MAINTENANCE MANUAL FOR DIESEL ENGINES ABC type DX(S)(C) ANGLO BELGIAN CORPORATION N.Y. Wiedauwkaai 43 B9000 GENT Tel.++32 9 267 00 00 Fax.+132 9 267 00 67 E-mail: info@abediesel,be Website: www.abediesel.be DOC. ABC[ABC owns the copyright of this document. it shall not be copied or disclosed without the prior consent of ABC (18) Maintenance manual OX{(S)(C) engines GENERAL CHAPTER CHAPTER CHAPTER CHAPTER 4 vr on 1.4. 1.2. 1.3. 1.4. 2ele 2.2. 4... 4.2. 4.3. CONTENTS DEFINITIONS AND TERMINOLOGY TECHNICAL DATA GENERAL MAINTENANCE RECOMMENDATIONS MAINTENANCE PROGRAMME TIGHTENING TORQUES CYLINDER HEAD Cylinder head The valves and their mechanism Starting valve and pressure relief valve Fitting the cylinder head onto the engine PISTON — CONNECTING ROD Piston The connecting rod CYLINDER HOUSING Cylinder housing or cylinder block INJECTION Nozzle holder and nozzle ‘or injector! Injection pump Injection pump drive mechanism Edition: 2[ABC owns the copytight of this document. It shall not be copied or disclosed without the prior consent of ABC. @ Maintenance manual OX{(SC). engines CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER 5 5.1. 5.2. 5.3. 6.4. 6.2. 6.3. 6.4. 7.4. 7.2. 7.3. 8 8.4. 8.2. 9.4. 9.2. 9.3. 9.4. 9.5. 9.6. 9.7. GOVERNOR The governor The governor drive mechanism Injection pump control mechanism CRANKCASE Crankcase The studs of the main bearing caps The main bearing shells Cylinder block holding down studs CRANKSHAFT Crankshaft The vibration damper Helical gear on crankshaft TIMING GEAR Camshaft Timing gearwheels PUMPS Fresh water pump Sea water pump Duplex lubricating oil pump Single lubricating oil pump Oil pressure - regulating valve Hand pump Pump driving gear case for water and oil pump Edition: 2[ABC owns the copyright of this document. IF shall not be copied or disclosed without the prior consent of ABC OB) Maintenance manual OX(SHC) engines CHAPTER 10 10.1. 10.2. CHAPTER 11 CHAPTER 12 12.1. 12.2. 12.3. STARTING DEVICE Air distributor Starting mechanism SUPERCHARGER Supercharger COOLERS Fresh water coolers Oil cooler Air cooler Edition: 2‘ABC ouns the copyright of this document, It shall not be copled or delosed without the prior consent of ABC (A}8) Maintenance manual OX(S)(C) engines PREFACE The first A.B.C. internal combustion engines left the factory in 1912. The present engines are the result of about 75 years of research and experience. Thanks to their excellent design, their robustness and their thorough standardisation, A.B.C. engines are easy and inexpensive to maintain, provided that they are treated properly. This manual contains the instructions necessary for the main- tenance of diesel engines type Dx(S)(C). This book has been compiled to assist the operator to look after the engine, by giving detailed information where it is likely needed, assuming that the operator will at all times and in all matters follow good engineering practice. The manual supplied with each engine has a sticker inside the front cover bearing the number of that particular engine. A copy of the manual supplied subsequently may be a later edition and consequently not apply to the engine concerned. Some differences may be noted between the descriptions given in this manual and the engine as received. This is because an engine may be supplied incorporating non-standard components at the client's request or according to the application. Our technical department "APPLICATIONS" will be pleased to answer questions or give advice in case there is no specific documentation available. Our after-sales department and our service stations in Belgium and abroad are at your disposal to ensure efficacious main- tenance. IMPORTANT = Before undertaking maintenance work on the engine, this manual should be read carefully. - This Maintenance Manual has been prepared using the manu- facturer's best knowledge and experience, taking into account safety and environmental aspects. - To assure the best efficiency, reliability and lifetime of the engine and its components, only original spare parts should be used. Edition: 2ot be copied or disclosed without the prior consent of ABC. ABC ouns the copyright of this document. It shall Maintenance manual DXISNC) engines Failure to comply with this Maintenance Manual may result in malfunction of the engine, short lifetime of components, personal injury or damage to property or environment for which the manufacturer takes no responsibility. Make sure that everyone involved in the maintenance of the engine has this Manual available, reads it and understands it. Machine components such as springs, clips, retaining rings, electric equipment, pipes, etc., involve a risk of damage or personal injury if opened, taken apart, fitted, lifted or transported in an improper way. It is therefore essential that no one attempts to do any work on the engine unless he has the necessary experience of the various tools and commonly used elements, materials and methods in machinery. Make sure that all equipment and tools for maintenance are in good condition. Always use the appropriate tools. The maintenance work described in this Manual shall only be carried out by trained personnel except where otherwise stated. ‘The manufacturer will not be responsible for any consequences resulting from incorrect translation or interpretation of the original text handed to the customer or user- Edition: 2é 2 OX(SMC) engines GENERAL apy Jo uasve> Jone ayy sneqyn pasepsyp 20 patdon ag jes 4 yunena0p Jo yybuhde sus sumo ey Edition: 2[ABC owns the copyright of this document, It shall not be coped or dislesed without the prior consent of ABC General Maintenance manual DX(S}(C) engines DEFINITIONS AND TERMINOLOGY TYPE ENGINE INDICATION 7) (B) (E) Dx(8)(c) = 750 - 100 {4} (T) (P) 750 100 number of cylinders marine propulsion engines generator set for see-going vessels industrial generator set railway traction diesel pumpset or compressor set engine type, 4 stroke, in line, natural aspiration supercharged engine supercharged and charge-air cooled engine engine speed, rpm degree of supercharging direction of rotation counter-clockwise, as seen by an observer facing the flywheel end of the engine direction of rotation clockwise, as seen by an observer facing the flywheel end of the engine Edition: 2 otod or declosed without the prior consent of ABC. 1 chall not be i ; General Maintenance manual DX{SIIC) engines 1.3. NUMBERING OF THE CYLINDERS The numbering of the cylinders begins with the cylinder closest to the flywheel. DEFINITION OF THE DEAD CENTRES In the following explanations and diagrams, the dead centres of piston travel are indicated by means of the following symbols : T.D.c. top dead centre B.D.c. bottom dead centre Edition: 2 0-2[AGC owns the copyright of this document, It shall not be copied or disclosed without the prior consent of ABC General Maintenance manual OX(SNC) engines 2. TECHNICAL DATA 2.1. TECHNICAL FEATURES - Continuous rated power 1S03046/1N, - Nominal rpm nos - Mean effective pressure Pos ~ Maximum combustion pressure P max = - Mean piston speed at nominal engine speed oF 2.2. CONSUMPTION = Fuel consumption at rated power h, according to 1S03046/1 in = 42 MJ/kg - 10.030 Keal/Kg = Oil consumption at rated power + 2.3. NOMINAL MEASUREMENTS - Number of cylinders - Swept volume per cylinder - Compression ratio - natural aspiration : = supercharged : kW(. metricHP) rpm bar( kp/cm2) bar( kp/cm2) m/s. g/kWh(_9/HP/h) tol. + 3% kg/h 3, 6 or & inline 14,72 dm3 1245/1 12,06/1 - Total cylinder volume : 3 cyl. 6 cyl. 8B cyl. 44,2L. 88,3L. 117,8 Le - Bore ~ Stroke ~ Diameter of of of of of the the the the the main bearing shell big end bearing shell piston pin camshaft bearing inlet and exhaust duct mm 242 320 184 168 95 63 90 Edition: 2 0-3(8) General Maintenance manual DX(SHC) engines mm - Diameter of the starting air valve 20 of the fuel pump plunger 18 Screw thread of the cylinder block stud M27x2 of the cylinder head stud M24x2 - Width of the main bearing shell 90 of the big end bearing shell 97 of the small end bearing bush 105 8 of the camshaft bearing 54 i - Length of the push rods 640 i of the cylinder block studs 372 z ~ Height of the crome-plated fire ring 4 é of the compression ring 4 2 of the oil scraper ring 8 : - Lift of the inlet valve 25,70 3 of the exhaust valve 25,70 & of the starting air valve 6 # of the injector nozzle needle 0,4 i of the inlet cam 18 : of the exhaust cam 18 of the injection cam 15 of the starting cam 18 - Spacing of the cylinders 380 - Spacing of the centre cylinders 400 - Number per cylinder : - inlet valve - exhaust valve - chromed top piston ring ABC owns the copyright of this document. It sh - compression ring BeBe = oil scraper ring Edition: 2& General Maintenance manual DX{SNC) engines 2.4. VALVE TIMING : THEORETICAL FIGURES Natural Supercharged aspiration crankshaft —Segrees | - Inlet : opens before TOC 14 closes after BDC 40 - Exhaust : opens before BDC 42 55 