LUBE OTL QUALITIES nL | 8402021 Cy 150/600 BOLNES engines have four separate lube of] systems: ~- Circulation lube ofl for the moving parts and piston cooling. Cylinder lube oil. Lube oi1 for the supercharger. Lube oil for the governor. Bach of these systems requires its own specific lube ofl. Circulation lube ofl Irrespective of the fuel on which the engine runs, this lube ofl must meet the following requirement: ~ Contains few additives. ~ Viscosity class SAE 30. ~ Minimum TBN level: 8 TBN ~ max. 45 TBN. = Detergent level: MIL-1-2104B or API Classification CC and be lightly doped. cylinder Lube oil The quality of the lube of1 must be suitable for crosshead diesel engines. ‘The choice of this lube of1 depends on the content of sulphur in the fuel. For gas oil with a sulphur content of max. 0.3%: Viscosity class SAE 30 or SAE 40. ‘TBN level: minimum 12 TBN, maximum 30 TBN. Detergent level MIL-L~2104C or API Classification CD. For marine diesel ofl distillate with a maximum sulphur content of 1.0 % : Viscosity class SAE 30 or SAE 40. TBN level: minimun 15 TBN, maximum 30 TEN. Detergent level NIL~L~2104C or API Classification CD. For blended marine diesel oil with maximum sulphur content of 2.0 % : Viscosity class SAE 30 or SAB 40. ‘BN level: minimum 30 TSN, maximum 45 TBN. Detergent level MIL-L-2104C or API Classification CD. For residual fuel with maximum sulphur content of 3.5 % + Viscosity class SAE 40 or SAE 50. TBN level: minioun 60 TBN, maximum 70 TBN. Detergent level MIL-L-2104c or API Classification CD.INTRODUCTION B-06-02 LUBE OTL QUALITIES 84020E1 vu. 150/600 Supercharger lube of} Refer also to the supercharger instruction manual under part H. A turbine ofl with the follgwing propgrties: = Viscosity from 30 - 55 m/s at 50 °C. - High viscosity index. - Little or no tendency to foam. - High air separation capacity. - Bigh aging resistance. Hydraulic governor lube oil Refer also to the governor instruction manual under part Be A turbine or lube oil with the following properties: = Viscosity class SAE 20 - 30. High viscosity index. = Detergent level MIL-L-2104 B or API Classification CC. In most cases the same type of lube of1 can be used for the governor as for the supercharger or the circulation lube oil system. a B-06-02@ B-O7-01 wi | 8-07-01 | TECHNICAL DATA COOLING WATER WNL | 8402081 150/600 COOLING WATER SYSTEM An efficient cooling water system is of importance to ensure the reliability of the engine. The cooling water system must be checked regularly - this will avoid expensive repairs. ‘The following phenomena present the most problems in a closed cooling water circuit : ~ Freezing. = Deposits of scale, sludge etc. ~ Corrosion, both on the surface as well as deeper caused by galvanic processes and cavitation. Some suggestions to combat these problems are given below FREEZING Freezing can be prevented by : = adding anti-freeze and/or ~ regulated heating. DEPOSITS Deposits can be prevented by : = using distilled water in the system ~ with the disadvantage that this encourages corrosion. = using a water softener in the system that is an ion exchanger or demineralization unit - this is quite an expensive solution. = using chemical additives - see corrosion. CORROSION : Corrosion can be prevented by : = using only one type of material in the system - which, however is practically impossible and prevents galvanic corrosion only. - using chemical additives. The following chemical additives may be considered : ~ Chromates. = Nitrite mixtures. Chromates provide excellent protection against corrosion but are hardly ever used because : = they are toxic. ~ they have the disadvantage that they do not mix with anti-freeze.TECHNICAL DATA 3-07-02 ‘COOLING WATER z 84020E1 | VNL 150/600 