SERVICE BULLETIN RUSTON DIESELS LTO Rumber RK/53 VURGAN. HORKS, NEWTON-LE-WILLOWS, MERSEYSIDE, ENGLAND Issued by ~ Technical Publications. Dept., Date 27th November, 1979 HIS) INFORMATION 1S IMPORTANT TO YOUR ENGINEERS ANO SHOULD “BE PASSED ON TO THEM IMMEDIATELY SUBJECT?= APPLICAT,|ON: = DESCRIPTION: - CONNECTING ROD BOLTS V and RK2, RK3 and RKC (AIL Applications) ‘There have been isolated instances of cracks occurring in earlier type connecting: rod bolts at a point close to the heed, It is therefore recommended that particular attention be paid to the crack detection procedure, Instruction A783 in the Instruction Manual, which should be carried out on the bolts at the Tight overhaul exanination of the pistons and connecting rods, Instruction A736, It is alvays good practice to crack detect the bolts at any tine when the connecting rods are dismantled.CCRANKSHAFT PROTECTION DRIVEN EQUIPMENT LIFE EXTENSION Most engines are fitted with one or two viscous shear type torsional vibration dampers attached to the crankshaft at the opposite end to the flywheel Why are Dampers fitted ? The crankshaft damper is fitted to minimise the influence of torsional vibrations developing in the crankshaft. This keeps material stresses arising from these vibrations within permissible design limits. The / uapuraro ees Pipes. INTERCHANGEABILITY:~ The new high-pressure pipe assenblies are basically interchangeable with their superseded counterparts. However, it.is strongly conmended that fue! pump and injector end connections are kept for use with a specific pipe, even when pumgs and injectors are changed. NOTE:=This recommendation need not be implemented when a new fuel pump or injector is Fitted, -4eINSTRUCTION MANUAL CHANGE: Oldatype manuals * segecthehiegs + Fuel pump sectiiokt 68 > “Fuel injector Modern ‘fiandal’s Section’ 7 © Fuel Inje tion Pumps and Fuel injectors Insert a reference to this Service Bulletin ‘SPARES CATALOGUE CHANGE: = Old-type manuals ~ Group 220.- Fuel Oil Pipes Modern.manyals-'- Section 18/3 - Fue! 011 Piptog In-line: engines Dalete:= Part Nov AT220231 - H.P, Fual Pipe (Standard) or Part No. AT22901A = H.P. Fuel Pipe (Double-Skin) Insertt Part No. 80-212-0090-720 H.P. Fuel Part No, 80-212-00804-740 H.P. Fuel ort= Part Ho. 80-212-00941-730 H.P. Fuel Part No. 40-212-00941-740 H.P, Fuel Pipe Vee engines Insert Part Ko. 80-212-0090H-710 H.P. Fuel Part No. 80-212-CO9u4~720 HP, Fuel and Part No. 80-212-0094%-730 H.P. Fuel Part Ho. 80-212-0090%-790 4.P, Fuel Part No. 80-212-00961-710 HP. Fuel Part Ho. 80-212-00941-720 H.P, Fuel 1GAT2ZOSIH H.P. Fuel Pipe (Standard) 400-00680 H.P. Fuel Pipe (Double Skin) = A Bank Pipe (Standard) or Pipe (Standard, with Clamp Asseably) Pipe (Double Skin) th Clanp Asseably (Double Skin) A Bank or AT220235 H.P, Fuel Pipe (Standard) ~ 6 Bank or ATZ901A H.P. Fuel Pipe (Double Skin) - B Bank Pipe (Standard) - A Bank or Pipe (Standard) with Clanp Assenbly - 4 Bank Pipe (Standard) ~ 8 Bank or Pipe (Standard) with Clanp Assembly = 8 Bank Pige (Double Skin) - A Sank or Pipe (Qouble Skin) with Clanp Asseably ~ A Bankand Part Wo. 80-212-00941-730 #.P, Fuel Pipe (Double Skin) = B Bank or Part No. 80-212-0094-740 4.P, Fuel Pipe (Double Skin) with Clanp Assembly ~ B Bank Insert a reference to this Service BulletinSERVICE BULLETIN RUSTON DIESELS LTD Number AT/36 VULCAN WORKS, i NEWTON-LE-W1LLOWS, t Issued by ~ MERSEYSIDE, y iy { ce 4 (SFEBI8A Be }/ Technical Publications Dept., UL syteas Wy ae 7 Date 8th November, 1983 THIS INFORMATION 1S IMPORTANT TO YOUR ENGINEERS AND SHOULD BE PASSED ON TO THEM IMMEDIATELY. ‘SUBJECT: = HIGH PRESSURE FUEL PIPES APPLICATION: AT Mky 2 = In-line and Yee Engines DESCRIPTION: Fuel ieaks, fron high-pressure fuel pipes with the existing ferrule, have been reported and to overcone such leaks we have introduced a new-type ferrule which gives an inproved grip on the vipe. This is achieved by a double lip, the resulting double bite on the pipe giving a better seal against the high pressures involved. For future spares, high-pressure pipes will be supplied in kits, conprising:~ (1) High-pressure pipe with nuts and new-type ferrule. (2) Fuel pump delivery connection, (3) Fuel injector intet connection with edge filter (8) Latest design pipe clanp and bracket assembly, where necessary to replace earlier rocker cover clanp. MODIFICATION MATERIAL: High-pressure fuel pipe kit (Standard unsheathed) Vee engines A bank Part No. 80-212-00085-710 roplaces Part No. A bank (with clanp assenbly)Part Ho. #0-212-00984-720 } 30-16AT 22061 -H B bank Part Ho. 80-212-00984-730 replaces Part No. B bank (with clanp assenbly)Part No. 80-212-0094H-740 J 30-4T 22023-4 In-line engines Without clanp Part No. 80-212-00944-730 } replaces Part No. with clanp assembly Part yo. 80-212-00944-740 30-AT 2023-4High-pressure fuel pipe kit ( double-skin) Vee engines A bank Part Ho, 80-212-00841-710 ) replaces Fart Hos. ) 400- 00660 ang A bank (with clamp assenbly) Part No. 80-212-00941-720 ) 0-212-00817-200 8 bank Part wo. 80-212-00941-730 .) replaces part yes. ) AT 229014 and B bank (with clap assembly) Part No. 80-212-009N1-740 ) 20-212-00018-200 In-line engines FITTING INSTRUCT 1ONS:— Without clamp Part No. 80-212-00941-730 ) replaces Part Nos. ) AT 229018 and With clanp assenbly Part Mor 80-212-00981-740 ) 80-212-00918-200 (1) Assemble the new fuel pune delivery connection, part no. FATC-200724 to the fuel punp on the engine, (2) Assemble the new injector inlet connection with edge filter, part nos. FA2T 23022 and FAT 22027, to the injector on the engine NOTES-1 eartier inlet connection/Filter assembly, Part no, FAT 23070; wes previously fitted, the joint, pert no. FYL 23026, must be removed. a {2) Check the pine to place and ensure that the