closes after TDC 12 58 ¥ - Overlap 26 118 : - Starting valve opens before TDC 16 16 3 Closes after TDC 124 124 8 = Opening time 140 140 i For these angles the valve clearances in cold condition have been taken into account. These are : outlet : 0,10/0,15 mm inlet : 0,10/0,15 mm NON SUPERCHARGED SUPERCHARGED ument. It shall got be coped or decosed witha ‘ABC ovns the copyright of TOC : Top Dead Center 10: inlet Opening BDC : Bottom Dead Center IC: Inlet Closing BI: Beginning of Injection £0 : Exhaust Opening EC : Exhaust Closing Edition: 2 0-5[ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC. cc General Maintenance manual OX(SNC) engines Set value "B.I." beginning injection Engine type rpm [4° crankshaft 3,6 and 8 cyl. DX 600 18 750 20 DXS DxC. 600-750 18 Remarks + - The set values mentioned "B.I." have been determined according to the "last drop" method = Adjustment tolerance = + 0,5° in function of difference in thickness of shims (0,1 mm). FIRING ORDER Number of Direction of rotation cylinders Counterclockwise (A) Clockwise (K) 1+3-2-1° 1423-1 6 1+2-4-6-5-3-1 1-3-5-6-4-2-1 1-4-7-3-8-5-2-6-1 1-6-2-5-8-3-7-4-1 CRITICAL SPEED Every installation is checked for critical engine speeds. These tests indicate if, at particular engine speeds, dangerous torsional vibrations occur, which can lead to catastrophic failure of the crankshaft, coupling, pro- peller shaft or generator shaft, damage to gears and bear— ings, overheating of the vibration damper or inadmissible irregularity of the driven electric machines. Continuous running at those engine speeds is very danger- ous and those speeds must be marked on the engine speed indicator as forbidden areas. Edition: 2 0-6ABC ouns the copyright of this dacunent. t shall not be copied or closed without the prior consent of ABC General Maintenance manual DX(S)(C) engines A.B.C. cannot be responsible for failures resulting from the non-observatin of these prohibital areas. In case of modi- fications to the installation effected subsequently such as, for example, alteration of the propeller or gears, the complete installation has to be recalculated again for critical speeds. For this purpose, it is necessary to contact A-B.C. 2.76 TEMPERATURES (in °C) Exhaust gases : cylinder heads see before turbine after turbine test sheet Supercharging air : inlet manifold (DXS) see before alr cooler (pyc) test sheet after air cooler Cooling system (engine outlet) - Normal working 75° to 60°C = Warning signal asec = Stop signal sore Lubrication circuit (engine inlet) = Normal working 75° to 60°C - Warning signal esec = Stop signal gore 2.8. PRESSURES Opening | Working pressure | pressure | Test pressure bar bar bar Cylinder head - combustion chamber max.85 120 = cooling water space 1,5 5 ~- starting air duct max.30 - Edition: 2 0-7‘ABC owns the copyright of this document. it shall not be copied or disclosed without the prior consent of ABC, (18) General Maintenance manual OX(S)(C) engines (NSI = GL) Opening Working Test pressure | pressure | pressure bar bar bar Cylinder head gasket - combustion chamber - 85 max. - Cylinder block - coolant passages - 1.5 4 Air cooler - water side - 2 5 - air side - 1.65 3 Fresh-water cooler ~ sea-water side - 2 8 - fresh-water side - 4.5 10 O11 cooler - water side - 2 8 - oil side - 10 "Bryce" injection pump - piston and barrel - 680 max. - = body - 2.5 max. 7 Puel feed - 0,06 min. - 2,5 max. Injection pipe - 680 - Nozzle-needle opening 220 - 225 - - Safety valve (head) 110 + 2 - - Safety valve (crankcase) 0.15 - - Lubrication (engine inlet) = at nominal speed - 3,25 ~ 3,75 - ~ at idling speed - 1,5 - 1,75 - Compressed air - 30 max. - 12 min. Safety valve (starting circuit) 30 - - Edition: 2‘ABC owns the copyright of this document. it shall not be coped or disclosed without the prior consent of ABC General Maintenance manual DX(S)(C) engines 3.2. GENERAL MAINTENANCE RECOMMENDATIONS WARNINGS - It is forbidden to disassemble or readjust speed gover- ors, overspeed devices or any other component which controls or limits the dynamic conditions of the engine unless this is expressly allowed. This procedure is described in the Manual. PRECAUTIONS - Prevent the engine from starting or turning during any maintenance work. = Open the decompression valves before beginning any re- pairs to moving parts. - Make certain that the crankshaft can turn without danger to the men working on the engine or driven machines (alternators, reversing gear, etc.). Beware of the rotation of the crankshaft when unbalanced after removal of piston / connecting-rod assemblies. = Inspect the nuts and bolts and their attachments,also the air, water and oil pipework before starting the engine. - Make certain that all moving parts are free, by turning the engine by a special provided bar. - Fill the starting bottles with air or carbon dioxide (CO,). Never use oxygen or hydrogen (explosion danger). ~ When testing the nozzles outside the engine with the nozzle tester, precautionary measures have to be ob- served ; in particular : + KEEP HANDS AWAY PROM THE NOZZLE SPRAY The spray from a nozzle can penetrate deep into the flesh of the fingers or hand and destroy the tissues. Gas-oil entering the blood stream can cause blood poisioning. + IN ANY CASE CLEAN GAS OIL OR TEST OIL. SHOULD: BE. USED FOR TESTING. + Do not test the nozzle near a flame or an open light. DANGER OF EXPLOSION ! Edition: 2 0-9this document. tt shall not be copied or disclosed without the prior consent of ABC ABC owns the copyright General Maintenance manual OX(SNC) engines 3.3. TOOLING The tools needed : ~ normal available tools : open end-, box, wrenches, screwdrivers, etc. ; - special tools supplied with the engine ; ~ special tools designed by A.B.C. and to be ordered separately ; - lifting equipment : hoisting tackle, slings, etc. 3.4. MASSES OF THE MOST IMPORTANT COMPONENTS 3.401. Section] Description Masses in kg 3 cyl. 6 cyl. 8 cyl. crankcase 1270 2054 2588 Crankshaft com- 705, 940 1145 plete 8 Cylinder block 1090 1566 2047 with liners 17 | camshaft 48 88,4 113,35 20 Turbo-charger 137 181 340 21 23 Aircooler 65 103 140 41 Sea water pump complete 64,3 64,3 64 45 29 Torsional vibra- tion damper complete - H & W 6770x125 - - 314 - 24"Holset or H & W 3610x95 162 162 - - Geislinger -D56/6 (without PTO) - ~ 188 —D63/5/7/2 (without PTO) 298 -D63/5/8/2 (with PTO) 200 Edition: 21 shall not be copied or disclosed without the prior conseat of ABC ‘ABC owns the copytight of this docunet General Maintenance manual DXISNC) engines Masses of the components common to_all_the DX-engines Section Description Mass in kg 1 Crankcase - Bearing cap + formal 14,6 + wide 18,25 + guide 17,10 - Main bearing stud 0,55 - Cylinder block stud 1,50 16 Timing gears - Crankshaft gear 12,50 - Camshaft gear 24 - Idler gear and bracket 32 assembly - Idler gear : 8 8/17/ 18/62 Cylinder block - Liner 65 - Tappet and airdistributor 12,20 housing - Camshaft bearing 2,3 - Camshaft guide 3,45 bearing 9/10 Piston - Complete piston connecting | 72,55 max. rod assembly - Piston 22,4 = Piston pin 8,30 = Set of piston rings 0,85 10 Connecting rod - Connecting rod complete = Small-end bush ~ Big-end bearing shell 41,00 max. 0,65 1,4 Edition: 2 o-tt“) General Maintenance manual OX(SNC) engines Section Description Mass in kg 11/18 | Cylinder head - Cylinder head complete with 143 rocker system ~ Bare cylinder head 128 - Inlet valve 1,5 3 - Exhaust valve 1,4 3 ~ Rockers with brackets 8,50 z 3 Push-rod (inlet/exhaust) 1,10 g = Valve guide 0,7 3 Tappet 3 - valve side (inlet/exhaust) 0,90 a = injection-pump side 0,88 3 & Starting valve complete 0,18 S 12 "Woodward" UG-8G governor 22,8 2 (with servo motor) Z "Woodward" UG-8L governor 19,6 3 14 Nozzle holder and nozzle 2 i 3 Injection pump 7,10 = 30 Double oil-pump complete 28,1 3 5 Single oil-pump complete 19,6 2 40 Fresh-water pump 20,15 Edition: 2 0-2g ; i 2 i Lot be. coh i z (8) General Maintenance manual DX(SI(C) engines 3.5. HANDLING OF COMPONENTS Use always a lifting apparatus for handling important pieces, such as cylinder heads, piston- and connecting rods and cylinders. It is possible to lift the complete engine on two ways : - without bridge 7 With brisse jpechenatically shown on fig-0.1 and 0.2 The cables or chains, lug and hook must be appropriate for lifting and handling the indicated mass. Edition: 2 anGeneral Maintenance manual OX(S)C) engines Fig, 0.2 Edition: 2 ottABC ouns the copytight of this document. It shall not be copied or disclosed without the prior consent of ABC. General Maintenance manual OX(S)(C) engines 3.6. 3.6.1. 3.6.2. 