Nitrite mixtures are greatly preferred because = = they give excellent protection against both corrosion and deposits. = their toxicity is low, so that they may also be used for equipment (desalinator). = they mix well with ethylene glycol without inhibitors (anti-freeze). = it is easy to measure the concentration by checking for the presence of sodiur-nitrite. = the presence of inhibitors adjusting the pH value between 8 and 11 gives optimum protection against galvanic corrosion. = they have no effect on the heat transmission. Refer to the supplier's instructions for the correct dosage. If required BOLNES can analyse the water samples. Note : Always use fresh water as a basis. B-07-02Part C COMMISSIONING and PRESERVATION c-00-01 84080E1 ML vx. 150/600 C-01 Starting stopping procedure -03 Preservation a ¢-00-01vNL PRESERVATION and COMMISSIONING ¢-01-01 STARTING/STOPPING PROCEDURE 84080E1 150/600 PREPARATION PRESERVATION: - Remove all preservative where present. FUEL SYSTEM: - Fill the fuel system. - Vent the fuel pumps and filters. = Check whether the fuel control mechanism works smoothly. LUBE OIL SYSTEM: = Check of1 level in: - engine crankcese. ~cylinder lubricator. “hydraulic governor. ~supercharger. - Prime circulation lube system up to 1.5 bar. - Turn crank(s) on the cylinder lubricator(s) at least 50 revolutions. = Turn engine during pre-lubrication with open compression cocks through at least one revolution. COOLING-WATER SYSTEM: = Check water level in the expansion tank. ~ Check concentration of chemical additives. - If relevant: open hullside valves. STARTING ATR: - Check pressure in the starting air vessels (30 ber). = Drain condensed water from the air vessels. = Purge starting air pipes to the engine. ALARM SYSTEM: - Energize alarm system. - If possible: check various alarm functions. STARTING: - Remove turning rod. = Close compression cocks. Start engine (see note). - Check working of pumps. - Engage engine. - Check all pressures and temperatures according to test bed report in B-08. ‘STOPPING: ~ Disengage engine. - Allow engine to run idle until the temperature is stable (see note). = Stop engine. Note: When using TFO fuel: switch over to gas ofl when starting and stopping. c-01-01‘COMMISSTONING c-03-01 | NL PRESERVATION 8206081 | VNL @ 150/600 MINIMUM PRESERVATION PROCEDURE for a PERIOD of 6 MONTHS MAXIMUM: = Drain cooling water system. = Close down fuel supply. - Grease external uncovered metal parts. - Close exhaust pipe and crankcase vent. = Open compression cocks. ~ Place bags of Shell VP1-280 powder, as protection against corrosion. int = crankcase. - scavenging air receivers. ~ receiver. - air coolers. = oil and water coolers. = Prime the circulation lube oil system once a week. = Turn the crank(s) on the cylinder lubricator 20 x by hand, once @ week. PRESERVATION PROCEDURE with SPECIAL PRESERVATIVE, IRRESPECTIVE of LENGTH of PERTOD: - Drain fuel ofl day tank and partly fill with: = "Shell Calibration Fluid B or shell Fusus Oil A. = Drain engine crankcase and fill with preserving oll (e.g. Shell Ensis Engine oil 30). - Start engine and run idle until: = entire fuel system is full of preservative. = entire circulation lube oil system is flushed. Both systems must remain filled. Drain cooling water system. ~ Preserve the uncovered external parts with: = Shell Ensis Oil or ~ Tectyl. = Close exhaust pipe and crankcase vent. = Open compression cocks. = Place bags of Shell VP1-280 powder, as protection against corrosion, int ~ crankcase. = scavenging air receivers. - receiver. > air coolers. = ofl and water coolers. Do not turn the engine after preservation. When the engine is being commissioned replace preservative with lube ofl. c-03-01Part D D-00-01 NL DISMANTLING, ASSEMBLY