Maintenance Procedures

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 Components:Components: 01 01 Connecting Connecting rod, rod, lower lower part, part, 05 05 Connecting Connecting rod, rod, upper upper part.part.

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 Tighten Tighten B1, B1, B2, B2, simsimultaneously ultaneously with stated with stated hydraulic hydraulic pressure.pressure. 

 Tighten the nuts if possible.Tighten the nuts if possible.



 Tighten A2, one or two nuts simultaneously on the same side. Pump to stated hydraulic pressureTighten A2, one or two nuts simultaneously on the same side. Pump to stated hydraulic pressure 



 Tighten A1, one or two nuts simultaneously on the same side. Pump to stated hydraulic pressureTighten A1, one or two nuts simultaneously on the same side. Pump to stated hydraulic pressure 

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 Components:Components: 01 01 Adjusting screw Adjusting screw for rocker for rocker arm, 02 arm, 02 Counter nCounter nut.ut.



 Ad Adjuju stst inin g thg th e vale valve clearve clearancancee 

 Put a feeler gauge corresponding to the valve clearance between the surface of the yoke and thePut a feeler gauge corresponding to the valve clearance between the surface of the yoke and the shoe at the rocker arm.

shoe at the rocker arm.



 Tighten the adjusting screw (1) until the feeler gauge can be moved to and fro only with slightTighten the adjusting screw (1) until the feeler gauge can be moved to and fro only with slight force.

force.



 Hold the adjusting screw and tighten the counter nut.Hold the adjusting screw and tighten the counter nut. 

 Check that the clearance has not changed while tightening.Check that the clearance has not changed while tightening.



 Ad Adjuju stst inin g thg the PCC e PCC vvalvalv e clearane clearancece 

 Put a feeler gauge corresponding to the valve clearance between the surface of the valve stemPut a feeler gauge corresponding to the valve clearance between the surface of the valve stem

and the adjusting screw (1) at the rocker arm. and the adjusting screw (1) at the rocker arm.



 Tighten the screw until the feeler gauge can be moved to and fro only with slight force.Tighten the screw until the feeler gauge can be moved to and fro only with slight force.



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 Components:Components: 01 01 Filter ring, Filter ring, 02 02 Tension Tension ring, 03 ring, 03 Trap Trap cover, 04 cover, 04 Cover Cover panel, panel, 05 05 Cover Cover panel, panel, 0606

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 Components:Components: 01 01 Top Top cover, cover, 02 02 O-ring, O-ring, 03 03 Filter Filter cover, cover, 04 04 Fastening Fastening plate, plate, 05 05 O-ring, O-ring, 06 06 Spring,Spring,

07

07 Spindle, Spindle, 08 08 Upper Upper filter cfilter cartridge, artridge, 09 09 Spindle, Spindle, 10 10 Shim, Shim, 11 11 Lower Lower filter cfilter cartridge, artridge, 12 12 Filter Filter plate,plate, 13 Spring.

13 Spring.

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 Connections:Connections: A A Fuel gas Fuel gas inlet, B inlet, B Fuel gas Fuel gas outlet.outlet.



 Spare Spare part part setssets 

 Sealing setSealing set

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 Components:Components: 01 01 Filer Filer body, body, 02 02 Filter Filter cap cap cover, cover, 03 03 Filter Filter insert, insert, 04 04 Filter Filter basket,basket,

05

05 Filter Filter mesh mesh with with rubber rubber rings, rings, 06 06 O-ring, O-ring, 07 07 Plastic Plastic ring, ring, 08 08 Half Half pipe, pipe, 09 09 Sealing Sealing screw,screw, 10

10 Magnetic Magnetic insert.insert.

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System components:

01 O-ring, 02 O-ring, 03 Flange, 04 Screw, 05 Sealing sleeve, 06 O-

01 ring, 02 ring, 03 Flange, 04 Screw, 05 Sealing sleeve, 06

O-ring, 07 Ignition coil, 08

ring, 07 Ignition coil, 08 Spark plug, 09 Gasket

Spark plug, 09 Gasket ring (Alternati

ring (Alternative)

ve)



Spare

Spare parts:

parts:

Spark plug with gasket r

Spark plug with gasket ring, O-rings.

ing, O-rings.