edi ofthe pipe "botton” without strain in the pump and injector connections. NOTE:+0n double-skin pipes only, assemble the sleeves, with 'O! rings, fo both ends of the pipe. Ensure that the drain sleeve. ia fitted to the pump end. (8) Assemble the nut and ferrule to each end of the pipe, ensuring that ‘the flanged end of the ferrule is towards the nut, as Illustrated. (8) it the pipe to place, ensuring that the ends of the pipe "botton” in the injector and puap connections. Lightly oil the threads and ferrules. Tighten the nuts until the ferrules grip the pipe and then tighten slightly further, no more that a quarter of a turn, to make the ferrules captive on the pipe. (8) Remove the pipe assenbly and also the punp and injector connections. (7) Clamp the punp delivery connection in a vice, fit the pipe then tighten the nut until the ferrule is gripped. Mark the nut and pipe, then tighten the nut one and a half full turns. NOTE:-A tube extension will be requiced on the spanner. (8) Remove the pipe from the punp delivery connection and then repeat Item (7) above with the injector inlet connection. -2-High-Pressure (%Q Fuel Pipex | i STANDARD PIPE qi Double-Lipped Ferrutes (Flanged end must be towards nut as shown DOUBLE-SKIN PIPE Drain Sleeve *O' Rings High-Pressure Fuel Pipe(9) Fit the injector and punp connections.to..the engine. (10) Fit the high-pressure fuel pipe assembly to -the engine and tighten the quts to normal spanaer tightness. (11) Locate the pipe clamp bracket on top. of, the cy! adjacent to the fuel punp and secure with an additional nut. Assenble the clanp to fit the pipe without straining. Cylinder Head Stud, Additional Nut Gap ta be Maintained XK, ‘Clamp Bracket Aperture for Dauble-Skin Fuet Pipes : Rubber Grommet for Standard Fuel Pipes Ss Packing Woshers (as required! INTERCHANGEABILITY The new high-pressure pipe assenblies aré basically interchangeable with their superseded countersarts. However, it is strongly re conmenced that fuel pump and injector end connections are kept for use with a specific pipe, even when pumps and injectors are changed. AOTES+Thi's recommendation need not be implemented wren a new fuel pump or injector is Fitted, ueINSTRUCTION MANUAL CHANGE: Old-type* naval ‘secthdn GQ: - Fuel pump gectiGn GR” - Fuel injector Modern mantal s Sectién 7 SPARES CATALOGUE CHANGE: = Old-type manuals - Group 220.~ Fuel Oil Pipes Modern manuals - Sect = Fuel Injection Punps and Fuel injectors In-line. engines Vee Delete:- Part No. Part Now Inserts Fart Now Part No. corte Part Ho. Part Nes engines and:~ Part No. Part No. Insert: = Part No. Part No. and Part No. Part Hos Part Ho. Part No. Service Bulletin n 19/3 ~ Fusl O11 Piping AT220234 - H.P. Fuel Pipe (Standard) or AT22901A ~ H.P. Fuel Pipe (Double-Skin) 80-212-C094~730 HAP. 30-212-00944-740 H.P. 80-212-00941-730 HAP. 90-212-00541-780 H.P, Fuel Pipe (Standard) or Fuel Pipe (Standard, with Clamp Asseably) Fuel Pipe (Double Skin) Fuel Pipe with Clamp Assembly (Double Skin) V6AT22061H H.P. Fuel Pipe (Standard) = A Bank or A00-00680 H.P. Fuel Pipe (Double Skin) - A Bank 47220234 H.?, Fuel Pipe (Standard) - 6 Bank or AT229014 H.. Fuel Pipe (Double Skin) - 8 Bank 80-212-00844-710 H.P. 80-212-COSu4~720 HP. 80-212-C0944-790 HP. 80-212-C084%-740 HP. 80-212-C0941-710 HAP. 80-212-0941-720 H.P. Fuel Pipe (Standard) - A Bank er Fuel Pipe (Standard) with Clanp Asseably - 4 Banke Fuel Pipe (Standard) ~ 8 Bank or Fuel Pipe (Standard) with Clanp Assembly ~ 8 Bank Fuel Pipe (Double Skin) - A Bank or Fuel Pipe (Oouble Skin) with Clanp Assembly - A Bankand Part No, 80-212-0841-720 H.P, Fuel Pipe (Double Skin) - 8 Bank or Part No. 80-212-00841-740 H.P, Fuel Pipe (Double Skin) with Clanp Assenbly + B Bank Insert a reference to this Service BulletinSERVICE BULLETIN RUSTON DIESELS LTD Humber AT/36 YULCAN WORKS, : NEWTON-LE-WILLOWS, e MERSEYSIDE, |. USFEB ISA eee ENGLAND. ‘ " ijuy Technical Publications Dept., ae tuys THIS INFORMATION 1S IMPORTANT TO YOUR ENGINEERS AND SHOULD BE PASSED OM TO THEM IMMEDIATELY. Date 18th November, 1983 SUBJECT: HIGH PRESSURE FUEL PIPES APPLICATION: = AT Mk, 2 = In-line and Yee Engines DESCRIPTION:~ Fuel leaks, from high-pressure fuel pipes with the existing ferrule, hhave been reported and to overcone such leaks we have Introduced a new-type ferrule which gives an improved grip on the oipe. This is achieved by a double lip, the resulting double bite on the pipe giving 2 better seal against the high pressures involved. For future spares, high-pressure pipes will be supplied in comprising:- its, (1) High-pressure pipe with nuts and new-type ferrule. (2) Fuel pump delivery connection. {3} Fuel injector inlet connection with edge filter (4) Latest design pine clanp end bracket assembly, where necessary to replace earlier rocker cover clamp. MODIFICATION MATERIAL: High-pressure fuel pipe kit (Stangaré unsheathes) Vee engines A bank Part No, 80-212-00988-710 replaces Part Wo. Avbonk (with clamp assenbly)Part Ho, 80-212-00994-720 } 30-1 6AT 22061-H B bank Part Yo. 80-2/2-00844-730 replaces Part to. B bank (with clanp assombly]Part Ho., 80-212-00944~740 } 30-AT 22023-J In-line engines Without clanp Part No. 20-212-00944-730 replaces Part No. with clamp assembly Part yo. 80-212-00944-740 30-AT 22023-5High-pressure fuel pipe kit ( docble-skin) FITTING INSTRUCT 10Ns Vee engines } A00- 00680 ang A bank (with clanp assenbly) Part Ho, 80-212-00941-720 ) 80-212-00817-200 ) AT 229014 and B bank (with clamp assembly) Part Ho, 80-212-00941-740 ) 80-212-00918-200 In-line engines ) AT 229014 and With clamp assenbly Part No. 20-212-00951-740 ) 80-212-00918-200 (1) Assemble the new fuel pump delivery connection, part no, FATC-20072A ‘to the fuel pump on the engine, (2) Assemble the new