and ADJUSTMENT 84080E1 | VNL 150/600 D-01 General D-02/D-05 Tools for both NL and VNL engines D-06/D-07 Cylinder head Air starting valve D-08/D-09 Exhaust valve Exhaust valve spring Injector D-10/D-11 Working piston D-12/D-13 Piston rod Piston rod seal D-14/D-15 Cylinder liner D-16/D-17 Crosshead scavenging air piston D-18/D-19 Connecting rod bearings Scavenging air piston liner D-20/D-21 Crankshaft bearing shells p-22 Crankshaft p-23 Scevenging air valves D-24/D-25 Exhaust valve clearance Valve timing D-26/D-27 Pilot air valve D-28/D-29 Fuel pump and injection timing D-30/D-31 Cooling water pump Shear pin coupling Draining the crankcase D-32/D-33 Fuel oil control mechanism D-36/D-37_ Use of hydraulic tensioning tool D-38/D-39 Scavenging air slides adjustment D-40/D-41 Cylinder cooling water de-aeration D-42/D-43 Cleaning instructions filter elements Cleaning instructions supercharger D-46 Tensioning camshaft chain D-47 Tensioning crankshaft/intermediate shaft chain Tensioning intermediate shaft/pump shaft chain Deas Lube of1 pump drive Gylinder lubricator drive D-49 Camshaft chain Chain wheels Alignaent p-50 Pump drive Chain Chain vheels Taperlock clamping bushes Intermediate shaft D-51 Lube of1 pump V-engine 0-55-01 Reversible scavening air valve D-55-03 Fuel booster pump @DISMANTLING, ASSEMBLY AND ADJUSTMENT p-01-01 | NL. GENERAL, 84080E1 | VNL 150/600 The following chapters describe the most common dismantling and assenbly processes. The reference numbers given refer to the corres- ponding numbers in the tool list, sce part D-02/D-05. The text refers to the technical specifications in part B for specific information end specifications. Consult the conserning instruction manual for work on coolers, super charger, governor etc. in part Hi Always pay attention to the following points when carrying out work: = Drain cooling or lubricating system involved before starting work. = Close down fuel supply, if necessary. = Remove vulnerable measuring instruments. = Clean bolt connections fastened with Loctite thoroughly and use correct type of Loctite when fitting, see part B04. = Wyloc nuts and locking washers should preferably be renewed. = Joints, O-rings, copper washers etc. must alweys be renewed. Grease the O-rings, before fitting, with acid-free vaseline or crankcase oil. ~ If a helicoil screwlock hes to be renewed in a moving part this should alvaye have an extra packing winding. ~ Parts are not interchangeable. - Yost parts are numbered corresponding to the cylinder number. @ p-01-01ZN BOLNES NY D-02-01 7804072STANDARD TOOLS \ J p-03-01 | NL BOLNES 7804082 QZ 150/600 Per [Per cyl. leng.|Ref. | order number | Description 2 | 1 |9,2.82569.0 Set of hex. spanners | (3-4-5-6-8-10-14-17 om) 1 | 2 |9.2.82538.0 Pair of citclips pliers (for house) 1 | 3 |9.2.82539.0 Pair of circlips pliers (for shaft) 1 | 4 |9.2.82549.0 Combination pliers 1 | 5 |9.2.82527.0 Screw driver 8", 10 um 1 | 7 |9.2.82526.0 Wand hammer 500 grams 1 | 8 )9.2.82534.0 Hand lubricator 0.5 litres 1 | 10 Tin of engine paint (contents 1 kg) 1 fan *Bolnes” Flag 2 | 12 “Bolnes” transfers 1 | 13 |9.2.82578.0 | Set of sockets (double hex.) 10 mm 1/2" square 1 | 14 |9.2.82579.0 Set of sockets (double hex.) 13 mm 1/2" square 1 | 15. |9.2.82580.0 Set of sockets (double hex.) 17 mm 1/2" square 1 | 16 |9.2.82581.0 Set of sockets (double hex.) 19 mm 1/2" square 1 | 17 |9.2.82582.0 Socket 24 mm (double hex.) 3/4" square 1 [18 |9.2.82583.0 Socket 30 mm (double hex.) 3/4" square 1 | 19 |9.2.82597.0 Adaptor with outer hexegonal 8 am 1/2" square | 1 | 20 |9.2.82585.0 Extension bar 1/2" square x 10" length | (250) 1 | 21 |9.2.82586.0 | Ratchet lever with 1/2" square, extra short 1 | 22 |9.2.82587.0 Ratchet lever with 1/2" square, normal 