Re

Replace spark plug

place spark plug s

s



Replace the spark plugs if the engine is started/stopped daily or more often.



Replace spark plugs if the engine is running more or less continuously at 2000 h



Mark the spark plug with the cylinder number to clarify the location for later

Mark the spark plug with the cylinder number to clarify the location for later visual

visual

checks. A possible operation malfunc

checks. A possible operation malfunction on a cylinder is often seen

tion on a cylinder is often seen on the spark plug.

on the spark plug.



Alw

Always replace the gasket

ays replace the gasket ring w

ring when spark plug removed.

hen spark plug removed. (Alternative)

(Alternative)



Clea

Clean a

n and check the conditi

nd check the conditi on of the igni

on of the igni tion c

tion c oil

oil



Clean and check the condition of the extension if the engine is started/stopped daily or

more often.



Clean and check the condition of the ignition coil if the

Clean and check the condition of the ignition coil if the engine is running more or less

engine is running more or less

continuously at 2000 h.



The ignition coil should be

The igniti

on coil should be replaced by a new coil in

replaced by a new coil in the event of malfunction.

the event of malfunction.



Replace O-rings.

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 Components:Components: 01 01 Filter Filter cover, 0cover, 02 2 Rotor Rotor unit, 04 unit, 04 Cutting Cutting off valve, off valve, 07 07 Paper Paper cartridge.cartridge.



 CleClean centrifugal fan centrifugal f iltersilters

It is very important to clean the filter regularly as it collects considerable quantities of dirt. It is very important to clean the filter regularly as it collects considerable quantities of dirt. If it

If it is found that the fis found that the f ilter has collected the maximum quanilter has collected the maximum quantity of dirt (tity of dirt (correspondcorresponds to a s to a 18 mm thick18 mm thick layer) at the recommended cleaning intervals, it should be cleaned more frequently.

layer) at the recommended cleaning intervals, it should be cleaned more frequently.

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System components:

01 Main gas filter, 02 Main gas

01 Main gas filter, 02 Main gas piping, 03 PCC gas piping, 04 Gas

piping, 03 PCC gas piping, 04 Gas

manifold,05 M

manifold,05 Main gas

ain gas admissi

admission valve, 06

on valve, 06 PCC gas channels in

PCC gas channels in Hot-box, 07 PCC gas

Hot-box, 07 PCC gas

delivery pipi

delivery piping, 08 Main ga

ng, 08 Main gas venting valve, 09 Actuator for main gas venting valve, 10 PCC

s venting valve, 09 Actuator for main gas venting valve, 10 PCC

gas venting valve, 11 Non-return valve, 12

gas venting valve, 11 Non-return valve, 12 Gas venting piping.

Gas venting piping.

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Pipe connections:

A

A 108 Gas i

108 Gas inlet, B

nlet, B 110 PCC gas

110 PCC gas inlet, C

inlet, C 727 Gas

727 Gas system vent,

system vent,

D

D PCC venting

PCC venting gas, E

gas, E 311 Control ai

311 Control air to main

r to main gas venting

gas venting valve.

valve.



Te

Testing t

sting t he gas system for

he gas system for lea

leak

k

WARNING!

Release the system pressure before

disassembli

ng any

connections.

If a leak is det

ected, shut off the supply of gas immediately.



Disassemble the leaki

Disassemble the leaking connection, examine the O-rings and sealing

ng connection, examine the O-rings and sealing faces. Replace

faces. Replace

worn parts.



Repeat the leak test for the repaired connection(s).

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NOTE!

Release the air pressure in t

he system before disassembling.

NOTE!

When the engine is running a portable gas leak detector can be used.