injector inlet connection with edge filter, part nos. FA2T 23022 and FAT 23027, to the injector on the engine. NOTE:-If earlier intet connection/Filter assembly, Part ne. FAT 23070} was previously fitted, the joint, part no. FYL 232026, must be removed. - {3) Check the pipe to place and ensure that the ends of the pipe "bottom" without strain in the puap and injector connections. NOTE: Cn double-skin pipes only, assenble the sleeves, with 'O" rings, fo both ends of the pipe, Ensure that the drain sleeve is fitted to the pump end. (4) Assemble the nut and ferrule to each end of the pipe, ensuring that the flanged end of the ferrule is towards the nut, as illustrated. (5) Fit the pipe to place, ensuring that the ends of the pipe "bottom" in the injector and pump connections. Lightly oi} the threads and ferrules. Tighten the nuts until the ferrules grip the pipe and then tighten slightly further, no more that a quarter of a turn, to make the ferrules captive on the pipe. (6) Remove the pipe assenbly and also the pump and injector connections. (7) Clamp the pump delivery connection in a vice, fit the pipe then tighten the nut until the ferrule is gripped. Mark the nut and pipe, then tighten the nut one and a half full turns. NOTE:-A tube extension will be required on the spanner. (8) Remove the pipe from the pump delivery connection and then repeat iten (7) above with the injector inlet connection. -2- A bank Part Ho. 80-212-00941-710 ) replaces Part Nos. B bank Part yo. 80-212-00941-730 .) replaces part nos. Without clanp Part No. 80-212-00941-730 ) replaces Part Hoss =High-Pressure Fuel:Pipe iS STANOARD PIPE Double-Lipped Ferrutes, (Flanged end must be towards aut as shown) *ORings High-Pressure Fuel Pipe N___S DOUBLE-SKIN, PIPE(9) Flt the Injector and punp connections to. the engine. (10) Fit the high-pressure fuel pipe assembly.to.the engine and tighten the nuts to normal spanner tightness. (11) Locate the pige clanp bracket on top of the cylinder stud nut adjacent te the fuel pump and secura with an additional nut. Assemble the clanp to fit the pipe without straining. Cylinder Head Stud, Additional Nut Gop to be Maintoined ‘Clamp Bracket Aperture for, oubie-Skin Fuel Pipes Rubber Grommet for Stendard Fuel Pipes INTERCHANGEASI LIT) The new high-pressure pipe assemblies are basically interchangeable with their superseded counterparts. However, it is strongly re~ connended that fuel pump and injector end connactions are kept for use with a specific pipe, even when punps and injectors are changed. Nore This recommendation need not be implemented wnen a new fuel pump or injector is Fitted. ~4-INSTRUCTION MANUAL CHANGE: = Old-type manuals Section 69 = Fuel puso Section 6% - Fuel injector Modern manuals Section 7 = Fuel Injection Pumps and Fuel Injectors : Insert a reference to this Service Bulletia SPARES CATALOGUE CHANGE: ~ Old-type manuals - Group 220 - Fuel Oi! Pipes Modern manuals - Section 13/3 - Fuel Oi! Piping In-line: engines Vee Deletes: Part No. Part Now Insertt~ Part No. Part No. Part No. Part Hos eng ines Delete:~ Part Ho. Part No. and Part No. Part Nor insert:= Part Nos Part No. Part Now Part No. AT220234 - H.P. Fuel Pipe (Standard) or AT22901A - H.P. Fuel Pipe (Double-Skin) 80-212-00845-730 H.P. Fuel Pipe (Standard) or 80-212-O0244-740 HP. Fuel Pipe (Standard, with Clamp Assembly) 80-212-C0S41-730 H.P, Fuel Pipe (Double Skin) 90-212-00941-790 HP, Fuel Pipe with Clanp Assembly (Double Skin) IGAT2206IH H.P. Fuel Pipe (Standard) = A Bank or A00-00680 H.P. Fuel Pipe (Double Skin) = 4 dank 47220230 H.P, Fuel Pipe (Standard) - 8 Bank or AT22901A HAP. Fuel Pi 80-2)2-00S4H-710 H.P. Fuel Pipe (Standard) - A Bank or 80-212-COStH-720 NP. Fuel Pipe (Standard) with Clan Aaseably ~ 4 Bank 80-212-00944-730 H.P. Fuel Pipe (Standard) - B Bank or 80-212-00944-740 H.P. Fuel Pipe (Standard) with Clanp Assembly = B Bank 80-212-0941-710 HP. Fuel Pipe (Double Skin) ~ A Bank or 80-212-00941~720 H.P. Fuel Pipe (Double Skin) with Clanp Assembly = A Bankand Part No. 80-212-00941~730 H.P. Fuel Pipe (Double Skin) = 8 Bank or Part Ho, 80-212-00S41-740 4.P. Fuel Pipe (Double Skin} with Clanp Assembly ~ 3 Bank insert a reference to this Service BulletinSERVICE BULLETIN RUSTON DIESELS LTD Number AT/36 VULCAN WORKS, NEWTON-LE-WILLOWS, =, MERSEYSIDE, , 1SFEBIEA ENGLAND. i i i ae {Udi guytea: bi atu Tha! eat Pebl ications Dept., Issued by - Date Ith November, 1983 THIS INFORMATION 1S IMPORTANT TO YOUR ENGINEERS AND SHOULD BE PASSED ON TO THEM IMMEDIATELY. SUBJECT:~ HIGH PRESSURE FUEL PIPES APPLICATION: = AT Mk. 2 = In-line and Vee Engines DESCRIPTION Fuel leaks, fron high-pressure fuel pipes with the existing ferrule, have been reported and to overcone such leaks we have introduced a new-type ferrule which gives an improved grip on the vipe. This is achieved by a double lip, the resulting double bite on the pipe giving a better seal against the high pressures involved. For future spares, high-pressure pipes will be supplied in kits, comprising! (1) High-pressure pipe with nuts and new-type ferrule. (2) Fuel pump delivery connection. (3) Fuel injector inlet connection with edge filter (#) Latest design pipe clasp and bracket assembly, where necessary to replace earlier rocker cover clamp. MODIFICATION MATERIAL: ~ High-pressure fuel pipe kit (Standard unsheathed) Vee engines A bank Part No. 80-212-00988-710 ) replaces Fart No. A bank (with clanp assembly )Part No, 80-212-00944-720 } 30-16AT 22061 -1 B bank Part Ko. 80-212-00984-730 replaces Fart Mo. B bank (with clanp assonbly)Part No. 80-212-0914-740 } 30-AT 2202-5 In-line engines Without clanp Part No. 80-212-c0344-730 ) replaces Part Ho. with cloap assembly Part yo 80-212-00004-740 | g0-AT 22028-h-pressure fuel pipe kit ( double: in) Yee engines A bank Part No. 80-212-00841-710 ) replaces fart Nose } 400- 00680 and A bank (with clanp assembly) Part Ho. 80-212-00941-720 ) €0-212~00917~200 B bank Part yo. 80-212-00941-730 ) replaces part yose ) AT 229018 ang Bbank (with clanp assembly) Part Ho, 80-212-00911-740 ) 20-212-00818-200 In-line engines FITTING INSTRUCTIONS: Without clanp Part No. 80-212-00941-730 .) replaces Part Nos. ) AT 229014 and With clamp assembly Part No 80-212-00981-740 ) g0-212-00918-200 (1) Assemble the new fuel pump delivery connection, part nos FATC-200724 to the fuel pump on the engine, (2) Assemble the new injector inlet connection with edge filter, part nos. FA2T 23022 and FA2T 23027, to the injector on the engine. NOTE:-If earlier inlet connection/ filter assembly, Pert ne. FAT 23070, was previously fitted, the joint, part ne, EYL 23025, must be removed. (3) Gheck the pipe to place and ensure that the ends of the pipe "botton™ without strain in the punp and injector connections. On double-skin pipes only, assenble the sleeves, with 'O" rings, fo both ends of the pige, Ensure that the drain sleeve is fitted to the pump end. (4) Assemble the nut and ferrule to each end of the pive, ensuring that the flanged end of the ferrule is towards the nut, as illustrated, (5) Fit the pipe to place, ensuring that the ends of the pipe "botton" in the injector and pump connections. Lightly oi] the threads and ferrules. Tighten the nuts until the ferrules grip the pipe and then tighten slightly further, no more that a quarter of a turn, to make the ferrules captive on the pipe. (6) Renove the pipe assenbly and also the pump and injector connections. (7) Glanp the punp delivery connection in a vice, fit the pipe then tighten the nut until the ferrule is gripped. Mark the nut and pipe, then tighten the nut one and a half full turass NOTE:-A tube extension will be required on the spanner, (8) Remove the pipe from the pump delivery connection and then repeat item (7) above with the injector inlet connection. -2-High-Pressure Fuel Pipe—_| S eI STANDARD PIPE qi Double-Lipped Ferrules, (Flanged end must be towards aut as showa) (DOUBLE-SKIN PIPE Drain Sleeve. OF Rings High-Pressure Fuel Pipe(8) Fit the injector and pump connections to the engins. (10) Fit the Righ-pressure fuel pipe sszenbly to the engina and tighten the nuts to normal soanner tightness. (11) Locate the pipe clamp bracket on top of the cylinder stud nut adjacent to the fuel pump and secure with an additional aut. Assenble the clamp to fit the pipe without straining. Cylinder Head Stud, Additional Nut Gap to be Maintained ‘Clamp Bracket Aperture for, Rubber Gremmnet for Standard Fuel Pipes INTERCHANGEABILITY:~ The new high-pressure pipe assemblies are basically Interchangeable with their superseded counterparts. However, it is strongly re- conmended that fuel pune and injector end connections are kept for use with a specific pipe, even when pumps and injectors are changed, NOTEs-This recommendation need aot be implemented when a new fuel pune or injector is Fitted, aeINSTRUCTION MANUAL, CHANGE: Old-type manuals Section 6@ - Fuel pump Section 62 - Fuel injector Modern manuals ee Section 7 - Fuel Injection Punps and Fuel injectors Inserta reference to this Service Bulletin SPARES CATALOGUE * * CHANGE: ~ Old-type manuals - Group 220 - Fuel Oil Pipes Modern manuals - Section 13/3 - Fuel Oil Piping In-line: engines ~ delete: Part No. AT22023J - K.P, Fuel Pipe (Standard) or Part No. AT22901A = HP. Fuel Pipe (Double-Skin) Inserts Part No. 80-212-00944-730 H.P, Fuel Pipe (Standard) or Part No. 80-212-00944-740 H.P, Fuel Pipe (Standard, with Glenp Assembly) ort= Part Ho, 80-212-00841-730 H.P. Fuel Pipe (Double Skin) Part No. 90-212-00841-780 H.P. Fuel Pipa with Clamp Asseably (Double Skin) Vee engines Delete:~ Part No. 16AT22061H H.P, Fuel Pipe (Standard) - A Bank or Part No. A00-00680 H.P. Fuel Pipe (Double Skin) ~ A Bank andi- Part No. AT220230 H.P. Fuel Pipe (Standard) ~ 8 Bank or Part No. AT22901A K.P. Fuel Pipe (Double Skin) - 8 Bank Inserti~ Part No, 80-212-00848-710 H.P. Fuel Pise (Standard) - A Bank or Part Ho, 90-212-C0044-720 ¥.P, Fuel Pipe (Standard) with Clanp Assembly ~ A Bank and Part No. €0-212-00984-730 4.7. Fuel Pipe (Standard) - 8 Bank or Part Ho. 80-212-009U4-750 4.9, Fuel Pipe (Standard) with Clanp Assembly = 8 Bank ° Part Ho. 60-212-008U1-710 #.P, Fuei Pipe (Double Skin) = A Bank or Part No. £0-212-0084/-720 #.P. Fuel Pipe (Double Skin) with Clanp Asseably = A Bankbet eee = and Part No. 80-212-00941-730 H.P. Fuel Pipe (Double Skin) - 8 Bank or ' Part No. 80-212-00841-740 H., Fuel Pipe (Double Skin) with Clanp te Assenbly + 3 Bank : Insert a reference to this Service Bulletin ~ * * 7 | i “ -6-RUSTON DIESELS LTD VULCAN WORKS, NEWTON-LE-WILLOWS, MERSEYSIDE, ENGLAND SERVICE BULLETIN Number RK/S6 Issued by = Technical Publications. Oept., - Date 28th November, 1980 THIS INFORMATION 1S IMPORTANT TO YOUR ENGINEERS AND SHOULD BE PASSED ON TO THEM IMMEDIATELY SUBJECT: ~ APPLICATION:— DESCRIPTION: - IMPROVED-DESIGN FUEL CAMS ALL RK engines Whenever replacement fuel cans are ordered, an improved~design version will be supplied, with socket-head screws and self- locking auts securing the two halves of the can together, and it fs important that the correct fitting procedure is. adopted, as fol lowsi- a) (2) @) 4) (5) (8) Locate the two halves of the can on the shaft. with the nunbers on the can halves adjacent, and fit the capscrens through the cam contour half into the base circle half, Screw on the nuts lightly. Adjust the position of the base-circle half to align with the dowel hole in the shaft, and enter the dovel for preliminary location. Tighten the nuts slowly and evenly then, with a 0.004 