1 | 23. |9.2.82588.0 Bar with sliding piece with 3/4" square, bent 1 | 24 |9.2.82528.0 Spanner 41 x 46 um 1 | 25. |9.2.82571.0 Set of combination spanners 10 um 1 | 26 |9.2.82572.0 Set of combination spanners 13 mm 1 | 27 |9.2.82573.0 Set of combination spanners 17 an 1 | 28 |9.2.82547.0 Combination spanner 19 am 1 | 29 9.2.82574.0 Set of combination spanners 2? am 1 | 30 |9.2.82575.0 Set of combination spanners 24 om 1 | 31 |9.2.82576.0 Set of combination spanners 30 am 1 | 32 [0.7.09028.0 Cap for mounting bearing scales 1 | 33. }9.2.09004.0 Clamp for mounting and dismantling piston 1 | 34 |9.6.09005.0 Hoisting plate for scavenging air liner 1 | 35. |9.6.09006.0 Tool for dismantling exhaust valve 2 | 36 |9.2.86665.0 Bolt M6 x 60 um for dismantling exhaust valve 1 | 37. |9.64.90071.0 | Assembling ring for piston (cam-profile sealing) 1 | 37 |9.6.09007.0 Assembling ring for piston ("O"-ring sealing) 1 | 38 |9+6-09008.0 Hoisting plate for scavenging ait piston 1 | 39 |9.2.09009.0 qj Tool for extracting nozzle (150/600)a 1 | 40 }9.6.09010.0 Grinding piece for exhaust valve 1 | 41 |9.6-09013-0 Spanner for nut cylinderhead 1 | ag [9-2-09014.0 Checkplate for valve clearance, type DNL 9.6.09003.0 Checkplate for valve clearance, type KNL 2 | 43° |9-6.09016.0 Hoisting bolt for cylindethead 1 | 44 |9.6.09019.0 Handwheel for overspeed safety 39 |9.6,49125.0 4 Tool for extracting nozzle (165/600) Attention: always state engine number when ordering parts. D-03-01ZN[u D-03-02 Xvi 7e0uo82 STANDARD TOOLS 150/600 Per [Per cyl.|eng.|Ref. | Order number | Description 1 | 45 | 9.2.09019.0 #3 Lever for priming fuel pump (150/600) 1 | 46 | 9.6.09021.0 Tool for mounting and dismantling sir pipes between the starting air valves 1 | 47 | 9.6.09026.0 Brace for dismantling cylinder liner 1 | 48 | 9.6.09024.0 Tool for mounting scavenging air piston 1 | 49 | 9.6.09029.0 Pin for mounting and dismantling crank- shaft main bearings 1 | 50 | 9.2.82553.0 Socket 41 mm (double hex.) 3/4” square 2 | Si | 9.2.82589.0 Extension bar 3/4" square x 300 mm length 1 | 52 | 9.2.82577.0 Ringspanner 65 um with tomny-bar 1 | 53 | 9.2.09060.0 Spring for valve scraping 1 | 54 | 9.6.09062.0 Turning bar with spring* 1 | 55 | 9.2.82584.0 Adaptor with outer hexagonal 10 um, 1/2" square 1 | 56 | 9.2.82497.0 Adaptor with outer hexagonal 14 mm, 1/2" square 1 | 57 | 9.2.82498.0 Adaptor with outer hexagonal 17 mm, 1/2" square 1 | 58 | 9.7.09026.0 Reducing aux. piece for bearingcap (VNL) bolts 1 | 59 | 9.7.09027.0 Straight aux. piece for bearingcep (VNL) bolts 1 | 60 |9.7.09042.0 Guiding-track for mounting aircoolers(VNL, 1 | 61 | 9-6.09009.0 Grinding tool for cyl.liner/head (O-ring Sealing) 1 | 61 |9.64.90091.0 | Grinding tool for cyl.1iner/head (camprofile seal) 1 | 62 | 9.6.09031.0 Air pistol for cleaning B & K filter * At an engine with 2 pneumatic turning device, the turning bar 9,6.09034.0 is cancelled. Instead of this should be delivered: 1 9.2,85419.0 Reversible ratchet lever. 45 | 2.21.90190.0 ax | Lever for priming fuel pump (165/600) 03-02 Attention: Always state engine number when ordering parts.@ D-04-01 wt | p-04-01 | sPECTAL TOOLS for ENGINES TYPE NL and DNL (CAN BE DELIVERED at EXTRA PRICE) 7511082 150/600 Per |Per cil.|mot.