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 Components:Components: 01 01 Adjusting screw Adjusting screw for rocker for rocker arm, 02 arm, 02 Counter nCounter nut.ut.



 Ad Adjuju stst inin g thg th e vale valve clearve clearancancee 

 Put a feeler gauge corresponding to the valve clearance between the surface of the yoke and thePut a feeler gauge corresponding to the valve clearance between the surface of the yoke and the shoe at the rocker arm.

shoe at the rocker arm.



 Tighten the adjusting screw (1) until the feeler gauge can be moved to and fro only with slightTighten the adjusting screw (1) until the feeler gauge can be moved to and fro only with slight force.

force.



 Ad Adjuju stst inin g thg the PCC e PCC vvalvalv e clearane clearancece 

 Put a feeler gauge corresponding to the valve clearance between the surface of the valve stemPut a feeler gauge corresponding to the valve clearance between the surface of the valve stem

and the adjusting screw (1) at the rocker arm. and the adjusting screw (1) at the rocker arm.



 Tighten the screw until the feeler gauge can be moved to and fro only with slight force.Tighten the screw until the feeler gauge can be moved to and fro only with slight force.



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 Components:Components: 01 01 Steam Steam or air, or air, 02 02 Perforated Perforated pipes, pipes, 03 03 Cooler Cooler insertinsert



 CleaCleaninnin g of charge air coolg of charge air cool ersers 

 Remove Remove the the cooler.cooler.



 Look carefully for corrosion.Look carefully for corrosion. 

 Check for possible leakage.Check for possible leakage. 

 Clean the air side of the cooler.Clean the air side of the cooler.



 Clean the water side of the cooler.Clean the water side of the cooler. 

 Replace parts if necessary.Replace parts if necessary.

Ai

Air

r s

sid

id e c

e clean

lean in

ing

g

Clean the air side of the cooler by immersing the air cooler in a chemical cleaning bath Clean the air side of the cooler by immersing the air cooler in a chemical cleaning bath for at least 24 hours. Use approved cleaning detergents. The best cleaning effect is for at least 24 hours. Use approved cleaning detergents. The best cleaning effect is

achieved if the cleaning tank is equipped with perforated pipes. During cleaning, steam or achieved if the cleaning tank is equipped with perforated pipes. During cleaning, steam or pressurized air is fed through the pipes. When cleaning is completed, the cooler should pressurized air is fed through the pipes. When cleaning is completed, the cooler should be flushed thoroughly with water.

be flushed thoroughly with water. NOTE!

NOTE!

The use of a high pressure water jet for flushing, sh

The use of a high pressure water jet for flushing, should be avoided beould be avoided because:-cause:-it will packit will pack

the dirt into the middle of the

cooler-the dirt into cooler-the middle of cooler-the cooler-the cooler fins will be damaged. Tthe cooler fins will be damaged. This will causehis will cause

lowered air cooling efficiency.

W

Water side cl

ater side cl ea

eaning

ning

Clean the water side by immersing the tube bundle into a chemical cleaning bath for at Clean the water side by immersing the tube bundle into a chemical cleaning bath for at least 24 hours. Follow the recommendations given for the air side.

least 24 hours. Follow the recommendations given for the air side.

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Components:

01 01 Measuring

Measuring unit,

unit, 02

02 Cable,

Cable, 03

03 Transducer,

Transducer, 04

04 Cable

Cable holder,

holder, I O

I Operating

perating

side

side II Rear

II Rear side

side (as seen

(as seen from

from flyw

flywheel end)

heel end)



Che

Check cr

ck cr anksha

ankshaft h

ft h ot

ot deflection

deflection



Check of deflection, use measurement record.



The crankshaft deflection measurement i

The crankshaft deflection measurement is always done

s always done on a thor

on a thoroughly w

oughly warm engine,

arm engine,

after the engine is stopped.



The measurement should be carried

The measurement should be carried out rapidly but

out rapidly but carefully

carefully..



If mounted on rubber not necessary to perform.