3.6.3. PRECAUTIONS TO BE TAKEN ON ASSEMBLING AND DISMANTLING Assembly and dismantling must be undertaken under stringent conditions of cleanliness. Before dismantling - Verify that the marks necessary for the reassembly are in place. If not, mark them as described in this manual. - Drain the oil, water and fuel circuits, depending upon the parts to be dismantled. When dismantling = Keep the components for each cylinder separated 5 - Label each of the components which cannot be marked (piston rings, bearing shells, etc.) 5 = Protect the dismantled parts from impact, oxidation and dust. Attach the machine parts securely to a plank. In that way you will reduce the risk of damage by impact, by other parts or concrete ; = Avoid dropping metal filings or other dirt into the crankcase ; - Clean each piece before examination ; - Keep the pipes and openings in the components plugged during the dismantling ; - Coat all items which are not to be re-used immediately with a rust-proof product and clean them just before reassembly. When assembling ~ Clean all the parts. If steam is used for cleaning, dry the parts with compressed air ; - Systematically renew all joints or gaskets: ASSEMBLY DIMENSIONS AND WEAR LIMITS The original, minimum and maximum dimensions of each part subject to wear are indicated. Also specified are the maximum limits of wear at which the parts must be either exchanged or reconditioned. These figures are the result of long experience, they represent the point at which it is considered that safety and proper functioning become endangered. Those figures are given in the OD (original dimensions) and LW (limit of wear) columns.& = [ABC owns the copyright of this document. It shall not be copied or disclosed wi 8) General Maintenance manual OX(S)(C) engines: 3.8. 3.9. 3.10. STANDARDISED DIMENSIONS FOR RECONDITIONING Parts which can be reconditioned (e.g. crankshafts, piston- ring grooves, etc.) have standardised dimensions and tolerances. If the parts are reworked to those dimensions, parts to be fit (bearing shells, piston-rings, etc.) can be supplied from stock. The dimensions for the first reworking are marked R1, those for the second R2, and so on. SPARE PARTS Spare parts for A-B.C.-engines types DX - DXS ~ DXC are available. The parts may be ordered on the basis of the Spare Parts List. Note + When ordering, never quote the numbers from the drawings and illustrations given in this Manual. Those numbers and figures indicate only the principles of the assembly, dismantling and functioning of the various components. Mention following data for each order of spare parts : = 1. the engine number (marked on the constructor's plate ) 3 - 2. the code number and description of the part, accor- ding to the Spare Parts List. TOOLS The tools necessary for assembly and dismantling and for the maintenance of the various components may be ordered by quoting the numbers given in this manual.[ABC ouns the copyright of this document, It shall aot be copied or dscesed vithout the prior consent of ABC oy General Maintenance manual DXIS)(C) engines MAINTENANCE PROGRAMME The maintenance schedule and periodic intervals are the manufacturer's recommendations in order to achieve best efficiency and reliability of the engine and life time of components. Periodic intervals are based on the manufacturer's experience. All the maintenance jobs set out in this programme are of a periodical nature. At regular intervals, usually ex- pressed in hours of service of the engine, they have to be repeated. In order to facilitate the maintenance and to mit as much as possible the time when the engine is out of service, the operations are grouped as a small number of maintenance jobs and overhauls. They have to be undertaken after periods of service which are multiples of one another. The jobs of the same frequency in each group are set out in the following pages. It is pointed out that in each group only the job is cited (maintenance or overhaul) which frequency is that of the group itself. Jobs, which frequencies should be twice, three times etc. to belong to that group also have to be carried out at the same time. The repetition does not appear in each case in the text, MAINTENANCE AND OVERHAUL The several groupes of maintenance jobs are classified under one or the other two classes below : 1. Normal maintenance works involving partial dismantling, which may be carried out by the operation staff. Five types of maintenance works are distinguished for the DX = DXS and DXC engines : Frequency Code Each week (about 100 hours) Ma At intervals of 500 hours m2 At intervals of 1000 hours M3 At intervals of 1500 hours Ma At intervals of 3000 hours MS Edition: 2[ABC owns the copyright of this document IF shall not be copied or dislased without the prior consent of ABC ee General Maintenance manuat OX(SHC) engines After each maintenance work, the checks C1 have to be carried out. The partial and complete overhauls involve substantial dismantling and more specialized work, which usually entails taking the engine out of service temporarily. There are three overhauls for the DX ~ DXS and DXC - engines. Frequency Code Minor overhaul at intervals of 0.1 6000 hours Partial overhaul at intervals of 0.2 12000 hours Complete overhaul at intervals of 0.3 24000 hours A.B.C. permits a maximum tolerance of approximate 20 % on the periodicity of maintenance and overhaul. NOTE : The running hours read off the meter or stated in the log book may in some cases be replaced by units that vary more or less linearly therewith (kilometers travelled by traction units, energy produced by pumping installations or by electricity generating sets). Edition: 2 nota14 without the prior consent of ABC [ABC ouns the copyright of His document. It shall oot be coplad oF ls (8) General Maintenance manual OX(SMO) engines Interval Code Component to be maintained or checked Before each | ci-ot | - check the water and of1 level in the engine start or at ~c2 | = Check the o11 level in the hydraulic governor 26 hours in | 03 | = Check the ofl level in the turbo-conpressor terval 704 | = Clean the edge type of1 filter (several turns on the handle) 05 | = Grease the sea water pump (part turn on greaser) ; do not overgrease 05 | = drain off the water from separator on starting air 07 | = Chack the starting air pressure 708 | = Brain off any water from the service fuel tank 09 | = chack the fuel level in the service tank Each week wit | - Top up greaser on the sea water pump or about 02 | = Top up the automatic lubricator on the starting air Line 100 hours ~03 | = drain off the water from the starting air botties 04 | = clean sea water filters (according capacity and dimensions) w05e| = Clean the rotor of the turbo-conpressor by water injection 05 | = Check free passage of blow off hole on charge-air cooler 07 | = Control position of contamination indicator on oil filters at normal working temperatures and nominal engine speed Each mounth | M2-0t | - Check the valve clearance, adjust if necessary for about 02 | = Lubricate Linkage on the hydraulic governor 300 hours 03 || = Lubricate the starting alr mechanism vote] = Clean the air filter(s) 705 | = Clean the centrifugal of1 fi1ter -06 | = If the engine is Frequently heavily loaded, o {f the fuel is not very clean, renew fuel filters elements (M3-04) About 1000 m3-01 | - Check the opening pressure of the nozzles and the spray pattern hours 02 | = Measure the combustion peak pressure at each cylinder 03 | = Change off on the turbo-conpressor 704 | = Renew elenents on the fuel Filters About 1500 ma-02 | - Replace elements on lub. oll filter hours 02 | = check quality of the water treatment or replace element of water treatment filter(s) About 3000 5-01 | ~ Change the engine of1 ~ clean the crankcase hours 02 | = Clean sea water circuit (water ofl and alr coolers, sea water pump) 02 | = Inspect the safety devices (overspeed, thermostats and pressostats) 04 | = Change off on the hydraulic governor In case of small or insufficiently ventilated engine rooms, the intervals batween overhauls have to be halved. Edition: 2 019,[ABC owns the copysght of this document. I shall not be copied or disclosed without the prior consent of ABC e General Maintenance manual DXISNC) engines Interval code Components to be maintained or checked about 6000 | o1-01 | ~ Thoroughly examine the nozzles and their holders hours Replace the nozzles, in case of suspicion or slightest doubt 02 | - Inspect the distribution : gearwheels, cans, camshaft bearing, taps and bearings: -03 | - Check the injection timing Check combustion peak pressure at full load and at idle 04 | - Inspect valve mechanism : push rods, tappets, shafts and rollers 305 | — Inspect gear drive of governor Measure gear clearance on Resitex gear and adjust if necessary 06 | - Inspect geacwheels punp driving 07 | = clean the alr intake ciecuit (clean the rotor of compressor) 08 | - Clean the exhaust system (clean the turbine wheel of turbo=compressor) ~09 | ~ Clean compietely water, of] and air coolers Inspect HT waterpunp and thernostatic valve =10 | = cheek deflexion on all cylinders =11 | = check sea water pump ; damaged or corroded parts must be replaced Aeout sz000 | 02-01 | - Remove cylinder heads ~ clean them thoroughly hours Remove valves ; if necessary lap