|Ref. | Bestelnummer | omschri jving 1} 100 | 9.6.09063.0 “Bosch” nozzle test apparatus with accessories and bracket 1/101 | 9.2.82593.0 Indicator in box with accessories 10 9.2.82594.0 Booklets indicator paper 1 9.2.82595.0 Collapsible tube with special grease 1/102 | 9.6.09059.0 Measuring point geuge for cylinder wear measurement 1/103 | 9.2.82596.0 Inner micrometer for measuring cylinder liner 1|104 | 9.6.09058.0 | Hookplate for mounting and dismantling scavenging eir piston 1 |105 | 9.2.82542.0 Dial gauge for crankshaft 106 1 [107 | 9.6.09065.0 Pressure apparatus with accessories for cams on camshaft 1 }108 | 9.2.82540.0 Torque meter wrench with 3/4" square (42 kgém) 1/109 2.82541 .0 Ratchet adaptor with 3/4" square 1}10 2.82590.0 Torque increasing apparatus with 3/4" square 1/111 | 9.2.82592.0 Reducer int. 3/4" and ext. 1” square 1/112 | 9.2.82591.0 Socket 65 mm (double hex) with int. 1" square 1 |113 | 9.6.09056.0 xx | Drilling geuge for dismantling exhaust valve seat (for CAST-IRON cylinderh.) * 1 |114 |9.6.09057.0 | Mounting piece for mounting exhaust valve seat 1 |115 | 9.6.09055.0 Mounting piece for retaining spring exhaust valve seat 11116 | 9.6.09075.0 Special hydraulic spanner for nuts eylinderheads and stay bolts (see D-05/D-04) 1/117) | 9.2.82599.0 Stub-drill DIN 1897, 7 um for dismantling exhaust valve seat 4/118 | 9.7.09076.0 Ring for hydraulic tensioning tool 1 119 } 9.6.09042.0 Hoisting clip for cylinderhead 1/120 | 9.2.82496.0 Torque meter wrench type 6006 M (1-10 kgm) 113 |9.6.09060.0 xx | Drilling gauge for dismantling exhaust valve seat (for VERMICULAIR cylinderhead) Attention: Always state engine number when ordering parts.p-os-01 | | ZN rsuom1 | ve. | LF 150/600 Ret 107}. acs J} Ret 16. at . z | : [ox Sp TLRet. 102 lan >| Ret 10 Ret. 109 == “Ret 108 Ref Mi Ref 112 Ref. D-05-01a NL | D-05-02 | TOOLS for both NL and VNL ENGINES vw | 8408082 150/600 Per [Fer cyl.|eng.|Ref. | Order number | Description 1 | 121] 9.6.49125.0 Tool for dismantling nozzle 2 | 122] 9:6.09105.0 Hook for fitting and dismantling piston rings | 2 | 123] 9.6.49127.0 Pin for centreing compression plate 1 | 124} 9.6.49014.0 Hoisting bracket for cylinder liner 1 | 125] 9.6.49129.0 Cover for fitting crankshaft bearing shells NL engine 1 | 126 Puller for removing sterting air pilot valve 1 | 127 Tool to rivet the triple chain in chain casing Always state engine number when ordering parts.ZO™N | | 0-05-04 | roots cor nor WL and VNL ENGINES BOLNES HYDRAULIC TENSIONING TOOL. 7 [| sosoet 150/600 Fer | Per cyl.l eng.| Ref.| Order number | Description 4 | 1 | 9.2.86016.0 | “o"-ring with support-ring 4 | 2 | 9.2:86015:0 | “o"-ring with support-ring 4 | 3 ] 9121843320 | ctretap 4 | 4 | 916:09070-0 | tightening cyinder complete 1 | 5 | 9.6.09080.0 | Junction block 1 | 6 |9:2:90770:0 | Pressure pump type TW 0, (Holmatra) 1 | 7 | 9.2.83350.0 | Manometer 0 ~ 1000 ke/cn’ 4 | 8 |9:2:90771:0 | Flexible tube 1/4", 500 mm Length with couplings 1 | 9 |9.2.90772.0 | Flexible tube 1/2", 1000 mm length with couplings 4 | 10 |9.6.09072.0 | Distance bush 2 Pes. without hole | end 2 Pes with hole, specify for stay bolts 1 | 11 | 9.6.09075.0 | tydraulic spanner assembly | 1-05-04 Attention: Always state engine number when ordering parts.0-05-05 | ML asoort | vnt. a) Nl 180/600 a] D-05-05,) mL | p-06-01 | DISMANTLING, ASSEMBLY and ADJUSTMENT ‘CYLINDERHEAD WWE | 77100E1 |AIR STARTING VALVE 150/600 CYLINDERHEAD see Fig. 1 and 2 and 2a 1. Drain the cooling water and disconnect all pipe fittings. 2. Remove the bolts of the exhaust manifold. 3. Turn the engine in such a way till the exhaust valve is in closed position. 4. Loosen the four fastening nuts with spanner Ref. 41, 51 and 52. 5. Remove (if fitted) retainer nuts and stud bolts of starter valve. 6. Use eye bolts Ref. 43 to lift cylinderhead from the engine. NB. Avoid damaging of the joint sealing surface. 