in. (0.10 mn.) shin between the ‘two halves along one side, continue tightening on that side until the shin is just "nipped". Lightly tighten the nuts on the opposite side and withdraw the shim Tighten the nuts evenly, in diagonal ly-opposed pairs, to a torque loading of 30 Ibf.ft. (40 Na). Check that the gags are equal and that the cam is correctly positioned on the shaft, then tighten the nuts ‘evenly, in diagonally-opposed pairs to a torque of 55 Ibf.ft. (75 Ma). Recheck the gaps, which should be equal and 0.002 in. {0.05 mm.) mininun, and should reach the shaft along the full length of the can,NOTE:-The gap at the cam track must not excee' (0.25 am.) {7) Tap the dowel fully hone, fit and tighten the locating serey ard lightly peen the cam hub to lock the screw in place.SERVICE BULLETIN RUSTON DIESELS LTD Humber INF /13 VULCAN WORKS, NENTON-LE-WILLOWS, Issued by - MERSEYSIDE, : ENGLAND Technical Publications. Dept., Date rd October, 1985 THIS INFORMATION 1S INPORTANT TO YOUR ENGINEERS AND SHOULD BE PASSED ON TO THEM IMMEDIATELY SUBJECT: CRANKSHAFT REGRINDING APPLICATION: = AIL Ruston, Ruston & Hornsby & English Electric Engines (including Engines with suffix 'D' or 'G' ~ Dual Fuel) DESCRIPTION: This bulletin describes tha reconmended test and inspaction procedures, which must be applied, when crankshaft regrinding becomes necessary. It is intended as a helpful guide to users, fon occasions where crankpins and/or main journals have euffered danage, and additionally where limits of ovality have been reached or exceeded after long periods of operation. Most engines have sufficient room to enable grinding to be carried out in situ, but In sone cases, it may be beneficial to renove the crankshaft from the engine. PROCEDURE: ~ Iv A pre-grinding operation may be necessary to clean up the Journal or crankpia surface, A mininun anount of metal ust be renoved, to just clean up the surface. 2 Where the pin or journal has been involved in a bearing failure, 7 the surface must be etched with 8% Nital (5% Nitric ecid in alechol or methylated spirits). This will reveal any areas which have been affected by excessive heating during the bearing failure, NOTE s-Ary reegrinding carried out mist be of sufficient depth fo remove al] heat-atfected ereas, 3, The pin or journal aust be subjected to a Magnetic Particle inspection to locete any cracks or defects. To Increase the sensitivity of this test, a thin film of white background Tacquer should be applied to the bearing surtace prior to Inspection. The test should be carried out using a black magnetic ink (see Appendix A). , 4, The inspection test may be carried out in situ using portable equipment i.e. hand held electro-magnetic yoke. Yhere an 7 electro-magnetic yoke is used, there must be sufficient overlayRE~GRINDING ALLOWANCES: ~ between tests to ensure that the entire pin end journal surface has been tested. The test aust also be carried out in two autually perpendicular directions so that both longitudinal and transverse defects are revealed. 5. If the crankshaft has been removed from the engine, Magnetic Particle Inspections using current flow and flux flow tech niques are preferred. NOTE: Whenever possible the crankshaft should be cemagnetised atter test, 6. All cracks must de ground out using a pencil grinder, or prior to the main re-grinding operation. This prevents extension of cracks during pin grinding and also gives an indication of the overall depthof grinding required, and thus the feasibility of re-grinding. After pencil grinding or filing, the crankpin or journal should be subjected to a re-exanination using white back- ground lacquer and black magnetic Ink. Gare should be taken to ensure that any dimple forned by local grinding does not fill with magnetic ink, thereby masking any defect indication. The crankshaft should therefore be rotated to a position which will allow the Ink to dr fron the dimple. After ensuring the removal of cracks by local grinding, the ‘crankpin or journal should be re-ground as normal. Prior to final grinding and polishing, the crankpin or journal surface aust be etched using e 5% Nital to ensure complete renoval of heat-affected areas. Any areas ronaining at this stage ust be subjected to a hardness test, using portable equipment, The hardness levels in these areas mist not be more than i00 HV, or 100 HB points higher than the specified naxiaun for the crankshaft material (Seé Appendix 8) and, in any case, not more then 400 HB, (420 HY, 42 HRc). 10, After final grinding and polishing, the crankshaft aust be subjected to a magnetic Particle Inspection to ensure complete resoval of cracking. NOTE:-I¢ is inpoctont that white background lacquer is used at Ihis stage, All traces of white background lacquer and black magnetic ink must be removed froa the crankshaft prior to its re-introduction inte service. Hl, The alignment of the crankshaft must be checked before it is returned to service. Grankshafts may have all crankpins and main journals reduced to a maxinun of I% of the original diaeter (see Appendix C). -2-INSTRUCTION MANUAL CHANGE: — SPARES CATALOGUE CHANGE: ~ In addition, any one crankpin or main journal may b, by 0,125 in. (3.2 mm.) provided all other crankpins main journals remain at or within the 1 Vimit. Users who wish to exceed these fi Ruston res should refer to ield Service Dept., before proceeding, Section | ~ Crankshaft Appropriate sections in older manuals. Insert undersize dianeter of any reground crankpin or main Journal. Insert a reference to this Service Bulletin. Section | - Crankshaft end Hain Boarings. Secti n & = Piston and Connecting Rod Appropriate sections In older manuals Insert part numbers of any undersize large end and main bear~ Ings