or grind valve seat faces. If necessary rework inserts Check valves, springs and collars. Measure valve guides. Complete control of valve mechanism on cylinder head (rockers, bushes, push-rods and shafts) Renew all gaskets (water, oil, air and exhaust connections) Check starting air valve and prassure relief valve ~02 | - Check the fuel injection pump, the clearance of the plunger and delivery valve. Check free travel of control rack, if necessary open up the pump and clean 03 | ~ Renew the turbo-charger ball bearings ‘About 24000 | 03-01 | - overhaul pistons : cenove and measure the clearance and wear of hours the piston rings. Replaceneat piston rings recommended. Clean pistons 02 | ~ Measure the wear, conicity and ovality (taper) of the Liners. Remove, cehoning is recommended: Replace all O-rings and steel packing -03 | - Washout the cylinder block ~ remove deposits and eventually re~ paint interior 1f necessary 04 | - Check connection rod bearings - replacement cecormended 705 | = Check main bearings - replacement recommended 06 | = Overhaul of fuel injection pump ~ replacing elements reconmended 707 | = Return the hydraulic governor = overhaul recommended -08 | = Take off sample of silicon from damper Holset or Hasse & Wrede -09 | = complete inspection for Geislinger damper Replace all O-rings Replace oi! seal in front cove Edition: 2 070[ABC owes the copyright of this document. It shall oot be copied or disclosed without the pri consent of ABC. Gd General Maintenance manual DX(SHC) engines SEQUENCE OF THE MAINTENANCE JOBS AND OVERHAULS Service Code + Check, M = Maintenance, interval Overhaul Each week Mt = (100 he approx.) Every 500 h. | M1 + M2 1000 h. | M1 + M2 + MB 1500 h. | Mi + M2 + M4 3000 h. | M1 + M2 + M3 + M4 + MS 6000 h. | M1 + M2 + M3 + M4 + MS + 01 12000 h. | M1 + M2 + M3 + M4 + MS + 01 + 02 24000 nh. | M1 + M2 + M3 + M4 + M5 + 01 + 02 + 03 Edition: 2 o-21Maintenance manual DX(SKC) engines General “pay 12 yuasue> soja ous snewu pases 40 poqder aq OU TENE aT {anceps =H ‘OF Zot torte ZL et Zoea | 2uray. toe TCE] eturae. Toe wet SB=GI-] sxoust - surenousepurtso mayece yenouxa sowvesduoo-ogsnd pos wend / eyeddus aseueweo eeu 2upurL Buyees dung soprou etzz0u / otzz0u dand woriseCuy toad ed 2p / sousono? poods ea _/ pos Buygzeuu0 eauya / woxsra ‘s9uyseeg UFO seuoquey fmesord aye auyaseae yt sue 30¥ Jeveaet Tyo pue soyen 457208 siuvd No SoO3HD SDNVNGLNIVH, 0-22Maintenance manual OX{SN(C) engines General 180004 D001 ABBAS “00S AMIAZ x x 0s 001 x x x quowyvesy seen oad oupdua/saozaoy ages euyt ate 2urga615 sorsgeq 21¥ se08 pus esaaz0as asdueyoxe 380i oxen vo / dund soaon eos xot009 150 seatsg Tye “a0 sodwep woysuaqya (wuoyes0L 0311s 2H seqo0o ape-enseU9 weeks aye oesuT shivd NONI NO S3DBHD JONVIGLNVH [By 49 yeasv02 Joud ay) ynoquN pators 40 potded oq YoU TENS M1 “yHeURDeD siy4 40 1BUKdoD ou suNe TAY 178‘ABC ouns the copyright of this document. It shall not be copied or dsclosed without the prior consent of ABC oe General Maintenance manual DXISNC) engines TIGHTENING TORQUES All dynamically strained bolts and nuts as well as functionally important fastening bolts are tightened by means of a torque wrench on a predetermined tightening torque as described in the "tightening torque table" pages 0-25 & 0-26. The nuts for fastening the cylinder block on the crankcase and for fastening of cylinder head are tightened according to the angular displacement method. Both specific tightening methods are described in detail in the Operating Manual. Fdition: 7[ABC ouns the copyright of this document. It shall not be copied or disclosed without the prior concent of ABC (8) General Maintenance manual OX(S)IC) engines COMPONENTS TO GE TIGHTENED FPG OF | TIGHTENING TORQUE OF REMARKS OR INSERTED ‘THREAD METHOD Na kgm GRANKCASE 1. Bearing studs mae 49 5 |assembie with Locrrre 245 2. Bearing stud nuts mez | sas-aea | 35 - 37 3. ALL other studs 2ana7 | 215-258 CRANKSHAFT 1. Vibration damper bolts ma2xi,s | 685-705 | 70 - 72 (Holset or Hasse & Wrede) 2. Crankshaft cone 8 118 2 flange bolts 3, Distribution gearwneel bolts m2 49 5 |Assenble with Locrrre 222 SXLINDER_sLocK | 1. Cylinder block studs M272 98 10 assemble with Loctrre 245 | 2+ vtincer block stue outs faze has-aase feoeaase 3. Cylinder block holding down | wzo | aaseaes | 25 - 27 ouneer2us R00 | 1+ Big end bolt nuts weoxt,s | 37392 | 38 = 40 CYLINDER HEAD 1. Cylinder head studs M2ax2 98 10 |acsemble with LocriTe 222] 2. cylinderhead nuts m2sx2 —_|196+2x72" J2oszx72* 3. Studs for rocker assembly and| mz | zo - 24 | 2 - 2,5 nozzle holder : 4. Nuts for studs rocker assem- m2 |39-4a |a-a,s bly and nozzle holder (yoke ute) FUEL FEEDING 1. Injection pump bolts m2 [a3 -as | 5,5-8,7 feoscet Lervce | 3/ana. Nozzle nut 100-120 Edition: 2 ne[ABC ouns the copyright of this document. It shall not be copied or asclosed without the prior consent of ABC eS General Maintenance manual DX(S)IC) engines COMPONENTS TO SE TIGHTENED fives oF [FEGHTENING TORQUE OR REMARKS OR INSERTED THREAD ‘METHOD Nm gn FLYWHEEL 1. Bolts flywheel marx, | 68s 10 CAMSHAFT — DISTRIBUTION 1. Camshaft thrust cing bolts Me 2a 2,5 2. Canshaft theust bearing maz e-85 | 8,5-8,7 bolts 2. Camshaft bearing bolts ma eas |8,5-8,7 |4: Screws camshaft coupling mioxt,25 | 68-72 7-7,3 Flange 5. Bolts fixing cap on bearing m6 206 2 support intermediate gear 5. Screws clamping assenbly cy “4 25 timing gear muffle 7. Fixing bolts of timing gear |urox1,25 | 68-72 7,3 on muffle 8. Fixing screws for tappet. m2 axa |.8,5-8,7 ascembly ‘TURBO & EXHAUST MANIFOLDS 1s Bolts exhaust manifolds m0 case [6,5 a7 maz me |S 88 STARTING AIR orsTRrBUTOR 1. Screw for fixing air rn distributor 2. Wut for starting - lever mioxt,25 | 37-29 © |3,8- 4 pivot pin Edition: 2[ABC owes the copyright of this document. If shall not Be copied or disclosed without the prior consent of ABC Maintenance manual OX{(S(C) engines CHAPTER 1 CYLINDER HEAD Edition: 2[ASC owns the copyright of this document It shall not be copied or disclosed without the prior consent of ABC CHAPTER 1 j Maintenance manual Cylinder head OXISNC) engines 1.4.2. CYLINDER HEAD Description (Fig. 1.1) The cylinder head (1), of a special cast-iron, carries an inlet valve (2) and an exhaust valve (3), working in valve guides (4). The valve seats (5) are inserted in the cylinder head at a low temperature. The seat face of the inlet valve is of induction-hardened steel ; that of the exhaust valve is of stellite. The cylinder head is mounted on the cylinder block by six studs (6). Weights : bare cylinder head .. steeeees 128 kg cylinder head complete with rocker assy - 143 kg Code Job R2-01 Complete overhaul of cylinderheads. Removing from the engine, cleaning and decarbonizing. Removing the valve. If necessary rework the valve inserts and valve seats. Measuring valve guide wear, replacement if needed. Replacement of all joints or gaskets, Edition: 2 a)[ABC owns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC 1.1.3. 1.1.4. CHAPTER 1 Cylinder head Spare parts (Figs.1.1., 1.3. and 1.4.) Maintenance manual OX(SNC) engines j Number Pig.n?/ j Sof eae Code Description B/cyl. 4/5 |610-011-8102.10 | Inserts 2 1/4 |610.011.8104.10 | valve guide 2 1/7 |100.004 .033.039 | Joint a 1/8 — |100.004 048.055 | Joint 2 610.011-9001.10 | Cylinderhead gasket 1 1/11 (DX-engine) 610.011-9002.10 | Cylinderhead gasket 1 (DXS- and DXC-engine) 1/12 |610.011.9003.10 | Exhaust manifold seal 1 1/13 |610.011.9004.10 | Cylinderhead cover-joint| 1 1/14 |610.011.1202.10 | Seal o-ring a 3/15 -|610-011.9014.10 | Joint 1 4/16 1/17 |100-004.021.026 | Joint 2 The table above applies only to the spare parts belonging to the cylinderhead. _ . The joints and washers for the ténnected pipes wre: . mentioned in the spare Part Listy Code Description 610.083.2100.10 | Eye-bolt for lifting the cylinderhead 610.083.1600.10 | Torque-wrench with sockets and accessories (rocker-bracket and nozzle-holder nuts) "610.084.2300.10 | Tools for fitting the valve seats "610.084.9006 .10 i tee -610.084.9007.10 | T0ol for removing and fitting valve guides *610.084.2100.10 |Equipment for the hydraulic test of the cylinder heads “Remark + Special tools, not standard delivered with engine (only delivered on order) Edition: 2 12CHAPTER 1 i Maintenance manual Cylinder head OX(S)(C) engines 2 \ 37 36 38 39 27 28 \A 26 29 consent of ABC 25 [ABC ovns the copytight of this document. It shall not be copied or disclosed without the px Fig 12 Fig 1.3 | | ¥ Edition: 2 13ABC owns the copyright of this document. IY shall not be copied or disclosed without the prior consent of ABC. ed CHAPTER 1 : Maintenance manual Cylinder head DX(SH(C) engines 1.1.5. 1.1.5.4. 1.1.6. 