7. After inspection or repair, mount in reverse order and carry out the following points: = revolve the engine till the piston goes below the upper edge of the cylinder liner. - clean thoroughly the seating surface of cylinder liners and cylinderheads and grind these with a grinding-ring Ref. 61, see Fig. 2a. NAB. Take note that by use, the grinding-ring will become unjust. Tt is necessary to ream the grinding-ring regulerly. ~ replace "O"-rings = check to see if the push rod covering pipe is in position, and make sure that the push rod end is fitted correctly under the rocker lever~arm during fitting of the cylinderhead. xx8. Tighten equally the four cylinderhead retainer nuts with tools Ref. 41 and 52. Apply after that hydraulic spanner Ref. 116 and bring the bolts twice to stress and fasten the nuts. For right working and pressure see page D-37. 9. Fasten “O"=ring under cover on cylinderhead with paste to cover. ATR STARTING VALVE see Fig. 1: Refer also to sectioned drawing of cylinderhead on page N4. 1, Remove pipes from both sides of the air starting valve with the tool Ref. 46 and take off both distributor air pipes. 2. Loosen the retainer nuts and lift the valve away from the stud bolts. 3, Dismantle, if necessary, the whole air sterting valve and use new “o"-rings when assembling. 4, Assemble valve agein in reverse order and use a new gasket between the valve housing and cylinderhead. ing cylinderhead sealed with camprofile-graphiteD-07-01 7710071 a D> 150/600 Ret61 D-07-01LO™ | wT 0-06-018 BOLNES NOT [vat | 9303071 150/600 i i tes ||| 11, lel | - : | i | i | | | | A |-——_——. Fi 1 i ! i | 1 | i I : tL DETAIL A Siliconen rin Can-profile/graphite 0-06-018,DISMANTLING AND ASSEMBLY INSTRUCTIONS o-o7z018 [ue | ZN eee eee TTT 150/600 Instruction cylinderhead (sealed with camprofile graphite ring) The cylinderheads which are sealed with an camprofile graphite ring have to be tightened with the hydraulic tensioning tools, NO PRETENSION. So don't use a torque wrench or ring spanner. This in order to prevent squeezing out of the graphite. First action : The cylinderheads have to be tightened with a pressure of 460 bar. This has to be done twice. Second_action After warming up the engine, tightened the cylinderheads with 460 bar again Third action After 100 running hours check the pressure with 460 bar. D-07-018& D-08-01 a) NL | 84080T1 150/600 Ref.3: Ref.36:DISMANTLING, ASSEMBLY and ADJUSTMENT p-09-01 | ML Zana EXHAUST VALVE BOLNES EXHAUST VALVE SPRING esosort | vt | YL, 150/600 EXHAUST ‘VALVE and SPRING see Fig. 4, 5 and 6 1, Remove injector holder and insert # screwdriver or something similar into the hole: the exhaust valve is then supported so as not to fall onto the pistonhead. 2. Remove lubricating pipe of rocker arm and socket head screws and press the shaft out on side, opposite of lube of1 connection, remove “o"-ring. This done, press shaft out on other side and remove the other “o"=ring. 3. Remove with two screwdrivers the valve stem retainer spring out of the valve cap. 4, Fit tool Ref. 35 and apply pressure to the valvespring by means of the bolts Ref. 36 (see Fig. 1) 5. Remove valve stem cotters, valve spring(s) and valve caps. 6. The valve spring(s) now to be examined or renewed. 7. If the exhaust valve has to be renewed or ground the cylinder head has to be dismantled. When re-grinding a valve use grinding clamp tool Ref. 40 and support spring Ref. 53 (see Fig. 2). 8. Mounted into the cylinderhead is a removable exhaust valve seating. If renewal is necessary, use drilling Jig tool Ref. 113 and stub-rill 7 nm, Ref. 117 in order to remove at 500 - 700 r.p.m. The knock-out with a chisel the piece between the two drilled holes. The valve seating now should be loose enough to be removed. Insert a new retainer spring and seating, using tools Ref. 114 and 115 respectively. By taping lightly on tool Ref. 114, the retainer spring will spring into its groove. After assembling the exhaust valve can be ground in. If a new guide-bush for exhaust valve has been fitted, after inspection the hole of the valve is to be reamed with a straight reamer diam. 21 H 