fitted. ; Insert a reference to this Service Bulletin.APPENDIX A RECOMMENDED PRODUCTS ‘ARDROX White background lacquer 386 W Black magnetic ink ref: 800/93 Cleaner PRES! ALL wpplied in 400g aerosols. Electromagnetic Yoke (110%, 240V, or HEV-all A.C.). BCI &3 MAGNAFLUX White background lacquer ref: 9WcP Black magnetic ink ref: 7CHF Cleaner ref C7 or RPC AIL supplied in 400g aerosols. - Electromagnetic Yoke ref: Y6 (¥2¥, 48V, I10V, 240¥, AC: I10V and 24OV units can also be operated on 12¥.DC). ADDRESSES Ardrox Ltd. Magnaflux Ltd. Furlong Road, Faraday Road, Bourne End, South Dorcan Industrial Estate, Buckinghanshire, Swindon, 818 5A Wiltshire, Na SHE Tel: 06285-24951 Tel: 0793-2566, Thx 848624 ARDROX-G Tix: $§9068-MFLUX-6APPENDIX B . Recommended mexinun hardness levels for Ruston crankshaft materials after salvage grinding, GRADE hor x Cor W Dory ForZz SPECIFIED HARDNESS. MAX, ALLOWABLE HARDNESS 170 ~ 212 48 312 HB 179 ~ 223 WV 323 WV 89 HRD ~ 98 HRD 34 Re is2 - 201 HB aut HB 202 - 256 HY 386 AY 4 HRD - 24 ARC 97 Re 207 ~ 255: 4B 955 18 218 = 268 HY 968 AY 97 HRb ~ 26 HRe 38 Re 229 = 277 HB 87 HB 242. ~ 292 HV 392 WV 22 HRe - 80 HRe BL ARE 298 - 902 4B Nop HB 261 - g18 HV 20 AV 25 WRe = 93 HRe 48 HRe 269 - 921 HB . 00 HB 283 - 938 AV 420 HY 28 HRe ~ 35 HRe 48 Re NOTE: (nominal) See ae (fee separate Test sheet for actual figures) Averepied 4 Tp aparaten at Approx. 15 above service rating ‘“pryoet FocARROoROSAS dlaneter tonn oe, fue pump: plunger stro 18 em 4 featie holder type "Bryce nTp0sz00G0000 — © = Nettie type ™ HINOTYSFS29 >| Nunber at helen [n nozzle ‘ 8 3 Hlanetar af fates In poszle 0603 mane Inetuted angle of spray Ht We Meiioff, progaure of noszle Eayeblir besercy $000 prests (819 kgs /egeemd “fahauet veiseay, number per oylinder , ce 2 2 Inlet valvagy number por sy) |nder Majer material Alesing pata, number per rod Ja-ond bearings ‘Wain earings Aten) shells, lead-bronze lined with lead-in overlay ‘teed shella, lead-bronze Hined with Aluntntun alloy ¥ tin overtay AMapler™ 54-085 > Tuketeating alt H0-60 pra ts (B-B-H68 Ii lagen) * Aneroved Iwarlesting alle. Aveo LUBRICATING OL SPECIFICATION) Heavy absolete Supplement } Aneel WIth the requirements of RAB. (805: 4905 - Type Bete, b Soho 400 stow pt Utron) appre Lubrienting al) vissoulty grade... * tho a)! sump capacity~ GENERAL DATA : INSTRUCTION: A703/97/ 1/2 4 7 poroximate we} ght of angine components Cylinder head complete with valves and valve gear 76 Ibe. (170 ka) Piston complete with gudgeon pin and rings 58 tbe. (2H koe) Connect ing rad 100 The. ( 45 kg) Cylinder Viner 143 Ibs. (65 kg) Flywhee) 2,190 Tbe. (903 kg) Turbo-bl ower 1,080 Tbs. (490 kg.) feat exchanger (empty) 526 Ibe. (238 kg.) Lubricating ofl cooler 583 Tbs. (269 ka.) Chargecaoler (empty) 959 Iba, (160 ka.) Pioowark feat preasures ye vressure: fuel pipes “. WO pee. i, (2-8 ka /aqsem-) ah pressure fuel pipes 16,000 ps1, (1054 kgs /sqom- ) Lubricating alt drain pipes 30 pessds (2el1 kav /sqvome) Lubricating olf law pressure pipes HO peste om.) Lubricating al} high pressure pipe 180 (12.88 kg. /sqzems) Cooling water syston’ pines 80 peste (2.1) on.) Air otarting system pip 700 (WO.21 ge [1 v) Ale’ manifold pipes 16 pees (1125 kos/aq.om- ) Exhaust pipes 30 pea. le(2.11 Ker /0a-oR, ) 4 JMARKING INSTRUCTION A705/2/1/1 MARKING OF ENGINE COMPONENTSINSTRUCTION A705/2/1/2 MARKING 12V and 16V ENGINES 8V ENGINE RK ENGINE MARKING OF ENGINE COMPONENTSMARKING INSTRUCTION A705/2/1/3 MARKING OF ENGINE COMPONENTS GENERAL. ‘The cylinders on all engines are numbered from the free end of the engine, the cylinder nearest this end being nunbered | and the others 2,°3, 4, etc., consecutively. On "V" engines, the banks are designated by the letters 'A! and 'B'; 1A! bank Is that nearest to the rear side of the engine and '8! bank is nearest the front side. The cylinders In ich bank are numbered consecutively and the cylinder nunber is preceded by its bank designation letter, i.e. Al, AZ, A3; ete., and Bl, 82, 83, etc. The lettering and numdéring is independent of the direction of rotation of the. crankshaft. In addition to the cylinder liners, the cylinder heads, sain bearings, pistons and con- necting rods are all numbered as outlined above. On the engine rating plate, the engine number is preceded by the letters IH, but this prefix is not included in the mark when a conponent is stanped with the engine nunber. The fact that many parts are sarked with the engine nunber during manufacture docs not indicate that the assemblies are not interchangeable. Rear Side OC x8 OO Free End Flywheel End @C #2 DO Front Side The diagran above serves to indentify the ends and sides of the engine as they are re~ ferred to In thls manual. BEDPLATE The engine number is stamped on the front sido near the upper edge, on the centre-line of No.t cylinder for "In-line" engines or on the centre-Line of BI cylinder for "VY" engine: The main bearing numbers are stanped on the bedplate upper surface on the front side adjacent to the bearing housing horns. CYLINDER LINERS The cylinder nunber is stanped on the upper surface of the liner flange. The location of the cylinder liner in the crankcase Is indicated by scribed lines on the poriphery of the flange and the top face of the crankcase as IIlustrated. MAIN BEARING CAPS ‘The engine and bearing nunbers are stamped on the front side of each bearing cap, near ‘to the top. The caps are not interchangeable and must be retained in their original positions.MARKING INSTRUCTION A705/2/ 1/4 MAIN BEARING SHELLS The engine and bearing numbers are marked In adjacent positions on each shell on the free end flange on the front side. Each thrust bearing shell Is marked on the rim of the free end flange on the front side. Engine and Main Bearing Nos. oa