11.6646 Dismantling (fig:1.1) Staff needed + one service man Empty the fresh-water circuit partially, so that no water remains in the cylinderhead, ‘ Take off the cylinderheadcover’ byunscrewing the hiahd— nuts (18), the nuts (19) and the studs (20). Detach the pipe-work (rocker lubrication, fuel-feed and return pipes of the nozzle and the starting-air feed-pipe) and the nuts (21). Remove the rockersystem»(22) and its ibrackets (23), as well as the push-rods (24). Remove the nozzle holder after taking off the nuts (27) and removing the yoke (28). Separate the cylinder head from the oblique port extension piece (25) by removing the fixing bolts. Release the cylinder head from the cylinder block by re- moving the nuts (26), which must be loosened in the reverse order to that depicted on page 1.28. Lift cis the cylinder head with tool fig.1-2- (610-083 .2100.10). Ma: ance Staff needed : one serviceman Cleaning the cylinder head Remove all components from the cylinder head, except the valve guides and the valve inserts. Degrease it with paraffin (kerosene) or white spirit. Clean the exhaust port by means of a blunt tool or by the use of a product recommended by the manufacturer. Examine carefully the state of the internal surfaces of the water jackets after having removed the inspection plates and the brass plugs. If the deposit is thicker than 0,4 mm, it must be removed. This can be carried out by the use of a special solvent, or of a mixture of 1 volume of 20/21° Baumé hydrochloric acid (specific gravi- ty : 1,16, concentration 35% vol./vol.) with 6 volumes of water (add the acide to the water). Close all the openings of the water jackets {except one, by means of wood or plastic plugs. Pour thé’ mixture into the cylinder head. Edition: 2 +4[ABC ouns the copyright of this document. It shall ot be coped or disclosed without the prier consent of ABC. @ 1.4.6.2. CHAPTER 1 i Maintenance manual Cylinder head DX(S(C) engines Be careful of the producéd gas; it is flammable (no open flames in the vicinity). Empty the cylinder head when no more gas is produced. al Rinse the cylinder head with running water when the depo- sit has désappeared ; if not, start the process , again. After the rinsing, dry the cylinder head with compressed air. Hydraulic test of the cylinder head After the cleaning and the removal of the deposit, the water jackets have to undergo a hydraulic test at 5 bar for 15 minutes. The illustration below depicts the arran- gements for the tests (Tool 610.084.2100.10) (Fig. 1.5.). Examine carefully the bottom of the cylinder néad, ~~ the air and gas passages, the plates and plugs closing the water jackets, particularly on the upper surface of the cylinder head (contamination of the oil in case of a water leak). No seepage may be tolerated, at the risk of damage to the cylinder ("water hammering") or damage due to-oil con= tamination’. == == : Zs | 610.084.2100.10 Edition: 2 15ut the prior consent of ABC all nat be copied or disclosed wi [ABC owns the copyright of this document @ CHAPTER 1 i Maintenance manual Cylinder head OX(S)(C) engines 1.1.6.3. Verification of the valve quides (fig.1.6.) The valve guides must not be removed unless they are to be exchanged due to damage or exceeding the limit of wear (LW). Measure the inside diameter of the guide gA as fitted in the cylinder head. If the limit of wear is exceeded, on one of the measures remove the valve guide by means of the tool 610.084.9006.10 (fig.1.7.). Before fitting a new guide, measure the bore of the housing gC and the outside diameter of the guide gp’ and verify that the fit will be tight enough. After fitting the 6 A are to be Measured again and must be in accordance with the original dimension oD. ZZZZZLZLLEH PO 34,033 8 3y.017 34,02 34,000 p Z{LLLLL LLL LDL OLLI — ee EZZ IZZZ 610.084.9006.10 610,084,9007.10 Fig 1.6 610.084.9006.10 Edition: 2ABC owns the copyright of this document, It shall aot be copied or disclosed vithout the prior consent of ABC (3) CHAPTER 1 i Maintenance manual Cylinder head OX(SHC) engines 1.1.6.4. Inspection, reworking or, if necessary, renewal of a valve insert 4. Inspection After a certain period of service, the face of the valve insert takes on a characteristic appearance, especially the exhaust valve insert, which acquires a marbled appearance, quite different from that of a new insert. This is the result of very small irregularities of the faces, not enough to impair the functioning of the valve. There is no need to rework it ; that would merely be a waste of material. Reworking is needed only in the following cases : a) damage : burns, mechanical shocks, leakage or hammering b) geometrical defects, that is to say, when a feeler gauge of 0,02 or 0,03 mm can be inserted between the insert and the valve (valve in good condition and pressed in by hand). 2. Reworking of the inserts When reworking is justified, it is to be done with the removal of as little material as possible. A special tool should be used ; the following device is recommen ded (£ig.1-8.) - (610.084.2200.10). The success of this operation assumes that valve guides are in good condition and do not exceed the limit of wear. after the rework, verify that the limits of wear have not been exceeded. Measure the run-out with respect to the valve guide (or the bore of its housing) by means of a concentricity gauge. The eccentricity must not exceed 0,02 mm (gauge reading 0,04 mm). 3. Renewal of a valve insert An insert must be renewed when the limit of wear is exceeded. It may be removed by two methods : (1) Drilling up the insert, taking care not to damage the cylinder head ; (2) Removing the insert by machining (turning or milling) Edition: 2 +(Bi) CHAPTER 1 ef Cylinder head Maintenance manual OX(S}(C) engines 610.084.2200.10 Fig 18 Edition: 2 +8ABC owns the copytight ofthis document. It shall not be copied or disclosed without the prior consent of ABC oe 4. CHAPTER 1 i Maintenance manual Cylinder head OX(S)(C) engines Limits on reworking of the insert (fig.1.9.) Inlet/Exhaust The diameter Q must be maintained. By reworking the op 99,5 (fig.1.9.a) is increasing more and more : the limit of wear is 6 101,5 (fig.1.9.b). ORIGINAL VALVE SEAT MAX. LIMIT OF REWORKING: {in and outlet) {in and outlet) a b Fig 1.9 Fitting a new insert (fig.1.10.) ~ Chill the insert to -194°C,for example, in a bath of liquid nitrogen (do not touch it with the bare hand). ~ Remove the insert from the bath and place it in the cylinder head, using tool 610.084.2300.10. When the temperature of theinsert rises again by contact with the cylinder head, the insert expands and ensures the desired tight fit. - Remove the tool. ~ Press the insert right home by means of the drift 610.084.2300.10 thereby ensuring that the seat is not fitted askew. = Inspect the insert geometrically after fitting. If out of limits, rework as previously described. - Before assembly, valves must be carefully lapped until a Close fit is obtained (see page 1.19) Edition: 2 ay(iB) CHAPTER 1 eC Cylinder head Maintenance manual DXISHC) engines TOOL: 610.084.2300.10 z @ \aph ENE yy, mount if the valve-guide is not used. uns the copyright of this document. it shall not be copied or disclosed ABC ot Fig 1.10 Edition: 2 110rot be copied or disclosed vithout the prior consent of ABC. ABC ouns the copyright of this document. I s ee 1.2.1. CHAPTER 1 i Maintenance manual Cylinder head DX(SH(C) engines THE VALVES AND THEIR MECHANISM The _rocker_assembly 1.26161. Description (fig.1.11.) 1.2.1.2. 1.2.1.3. 162.104. The rockers (22) are equipped with bearing bushes(27)'and are mounted on a shaft (28) secured in the rocker brackets (23) which are attached to the cylinder head by the studs (29). The rockers are pressure lubricated, the oil passing through the shaft and returning to the crankcase by way of the push-rods (24) The push-rods transfer the movement to the rockers through the ball-ended adjustment screws (30). Weight : rockers with brackets ... a 8,5kge Recapitulation of the maintenance jobs Code Job R2-01 Complete inspection of rocker assembly (rocker arms, bushes, push-rods) Spare parts Optional Figen 4, Code Description Number ef en per cyl. 11/27 610.011.8202.10 Bush 2 Tools Code Description * 100.920.019.001 Riter for retaining ring for shafts straight tips |-610.084.9008.10 | took PSE aFEREAtiing the bushes (27) Remark : Special tools, not standard delivered with engine (only delivered on order) Edition: 2 1.ABC owns the copyright of this document. it shall wot be cqpied or disclosed without the prior content of ABC (2) CHAPTER 1 Maintenance manual Cylinder head DXISNC engines 79 0 35 33 27 2 N N N pL pI 93,25 £0.25 134,35 ¢ 0,25 j30,000, 130,021 135,975 Z=Measured cold Fig 1.12 610.084.9008.10 PQ VF Fig 1.13 Edition: 2 1-2sd without the prior concent of ABC. ‘ot be copied or ‘ABC ouns the copyright of this document. Its @ 1.21.56 1.2.1.6. CHAPTER 1 i Maintenance manual Cylinder head OX(SNC) engines Dismantling (fig 1.11) Staff needed : one service man - Detach the oil feed pipe (31) from the shaft ~ Remove the nuts (21) and lift off the rocker assembly ~ Dismantle the shaft - retained by the two circlips (32), the rockers and the spring (33) - Clean the oil-bores in the shaft and rockers Maintenance