7 (see Fig. 3). After reaming, inspect the hole, at which the diameter should be aan, 2119%021 10. After inspection and repair, clean each component thoroughly and mount in reverse order.a B4osorlDISMANTLING, ASSEMBLY and ADJUSTMENT v-o3-03 | | ZS INJECTOR BOL, s4oaor | ve | XO 150/600 DISMANTLING INJECTOR HOLDER with INJECTOR = Take off fuel pipe. = Remove gland. = Pull out nozzle holder. If holder is jammed, proceed as follows (fig. 1). = Remove the injector holder cap. - Fit studs and nuts of Ref. 108, = Sctew injector puller Ref. 108 onto the nozzle holder. Place flat side of gland on nuts. = Serew nuts up to puller bridge and pull out nozzle holder away CHECKING INJECTOR - Connect nozzle with holder to testing equipment Ref. 102. = Pressurize injector and check that pressure correspon that given in B-03. Readjust with adjusting screw, if necessary. ~ Reduce pressure in the testing equipment to approx. 20 bar lover than testing pressure and leave this on the injector for 10 s. = Check for leakage. I€ injector leaks, does not atomize well or has other defects, it must be replaced. REPLACING INJECTOR = Unscrew adjusting screw to remove spring tension from nozzle. = Unscrew union nut. - Thoroughly clean new nozzle of any packing material or preservative. = Clean nozzle and holder with clean gas ofl. - Check sealing faces for danage. - Fit nozzle in holder and tighten union with a torque wrench. For correct torque see B-03. = Set nozzle to correct pressure. FITTING NOZZLE with HOLDER ~ Clean hole in the cylinder head. = Fit nozzle holder with washer. ~ Attach fuel injection pipe to both pump and injector and tighten by hand. = Place gland with curved side on nozzle holder. = Fasten nuts on glend evenly with torque wrench. For correct torque see B-03. = Secure fuel injection pipe. D-09-03cM BOLNES XN4 NL | _D-10-01 | DISMANTLING, ASSEMBLY and ADJUSTMENT WORKING PISTON vw. | 84080E1 150/600 DISMANTLING ~ Remove scavenging air receiver cover. In the V-engine also remove covers behind camshaft. ~ Remove cylinder head, see D-06/D-07. ~ Turn engine until piston 1s in B.D.C. position. ~ Remove bolts which connect piston rod. - Turn engine until piston is in T.D.C. position. - Fit clamping bracket Ref. 33 on piston and pull out of cylinder by hand (see Fig. 1). = Decarbonize and clean piston. Tool Ref. 122 can be used for dismantling and fitting piston rings. Piston rings must be supported with fingers to avoid deformation (see fig. 2). If working piston only has to be cleaned, piston rings must not be removed. A working piston ring may be fitted only once. If a working piston ring is removed, it must be renewed. Fit piston rings with the marking TOP at the top. Upper piston ring has an additional material code. In an HF engine this applies to upper two piston rings. ASSEMBLY Check for damage: - piston, ~ compression plate and - piston rod. = Replace O-ring around top of piston rod. ~ Check that number on the compression plate corresponds to cylinder number and fit compression plate with some grease to prevent displacement during fitting. ~ Place centre locating edge of mounting ring Ref. 37 in cylinder liner. ~ Turn piston rings so that ring gaps are distributed around circumference of piston. - Fit two locating pins Re! = Oil piston and liner. With aid of clamping bracket Ref. 33 slide piston in Liner on piston rod; locating pins must drop into fixing holes. - Turn engine until piston is just before the B.D.C. piston must be pushed down simultaneously. - Remove locating pins. ~ Fasten piston to piston rod with bolts and tighten bolts with torque wrench - for correct torque see B-03. Avoid damage to piston rod in view of piston rod seal in gland. - Check that distance pieces are secured. ~ Check that O-ring of piston rod is seals properly by priming with lubricating oil. 123 in working piston. For running-in procedure after fitting new piston rings see F-05. D-10-01D-11-01 g4080r1 150/600 Fig. 1 Fig. 2 @ D-L-O1i 12-01 D-12-01 8408orl 150/600DISMANTLING, ASSEMBLY and ADJUSTMENT paso | ma] Zo PISTON ROD BOLNES PISTON ROD SEAL 84080E1 | VNL XT 150/600 PISTON ROD DISMANTLING (Fig. 1) = Revove cylinder head, see D-06/D-07. - Make receiver space accessible. = Renove four crossbars and bolt connection from divided retaining cover around the metallic piston rod seal. - Dismantle scavenging air valve on suction side of scavenging air piston. = Place two small wooden blocks on scavenging air piston and turn engine so that retaining cover is pushed upvards. = Renove O-ring and carefully renove both halves of cover- Avoid damaging metallic gaskets. ~ Remove piston rod/scavenging ait piston fastening bolts using 10 mn socket head screw wrench Ref. 1. ~ Pull piston with rod out of cylinder liner with aid of clamping strip Ref. 33. PISTON ROD SEAL (Fig. 2) ‘The piston rod seal consists of: 1. scraper ring (top ring in three parts) 2. sealing rings ( bottom rings, each in six parts) Parts of ring are held together by an annular spring and pressed against the piston rod. This spring can be removed for dismantling. The parts are not interchangeable; fit the marks next to each other. ASSEMBLY - Thoroughly clean piston rod and ring parts (do not mix these up). - Fit sealing rings carefully on piston rod. Check that rings lie flat on each other and seal well around piston rod. ~ Thoroughly clean mounting faces of piston rod and check for damage. - Fit piston rod with two new O-rings onto scavenging air piston. = Check that of1 ducts in scavenging air piston correspond to those in piston rod. - Fasten bolts in piston rod foot evenly. - After fitting retaining cover check whether piston rod seal can be rotated. ~ By priming check that of1 runs out of drain hole in scavenging ait piston. D-13-01NL | D-14-01 | DISMANTLING, ASSEMBLY and ADJUSTMENT CYLINDER LINER ve. | 8408021 D-14-01 150/600 GENERAL The internal diameter of the cylinder liner must be measured regularly to check for wear. It is important that these measurements always be taken at the same places in the cylinder, in order that the results can be compared. MEASURING LINER DIAMETER (INSPECTION) - Remove cylinder head. - Place measuring point gauge Ref. 102. - Measure below and above the return point of the top working piston ring (in the lenghtwise direction of the engine) with internal micrometer gauge Ref. 103. i ~ Turn internal micrometer gauge through 90° (in the crosswise direction of the engine) and repeat measurements. NsB. In order to be able to assess wear accurately also measure part of liner not travelled through by piston (highest point of measuring rod). For maximum tolerance see B-02; liner should be replaced if the chromium layer is broken. DISMANTLING ~ Remove cylinder head, see D-06/D-07. Remove working piston, see D=10/D-11. = Disconnect both cylinder lube oi1 pipes. = Turn engine until piston rod is in B.D.c. Place tool Ref. 47 on piston rod (figure 2). Turn engine so that cylinder liner is pushed upwards. Fit hoisting bracket Ref. 124 and remove cylinder liner. ' ASSEMBLY - Carefully clean - supporting rim of cylinder liner “supporting rim of cylinder jacket ~sealing face for O-rings in jacket. Check supporting surfaces for damage. Replace O-rings. Place inspected or new cylinder liner so that mark on circumference of the supporting rim points in lengthwise direction of engine. Fit the cylinder lube ofl pipes. ' Before commissioning check that: = cylinder liner lubrication is working, - cylinder jacket does not leak.