No Lloyds Inspection No. and Date aay Part Reference No Main Bearing No Bedplate. Front Side CRANKSHAFT. The engine nunber is ‘stamped on the end of the web of ithe last crankpin at the flywheel end. CAMSHAFTS: Each camshaft Js stamped with the engine number on tho free end face of the free end bearing journal. *Y" engine canshafts are also stamped with the bank letter. CAMSHAFT SECTIONS ‘The end of each keynay, on cach camshaft end which makes a coupling joint, is stamped sively with the numbers 1, 2, 3, etc., and, on "VW" engines, with the bank letter. progr CAMSHAFT COUPLINGS Both halves are stamped, at each end, with the number of the respective koynays. On "V" engines, the bank letter Is included with the numerical marking. Suffix Letter denotes 'B! Bank Camshaft CONNECTING RODS ‘The engine and cylinder numbers are stanped on the foot of the connecting rod at the front side. The nut numbers are stanped immediately below each nut, as Illustrated,MARKING INSTRUCTION A705/2/1/5 CONNECTING ROD CAPS The engine and cylinder numbers are stamped on the cap, adjacent to the similar mark- ing on the rod. The caps are not interchangeable and each must be kept with Its original rod. The big-end bolt nunbors’ are stampod inzediately above the bolt heads, BIG-END BEARING BOLTS Each bolt is stamped with the bolt number and suffix letters on the side of the bolt head facing outwards. The four bolts of each connecting rod are progressively nunbered 1, 2, and 4, each nunber being followed by.the sane suffix letter or letters as stamped on the connec ting rods and nuts. Thus, the four bolts and nuts in any one rod have the same suffix letter(s). BIG-END NUTS Each nut is stamped, on the side of the curved surface, with the sane markings as the nating bolt as Illustrated. The mating nut and bolt must be kept together. BIG-END WASHERS Each washer is stamped on one surface with its respective bolt and nut marking. It must be kept with that bolt and nut. Woshers similarly stamped ‘on one face Engine and Cylinder Nos on Front Side only BIG-END BEARING SHELLS The backs of the bearing shells are etched tovards the front side with the connecting rod suffix letters and the word ROD or CAP as the case may be. It Is important that the tang in the bearing shell is fitted to the front side of the engine,MARKING INSTRUCTION A705/2/ 1/6 PISTONS "Vv" engines "A" bank pistons are stamped with the cylinder number and bank designation letter on ‘the crown at the rear side of the engine. "BY bank pistons are stamped with the cylinder number and bank designation letter on the crown at the front side of the engine. In-line engines The pistons are stamped with the cylinder nunber on the crown at the front side of tho engine. CYLINDER HEADS The cylinder head is marked with the cylinder number and, on *Y* engines, with the bank designation letter. The marking Is on a vertical face close to the Injection pump mounting posi~ tion. FLYWHEEL "V" engines The engine number is stamped on the flywheel face remote fron the engine In tine with 7.0.0. of Nout cylinder on 181 bank. In-line engines The engine nunber Is stamped on the flywheel face renote from the engine In Tine with 1.0.0. of Not cylindersOPERATING INSTRUCTIONS INSTRUCTION A707/5/1/1 OPERATING INSTRUCTIONS CONTENTS: BEFORE STARTING . 7 7 7 7 : : : : . 2 STARTING 7 7 7 7 : : . : . . 2 RUNNING . . . 7 . : : . . : 3 STOPPING . 7 7 7 . . : : : . a SIMPLE FAULTS 7 : 7 7 7 7 . . : i 3OPERATING INSTRUCTIONS INSTRUCTION A707/5/1/2 OPERATING INSTRUCTIONS BEFORE STARTING When preparing to start the diesel engine after it has been shut down for @ perlod ex- ceeding twelve hours, adopt the following procedure (1) Check the levels of lubricating ofl, fuel ofl and cooling water; top up as necessary. (2) Turn on the fuel. Check that the handle of the filter Is correctly set (for left-hand, right-hand, or dual flow) and that the filter is properly vented. Prine tho fuol aysten ty opening the vent at the end of each fuel rail. Close the vents when fuel, fr air bubbles, begins to flow. Slacken the air vent plug on each fuel puap body, Lightening as soon as air-free fuel begins to flow. Wire-lock each vent and plug efter tightening, Aftor vonting tho fuel system, it should not be necessary to ropeat the op- ation unless sone portion of the system Is disturbed, fron NOTE!~ On no account must @ lever of any sort be inserted under any fue! pump plunger for the purpose of priming the pump. Such action will inevitably damage the pump Yappet assembly, (3) Open the compression relief valves and bar the engine round through two complete revol~ utions to ensure that no water has leaked Into the engine cylinders and that there Is no other obstruction. The possibility of serious damage can easily be obviated by this simple precaution. NOTE!= 11 fs considered good practice to operate the lubricating oi! priming pump whilst barring round. (') Check the alr recoiver prossure and build up if loss than 260 p.sei- (17.6 kg: /sqecn.)- Blow_off any water through the drain cock. Open the valve to the engine, (5) Set the hand control lever to the START position. (6) Ensure that the shut-down device Is disengaged. (7) Circulate lubricating oi! by the priming pump and raise the ol! pressure to about 15 pose te (1.05 kg. /sqecm NOTE:- This dees not epply when the governor has # self-contained oi) system, but pre: liminary priming to 2 or 3 p.s.f. (.l4 to .21 kg./sq.em.