Staff needed : one serviceman 1. Dimensions and limits of wear of the rocker bushes Pimensions and limits of wear of the rocker bushes The limits of wear are given in fig.1.12- 2. Renewal of the bearing bushes (27 The bushes need to be removed and new ones fitted only when the limits of wear are exceeded or when damaged = Bearing bushes are removed and fitted with tool Lo 610.084.9008.10 (fig.1.13) é After fitting, drill the oil-bore in the bearing bush! 1.2.1.7. Assembly Staff needed : one serviceman 1. Before installing the rockers ~ put the push-rods (24) in place 2. Installing the rockers Before mounting the rockers on the cylinder head, verify : ~ that the adjustment screws (30) are fully slackened; - that the push-rods are at the bottom of their travel and that the piston is at TDC (injection) Tighten the bracket nuts (21) in accordance with the tightening torque table. Connect the oil feed pipe. On starting the engine, verify that the oil is reaching the points to be lubricated. Edition: 2[ABC owns the copyright of this document. It shall nat be copied or disclosed withaut the prior consent of ABC. ee CHAPTER 1 i Maintenance manual Cylinder head OX{S)(C) engines 3. Adjustment of the valve clearances (fig-1-11 and 1.12) The clearances are to be measured by feeler-gauge when the engine is cold. The blade is to be placed between the rocker and the valve stem. Grease both surfaces slightly before measuring. - Turn the crankshaft in the normal sense of rotation until the piston is at TDC (end of the compression stroke), that is, when both valves are closed. Make the adjustment in the same way © for all the cylin- ders, in the firing order indicated on the engine. - Before the adjustment, slacken off the lock-nut (35) and the adjustment screw (30) by one turn. - Tighten the adjustment screw (30) with an openend wrench until the rocker just makes contact with a 0,1 mm feeler gauge. Prevent the screw from turning by means of the dpetiend wrench, and tighten the locknut (35). Verify the clearance of 0,1 to 0,15 mm. 1.2.2. Inlet_and exhaust valves (fig. 1.1.) 1.2.2.1. Description Each cylinder head carries one inlet valve and one exhaust valve (2,3). The valves are of heat-resisting austenitic steel and move in wear-resisting grey cast-iron guides (4), which are extended above the cylinder head to serve as guides for the valve springs. There are two springs (38, 39) for each valve. The upper ends of the springs bear against a collar (36), held in place by a pair of half-conical collets (37). Mass: inlet and exhaust valves + 1,5/1,4 kg. 1.2.2.2. Recapitulation of maintenance jobs Code Job E2 - 01 | Check and adjustment of the valve clearance if needed R2 - 02 | Inspection of valves, springs and collars Verification of the valves and of necessary regrinding of the valve seats Ecition: 2 14[ABC owns the copyright of tis document It shall oot be copied oF disclosed without the prior consent of ABC RB) CHAPTER 1 i Maintenance manual Cylinder head DXISKC) engines 1.2.2.3. 162.204. Spare parts Optional Figen?/ Number Bef en? Code Description per cyl. ve 610.011.1101. 11] Inlet valve 1 V3 610.011.1102. 11] Exhaust valve 1 1/38 | 610.011.1103. 11] Inner valve spring 2 1/39 | 610.011.1104. 11] Outer valve spring 2 Tools Code Description 610.083.1200. 11|Lever and nut for fitting and releasing 610,083-3105-11) Retaining nut. 1.2.2.5. Dismantling (Fig.1-14.) Staff needed : one serviceman ~ Screw the nut 610 .083.3105.110n the nearest rocker— bracket stud, which will act as a pivot. - Place the cylinder head on a bench, resting on the valves. - If necessary, strike the spring collar (36) several times with a hammer, preferably using a copper drift, in order to free the collets (37). - Place the lever on the spring collar. - Press it down and take out the collets. - Cautiously raise the lever to permit the springs to expand and then lift them out. - Attention : Take care of the proper tenacity of the lever on the assisting stud. It can be dangerous if the lever slides sidewards and bounds back in the face of the user. Edition: 2 115‘ABC owns the copyright of this document, It shall not be copied or disclosed without the prior consent of ABC (MIB) CHAPTER 1 so1d sys snoyL posDPSIp 10 paxio> 8q Jou yeUS 4 WENO sNK JO IYbLKHoD eu) SURO Day Fig 1.23 Fig 1.22 wan Edition: 2i 3 z 5 i i 2 i i a z (8) CHAPTER 1 i Maintenance manual Cylinder head OXISN(C) engines 1d. 1.4.1. 1.4.2. FITTING THE CYLINDER HEAD ONTO THE ENGINE (Fig. 1.1.) EERRING THE CYLINDER HEAD ONTO THE ENGINE Fitting Personnel required : one serviceman ~ Clean all parts thoroughly ~ Inspect the cylinder head gasket(11)if damaged or scratched and if any doubt, replace it. - Replace exhaust side gaskets, grease with "MOLYKOTE" or graphite paste. - Place the cylinder head on the cylinder block by means of a lifting device (fig. 1-2.). ~ Grease the fixing bolts on the oblique port extension piece with "MOLYKOTE" or graphite paste and screw the bolts hand fast, - The lower face of the washers (29) on fig.1.1 must be Coated with CURIL-K2 to render it oil tight. ~ Tighten the cylinder head nuts and tighten the fixing bolts on the oblique port extension piece ~ Mount rocker arm systém.; (22) with push-rods (24), injector, starting air valve and pressure~ relief valve. Remount pipe work (rocker lubrication, fuel-feed and return pipes on the nozzle holder and start- ing air feed pipe). Remount the rocker cover with studs (20) and nuts (19). its (Fige1.24) The order of succession for tightening is shown on figure 1.24; below. The nuts are tightened in 3 times according to the angular displacement method. New studs have to be pre-tightened a first time in order to avoid wrong extensions. Tightening values : + stage 1: 0 to200Nm (20kgm) + stage 2:4 65 ° angular disp + stage 32+ 65° om ” Fig 1.24 Edition: 2 178‘or disclosed without the prior consent of ABC. [ABC ouns the copyright of this document. It shall pot be oy CHAPTER 1 i Maintenance manual Cylinder head OXIS)C) engines 1-463. Remark Enginesof previous delivery may have cylinder heads tightened by torque wrench (special tool). Tightening torgues : + Stage 1: secure all nuts by hand + stage 2: up to 300 Nm (30 kgm) + stage 3 : up to 630/650 Nm (63/65 kam) Special tools : Torque wrench + sockets for tightening nuts cylinder head & short tie-rods. Code : 610.084.1300.10 This tool is only delivered on order. Edition: 2 1-29[ABC owns the copyright of thie document, It shall not be copied of disclosed without the prior consent of ABC. CHAPTER 2 PISTON - CONNECTING ROD Maintenance manual OX{SNC) enginesot be copied of disclosed without the prior consent of ABC. [ABC owns the copyright of this document. It 2.1.2. CHAPTER 2 Piston - Connecting rod Maintenance manual DX(SHC) engines PISTON iption (Fig.2.1.) The pistons are cast in a light silicium-aluminium alloy. All the DXC-engines and the DXS-engines have, for the two uppermost piston rings, Ni-resist cast iron inserts. (DX-engines have only a top ring insert in Ni-resist). ‘The piston pins are made of a special chromium-steel alloy having a small carbon content ; when hot, the piston pin is free in the piston. The piston pin is restrained from axial movement by two Seeger circlips. The piston is fitted with rings of three types : = 1 chrome-plated top ring with barrel-shaped surface 5 - 3 compression rings with cylindrical surfaces 5 = 1 oil scraper ring, expanded by means of a helical spring. Mass : Complete piston / connecting rod assembly «-+max+72,55 kg Piston ....eeee eeeeee 22,40 kg + 8,30 kg Piston pin seeeseee Set of piston rings .-.-++ 0,85 kg the maintenance jobs Code Job 03 - O1 Overhaul of piston : remove and measure the clearance and wear of the piston rings Clean pistons Piston rings replacement recommended) & i i i 3 ‘ABC oun the copyright RING ARRANGEMENT TOP_RING KZ. 2.1.3. COMPRESSION RING SCRAPER RING CHAPTER 2 Piston - Connecting rod Maintenance manual DXISKC) engines OXS-DXC [ Dx H+} -9—4+- One complete set of rings for each piston. The correct types of rings may be ascertained by reference to the Spare Parts Manual. The previous maintenance work and wear, if any, of ring grooves must be taken into consideration for fitting ring groove spacers. These spacers may not be used in ring grooves, machined in the cast-iron insert. 22sed without the prior consent of ABC i i | 3 & i 3 @ 2.164. 2.4.5. 2.15.16 _. CHAPTER 2 Piston - Connecting rod Maintenance manual ols. Order number Description 610.083.1600.10 |Torque wrench with sockets and accessories In order to tighten the connecting rod big end nuts without removing the coolers, a suitably shaped torque spanner must be used *100.922.040.001 | Plier for retaining ring for bores (straight tips) 610.084.9004.10 |Piston ring opener for removing and re- placing the piston rings 610.083 .3102.10/ 900.102.113.030 |Extraction plate for lifting out the pis- ton / connecting-rod assembly '610.084.1200.10 | T001 for ‘mouriting the piston / connecting-rod assembly and for measuring the piston ring gaps - 1/2" tap for cleaning the holes in the piston crown before fitting the extrac- tion plate Remark : special tools, not standard delivered with the engine ~ (only delivered on order) Dismantling s taff required : one service man and one assistant Removal of the piston / connecting rod assembly Remove the cylinder head (Chapter 1) Rotate the crankshaft, so that the piston is about 5 cm below the TDC Stuff the space between the piston and the liner with grease Decarbonize the upper part of the liner with ascraper Lower piston to BDC and wipe offgrease and carbon Raise the piston to the TDC By means of the 1/2" tap, clean out the holes used for lifting. Place extraction plate (Fig.2.2.) (610.083.3102.10 and 900.102.113.030) If necessary, remove the coolers and inspection doors adjacent to the assembly to be lifted out (not necessary with suitably shaped torque spanner) 23sclosed without the pri consent of ABC. [ABC ohne the copyright of thie document. IF shall not be copied or eS CHAPTER 2 i - necti od Maintenance manual Piston - Connecting r Maintenance mar = Dismantle the big-end cap (tool 610.083.1600.10) by re— moving nuts, taking care that it does not fall into the crankcase. To that purpose, remove first only three of the nuts, support the cap by means of a piece of wood, then remove the fourth nut and take out the bolts. Note : Keep the nuts and bolts together in their original ov" pairs. = Attention must be paid that the con-rod doesnot touch the cylinder liner during lifting Raise the assembly a little and_as soon as possible, re- move the upper bearing shell from the big end - Lift the assembly out of the liner. Remove the extraction plate. = Place the piston upside-down on wood, secure the connec ting rod in a vertical position by means of two wooden wedges, one on each side of the connecting rod- 1 610.083.3102.10 Fig. 2.2 ra[ABC ouns the copyright of this document. It shall nat be copied or disclosed without the prior consent of ABC. CHAPTER 2 Piston - Connecting rod Maintenance manual OX{S)(C) engines 2.1-5-26 2.1.6. 21.661. 241.6.2. Removing the piston = Detach the piston rings (tool 610.084.9004.10) - Detach the circlips (tool C40 DINS256) — Heat the piston to between 40° and 50°C. This can be done on a heating plate or by filling the piston with denatured alcohol (methylated spirit) and setting fire to it. Support the weight of the connecting rod by means of a sling, so that the piston pin is free in the small end bush. Let 20 to 25 cc of denatured alcohol burn for about two minutes. = Slide out the piston pin by striking it with a block of wood. Warning : Never attempt to drive out the piston pin when it is cold Maintenance Staff needed : one servite man Cleaning 4. The piston Decarbonize the piston by means of adequate products. Never use sharp scrapers for this purpose. Special attention must be paid for cleaning the piston Grooves, especially to have the bottom free of carbon deposits. (a broken part of a piston ring can be used for this purpose) 2. The piston pin Wash the piston pin in kerosene or cleaning oil. Dry it by compressed air. General examination of the piston This consists in a visual inspection for possible cracks or other damage. For this purpose, organol red may be used (spot check). Examine in particular . the piston crown (particularly in the valve recesses) . the piston ring grooves, « the piston pin bosses. A new piston must be fitted if there is any crack in this area.CHAPTER 2 C8) Piston - Connecting rod Maintenance manual DX{SHC) ‘engines 1 copied of disclosed without the prior consent of ABC Fig 2.3 (a) = Clearance 3 = | PIN GAP. RING GROOVE i aA |B | c [si [szadss [zr |z234 G2 [Gx] os 3 op REDeasEmDOESeT ae] aa | Ox [3900 [saEo 7060] 2050 | 8030 ig 14,955 |95,035 94,976 | 1.2 415, 08 |3,960 | 3,978 4,080 | 4,070 | 8,050 =. LW1[94,800)95.150}95,000) 3 3 3° 5 ; {a) 0,30 | 0,25 | 0.25 | 0.20 5 1. The piston ring grooves Measure the width "G" of each groove at four places equally spaced around the circumference. Use feeler gauges for this purpose, in conjunction with a new piston ring whose height is within the OD. Any piston ring groove whose clearance exceeds the limit (a) must be reworked.‘ABC owns the copyright of this document. It shall nat be coped or disclosed without the prior “onsent of ABC CHAPTER 2 i - i od Maintenance manual Piston - Connecting r Maitre men + The piston pin and bore Measure the outside diameter (A) of the piston pin and fit a new one if the LW figure is exceeded. Measure the bore (C) in the middle and vertically. A new piston must be fitted if the LW figure is exceeded. 3. Piston ring wear (Fig. 2-4.). The wear of the piston rings is determined indirectly by measuring the gap width. Use the tools : 610.084.1200.10 Fit a new ring if the LW figure is exceeded. 4. Reworking of piston ring grooves without cast-iron insert (Fig. 2-6- and 2-7.) Special precautions must be taken if the necessary precision is to be obtained in this delicate work on the lathe. a) Setting _up_on the lathe Clamp the piston crown between the three soft metal jaws of the chuck and centralize the piston skirt by means of a dial gauge on A. Check the centricity-by means of a dial=gauge applied as indicated by the arrow B. . Do not apply a dial-gauge elsewhere, because it would then give a false reading as a result of the ovality of the piston. The run-out at B must no exceed 0,05 mm. If necessary correct. The reading in A can in some cases increase up to 0,1 mm, depending of the con- dition of the piston crown. If the positioning seems incomect: start again the setting-up by clamping the piston crown in an other position. The tool holder should be adjusted so that the sur- facesto be machined are at square angle to the pis— ton centre line. Max. run out : 0,02 mm; Machine only one surface at a time, the lower face first. Turning speeds : 130 RPM with tools of high speed steel 400 RPM with tungsten carbide tools Feed rate + 0,10 mm/rev. Cooling spray with oil emulsiondisclosed vithout the priar consent of ABC [ABC owns the copyright of this document. It shall not be copied oF e 5. CHAPTER 2 Piston - Connecting rod Maintenance manual OX(SHC) engines In accordance with the figures on the drawings. ¢) Verification + = Verify the dimensions at four places at least, equally spaced around the circumference- Use feeler gauges for this purpose. ~ Perpendicularity : use a dial-gauge with a lateral pointer with the axis parallel to the piston- Rotate the piston. The run-out of either wall must not exceed 0,02 mm~ The total run-out of the two walls, over one full ro~ tation, must notexceed 0,04 mm. - Platness : place the piston on a surface-plate+ The difference between the edge and the bottom of the groove must not exceed 0,02 mm. Reworking of piston ring grooves with cast-iron insert Generally wear of ring grooves with cast-iron insert is very low. Except, after along service time or when fuel with high sulphur content is ih use, reworking may become necessary- Also the first ring groove can be reworked- Because this is not a Usual practice, please contact our technical department ! 2-8; _ CHAPTER 2 Piston - Connecting rod Maintenance mancal MEASURING THE GAP Fig 2.4 610.084.1201.10 ‘ABC owns the copyright of this document, It shall not be copied or disclosed without the pri a MOUNTING THE PISTON INTO THE LINER Fig 2.5 29suns the copyright of ths document, If shall not be copied or dls without the prior consent of ABC. Ae 0 (8) CHAPTER 2 << Piston - Connecting rod Maintenance manual OX(SHC) engines SETTING UP THE PISTON IN THE LATHE Fig. 2.6 2193°83 N Fig. 2.7(SB) CHAPTER 2 55, Piston - Connecting rod Maintenance manual OX{S)(C) engines 2.1.7. Assembly Staff needed : one service man 2.1.7.1. Preparing the piston rings (Fig.2.4.) Verify the gaps (2-1-6.2.-3) 2.1.7.2. Assembling the piston pin and connecting rod - Heat the piston to between 40° and 50°C = This can be done in an oil-bath on a heating plate or by burning denatured alcohol (see 2+1.5.2-) - Put one of the circlips in place = Oi1 the piston pin and slide it into the piston ‘The markings on the connecting rod must be on the same side as the mark "AVANT" (Front) on the piston. = Put the other circlip in place. 