} #3 essential, STARTING (1) Press tho air starting controt valve knobs release it as soon as the engine fires. If the engine does not fire after two or three revolutions, release the control valve knob ‘and Investigate the cause of non-starting, e-g., hand control wrongly positioned, low lubricating ol! pressure, otc. (2) Check the of! pressure when the engine is runnings (8) Ralse the engine speed gradually’ to the normal value. Hove the hand control lever stoadily to the RUN position. (4) Shut the valves In the starting alr pipe and on the air receivers. Open the drains In the pipeline. NOTE:- After stops of short duration, the full pre-starting procedure 1s not necessary. For such starts, turn on the fuel and proceed 2 in (1) to (4) above,OPERATING INSTRUCTIONS INSTRUCTION A707/5/1/3 RUNNING Before applying load, check that the engine is operating correctly. Proof of correct firing of a cylinder may be obtained by slackening the compression release valve on the cylinder head. Puffs of blue snoke indicate misfiring and, If a cylinder is not firing correctly, the en gine should be stopped for examination and correction of the fault. Maintain the water and lubricating oll temperatures within the na um figures quoted below: Full loa Water temperature 1e0°F (82.2°C.) O11 temperature 165°F (73.9°C.) ‘STOPPING (1) Take off the load. (2) Move the hand contro! to STOP, (3) Turn off the fuel valve. (4) Maintain the flow of cooling water, wherever possible, until the engi COOLING WATER SYSTEM. NOTE: IF there 4s any danger of the cooling water Freezing when the engine is to be out of service for any length of tine, drain the system. Orain the cylinder heads 3/0 and leave out the drain plugs until ready for refi iting. is cool. See SIMPLE FAULTS If the engine falls to start after the correct procedures have been followed, Inve gation should be nade to determine the possible cause before the engine Is preparad for a fur- ther starting attenpt. Sone simple causes ari (I) Fuel filter choked. change over to clean element and clean or renew the faulty clement. (2) Alr-lock In fuel system. Prime the systen. jel and con (3) Insufficient ol pressure at the governor. Examine the governor to check 1 dition of the ofl. (4) overspeed trip In tripped position. Reset.GENERAL MAINTENANCE ‘yt GENERAL MAINTENANCE GENERAL The maintenance schedules Included In this section outline the suggested periods between Inepéctions. It may be found in practice that these periods can be extended or reduced, but this WII depend upon service conditions. A careful record of engine maintenance will provide an inval= uable guide to the determination of service Intervals. In sone cases, individual instructions contain data in which renewal limits are quoted and It will be noticed that these limits are not in conformity with the maximum permissible wear limits detailed for the particular part. This Is because it is extremely unlikely that the part will un to the next overhaul period without being worn beyond the maxinun permissible limit. tf, @ result of working to these reduced limits, it Is found that renewal to a considerable extent Is necessary, the periods between the relevant overhauls should be reviewed. Operators with a nunber of engines are advised to stock sufficient assenbl les of sp eylinder heads, pistons, connecting rods, fuel pu ctors, etc., so that an exchange set Is aval lable for maintenance purposes. When an overhaul is dua, tho rolovant assenbl ies can be re noved for reconditioning and the spare assemblies can be fitted Innediately so that the engine can bo returned to service quickly. The renoved assenblies would then be reconditioned In the mainten- ance workshops and returned to store as the spare set in readiness for fitting to the next engine to be overhauled. Many parts are stamped with the engine and line nunbers during manufacture but thie doos not indicate that these parts ere not completely interchangeable. The tines between maintenance periods, as Indicated in the schedules, are arranged to ensure that @ heavy overhaul is carried out after 20,000 hours running (subject to review of the maintenance records) and, at heavy overhaul, the engine aust be dismantled. The parts should then be transferred to a properly equipped workshop for cleaning, examination and, where necessary, renovation, Suggestions for suitable workshops and/or equipment can be obtained fron Engl ish Electric Diesels Ltd. At the heavy overhaul, the aim aust be to restore all parts of the ongine to first class condition, which will ensure that the engine will perform satisfactorily with only routine main tenance until the next overhaul. Cleanliness is of great inportance and all parts, particularly those in the fue! and lubricating oi] systens, must undergo a final exanination just before re~ assembly, to ensure that they are clean. NOTE: Cotton waste should never be used for cleaning because of the danger of leaving dust, threads or Fluff, Use only well-washed cofton rags or wipers. Reconnended torque wrench figures for tightening of certain components are quoted in this book. It nust be remonbored that torque loadings are affected by dasage to the components and therefore it is important to check thet threads are lubricated and free-running and that pressure faces are snooth, flat and free fron scratches or bruising, before using a torque wrench. As a general principle, locking devices should be used once only and this also applies to non-metallic Joints, hose connections, etc. Tab washers should be renowed whon all available corners have been used once. ZX The recomended periods betwe Every watch, Daily, 100 hours, 125 hours, 250 hours, 500 hours, 1,500 hours, 5,000 | hours, 10,000 hours (Light Overhaul), 15,000 hours and 20,000 hours (Neavy Overhau! ). { Additional inspections nay be required after fitting now conponents such as cyl inde! heads and reference to the particular instructions Is advisable to ascertain the correct perlodi- Cities of such inspections. examinations are as fol love!~ {