2.1.7.3. Fitting the piston rings = Use tool : 610.084.9004.10 - Fit, in the following order : = the scraper ring, with the marking "TOP" upside ; « the three compression rings ; = the chrome-plated top ring, with the marking "TOP" upside Verify that the piston rings are free in their grooves- = Arrange the gaps out of line (see diagram below) Fig.2.8- - For the oil scraper, arrange the spring join faces opposite to the gap opening. Gap for new rings measured with tool 610.084.1200.10 t i : : 4 4: 0,8-1,2mm 23,4 : 0,9-1,15mm 5S : 0,4-0,8mm ! & T™\8, [1 12 [4 oe | | | ra cylinder[ABC ouns the copyright of this document. It shall ot be coped or disclosed without the prior consent of ABC. oe) CHAPTER 2 i - i Maintenance manual Piston - Connecting rod DM hai 2.1.7.4. Fitting groove spacer(s) (Fig-2.7. & 2.9.) Put the spacer in place Fit the piston ring and push it home until the spacer jams, then strike the spacer gently with a hammer and blunt screwdriver until it slides into its slot Start striking at the point A and work toward the gap Verify that the piston ring is free in its groove If the spacer is not correctly fitted (not properly entered in its slot), the piston ring will jam. Arrange the spacer gap opening approximative at square angle in regard to the engine centre line - Fig 2.9‘ABC ovns the copyright of this document. It shall not be copied or disclosed without the prior consent of ABC (8) 2.1.7.5. CHAPTER 2 Piston - Connecting rod Maintenance manual OX{SNC) engines Fitting the piston / connecting rod assembly - Verify that each piston is fitted in his corresponding cylinder - Verify that the pistons and liners are clean = Examine the side faces of the big ends and if necessary remove any roughness by means of a stone. with-fine grain - Lubricate the liner and piston rings with clean oil = Put the tool for mounting the piston in place (Fig.2-5.) = Attach the piston / connecting rod assembly to the ex— traction plate (Fig.2-5-) - Turn the crankshaft to the TDC position for the cylinder in question = Lubricate the crank pin with clean oil - Verify that the piston/connecting rod assembly is in the correct position, with the marking on the side of the injection pumps - Bring the assembly to the engine and lower it until it is just over the crank pin. - Push the upper bearing shell into the connecting rod (see 2.2.7.3.) ~ Lower the assembly on to the crankshaft = Put the big end cap, complete with the lower bearing shell and one bolt, in place and tighten the nut as far as the nylon ring = Put the other bolts in place and fit their nuts. = Tighten the nuts to the correct torque (see 2-2.7.4.) - Fit the inspection plates and coolers (if taken away) - Fit the cylinder head (see chapter 1) Remark : If new piston rings and/or liners (Chapter 3) have been fitted, the running-in procedure must be followed. See Operating Manual (Chapter 6). After complete dismantling of piston, we also recommend to follow this procedure.{ABC owns the copyright of tis document, If stall ot be copied or dsclsed without the prior consent of ABC @) 2.2. 2.2.4. CHAPTER 2 Piston - Connecting rod Maintenance manual DX(S)(C) engines THE CONNECTING ROD The connecting rod shank (1) and the big end cap (2) are bored as an assembly and are kept together by means of four bolts (3) and nuts (4). The cap is positioned by the ¢¥lindrical pin’ (5) which is of centre relative to the connecting rod. Identification of the connecting rod : - Each connecting rod carries the following marking : + the engine number, + the cylinder number, + its mass; + the tightening torque for the big end nuts. This marking is mentioned on the fuel injection pump side.nent. it shall not be copied or disclosed without the prior consent of ABC. ‘ABC owns the copyright off 2.2.2. 2.2.3. 2.2.4. CHAPTER 2 Piston - Connecting rod Maintenance manual OX(SKC) engines Mass’ Connecting rod complete with small end bush, big end cap and bolts. The connecting rods are machined to obtain the following series of mass: 39 - 39,5 - 40 - 40,5 or 41kg All the connecting rods in one and the same engine must be of the same mass. Big end bearing shells .. cess 1,40 kg ++ 0,65 kg Small end bearing bush -- Recapitulation of _t! mainten: Code Job 03 = 04 | Check connecting rod bearings (replacement recommended) Numb Code Description per evi. 10/6 |610.010.1101.10|Smai1 end bush (green) 1 610.010.1102.10|Smal1 end bush (white) 1 10/7 |610.010.9001.10|Big end 1/2 bearing shell] 2 (6168) 610.010.9101.10|Big end 1/2 bearing shell] 2 (undersize 167,75) 610.010.9201.10|Big end 1/2 bearing shell] 2 (undersize 5167,50) 610.010.9401.10|Big end 1/2 bearing shell] 2 (undersize 4167) Tools Order n®* Description 610.083.1600.10 | Torque wrench (big erd bolt nuts) *610.084.1600.10 | Spec. tool for mounting & dismounting small end bush ‘Remark : special tools, not standard delivered with the engine (only delivered on order)‘AGC owns the copyright of this document. shall ot be copied or disclosed without the prior consent af ABC @ 2.2.56 2.2.5.1. 2.2.5.2. 2.2.6. 2.2.6.1. 242.62. CHAPTER 2 Piston - Connecting rod Maintenance manual OXISHC) engines Dismantling Staff needed : one service man and one assistant Removal of the piston/connecting rod assembly See 2.1.5.1. Removing the connecting rod See 2.1.5.2. Maintenance Staff needed : one service man Inspection of the big end bearing sheils Clean the shells by means of a soft cloth. Examine very carefully the anti-friction coatings. Any shell must be exchanged in the following circumstances : - if the Teadstin=fI5shuts loose, _ if there is damage (severe scratching or many grooves due to dirt or particles) Minor roughness or slight wear does not necessitate to re— place the shell. Slight cavitation round the oil4H6re does not necessitate replacement. Attention ! The bearing shells used are of the copper-lead type. After a long service time i.e. 24.000 hours or mores due to normal wear a part of the anti-friction coating can be absent and consequently the hard Nickel intermediate layer becomes partly free. This can only be checked by skilled personal after visual inspection. If this condition can not be satisfied, we recommend to replace the bearing shells. Cleaning & visual examination of the connecting rod Clean out the oil-boresby means of compressed air (do not remove the small end bearing bush). Clean the holes for the bolts, the bolts themselves, the nuts, the inner surface and oil-bore of the small end bearing bush and the big end bearing shells housings. In case of damage, test the connecting rod and the bolts by means of organol red or Magneflux. Renew any part showing cracks or damage.‘ABC owns the copyright of this document, It shall nat be copied or disclosed without the prior consent of ABC. ) CHAPTER 2 Piston - Connecting rod Maintenance manual DX(SNC) engines 2.2.6.3. Verif: ication of the dimensions Dimensions in_mm For reworked crank-pins ‘st. undersize | ‘2nd. undersize | 3th. undersize oD LW R1 | LW R2 LW | R3 Lw_| TAPER |OVALITY| 766,10 167,860 67,610 167,110 A [REA | t5,36o [167.860 [ wo. ierete 17.880 | eres, | 167360 | 9.04 max | 0,08 max B | 95.000) 95,150 0,03 max | 0,05 max 95,035. C 175,000 Lit 1. Control the big end bearing shells Carefully clean all the parts of the connecting rod. Insert the bearing shell in the big end and tighten the nuts in accordance with the tightening torque table, in the proper order (see 2.2.7.4.). Measure the diameter "A" in six places. Fit new shells when any diameter exceeds the LW figure.CHAPTER 2 (8) Piston - Connecting rod Maintenance manual OX(SI(C) engines - Undersize shells are available for use with reworked crank pins. 2. Verifying the bore of the big end This is not a routine verification ; it only need to be carried out incase of accident. Measure the diameter "C" in the same way as the diameter "A", but with the bearing shells removed. 3. Verifying the small end bearing bush Measure the diameter "B" in the vertical sense. Fit a new bush if the LW figure is exceeded. (see 2.2.7.2.) 610.084.1600.10 tis document, It hall not be copied or disclosed withaut the prior consent of ABC. ‘ABC owns the copyright Fig 2.12‘ABC ons the copyright of this document, it shall not be copied oF disclosed without the prior consent of ABC. @B) CHAPTER 2 Piston - Connecting rod Maintenance manual OX(S)(C) engines 2.2.76 2.2.7.4. 2.2.7.2. 2.2.7.3. Assembly Staff needed : one service man Assembling the connecting rod and piston See 2.1.7.2. Replacing the small end bearing bush (fig-2.12) The assembly and removal of the bearing bush should be carried out by means of the tool 610.084.1600.10 and a press. Assembly : - Remove any burrs from the oil-bore in the small end by means of a scraper ; - Press in the new béaring bush ; = Set up the connecting rod vertically and drill the oil- bore through the bearing bush ; ~ Remove any burrs by means of a scraper ; - Verify the inner diameter : + with the piston pin,using prussian blue ; + by measuring the dimensions. Note : When ordering a new small end bush, mention the colour mark (green or white) on the confiecting rod shank. Replacing the big end bearing shells A.) O 1 = Clean out the bore of the connecting rod ; - Carefully note the dimensions of the shells : +6168 -R on initial assembly + 6 167,75 - R1 - first undersize + 6 167,5 -R2- 2nd undersize + 6 167 R3 - 3th undersize = Remove any roughness in the bore of the connecting rod by means of a stone with fine grain. B.) On_assembly ~ Verify the cleanliness of each part ; - Place the bearing shells into the connecting rod with their backside dry.