Only the crankcase cover for the cylinder

Only the crankcase cover for the cylinder being measured should be opened and

being measured should be opened and it

it

should be closed immediately after measuring.



It is recommended to swi

It is recommended to switch of

tch off any forced ventilation close to the engine.

f any forced ventilation close to the engine.



Che

Check t

ck t hrust

hrust bea

bearing

ring axia

axial

l clea

clearance

rance



Lubricate the bearings by running the pre lubricating pump for a few minutes.



Apply a

Apply a measure gauge,

measure gauge, for instance,

for instance, against the

against the plane end surface

plane end surface of the fly

of the flywheel

wheel..



Move the crankshaft by a

Move the crankshaft by a suitable lever in either

suitable lever in either direction until contact is established

direction until contact is established

wi

with the

th the thrust bearing.

thrust bearing.



Set the measure gauge at zero.



Move the crankshaft in the opposite direction, and read the axial clearance from the

measure gauge.

NOTE!

During the deflection procedure the crankshaft should be

turned in the direction of

rotation, only.

NOTE!

Repeat the movement of crankshaft to ensure that

correct clearance is

measured.

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 System System compocompo nents:nents: 01 01 Valve Valve cotter, cotter, 02 02 Spring Spring retainer, retainer, 03 03 Spring, Spring, 05 05 WasherWasher,08 Extens,08 Extensionion

piece,

piece, 09 09 Rod, Rod, 11 11 Valve Valve guide, guide, 12 12 O-ring O-ring ,13 ,13 Valve, Valve, 14 14 Valve Valve seal, seal, 15 15 Nozzle, Nozzle, 16 16 Sealing Sealing ring, ring, 1717 Sealing

Sealing ring, 18 ring, 18 GrommGrommet, et, 19 19 Spring, Spring, 20 20 Boot.Boot.



 Connections:Connections: C C Gas Gas from connection from connection channelchannel 

 SpaSpare part kitre part kit :: Spare part kit for Spare part kit for ignition coilignition coil



 Replace Replace the prthe pr e-chamber nozzle ae-chamber nozzle and O-rinnd O-rin gsgs 

 Drain the cooling water system.Drain the cooling water system. 

 Remove the prRemove the pre-chamber.e-chamber. 

 Protect the bore in the cylinder head.Protect the bore in the cylinder head.



 Clean and check the condition of the pre-chamber.Clean and check the condition of the pre-chamber.



 Replace the pre-chamber nozzle.Replace the pre-chamber nozzle. 

 Check the sealing faces on the bottom of the pre-chamber.Check the sealing faces on the bottom of the pre-chamber. 

 Renew O-rings, sealing ring of nozzle and bottom sealing ring.Renew O-rings, sealing ring of nozzle and bottom sealing ring. 

 Pressure test the cylinder head water side after mounting.Pressure test the cylinder head water side after mounting.



 CleaClean and check thn and check th e pre-chamber valvee pre-chamber valve 

 Dismantle and clean the valve and check for wear.Dismantle and clean the valve and check for wear.



 CarefullCarefully y clean the valve and clean the valve and the upper body the upper body and body and and body and inspect the sealing surfaces.inspect the sealing surfaces. 

 The valve should be lapped if needed. The valve and the seat should either be machine grindedThe valve should be lapped if needed. The valve and the seat should either be machine grinded or renewed if deep pitting has occurred in the sealing surface. Renew the valve if the measure Y or renewed if deep pitting has occurred in the sealing surface. Renew the valve if the measure Y exceed

exceeds 1.5 mms 1.5 mm ,,



 Renew O-rings and renew parts if necessary.Renew O-rings and renew parts if necessary.



Maintenance

Maintenance of ignit

of ignit ion coi

ion coi ll



The spring, boot and grommet of the ignition coil should be replaced according to the

maintenance schedule.



The ignition coil should be

The igniti

on coil should be replaced by a new coil in

replaced by a new coil in the event of malfunction.

the event of malfunction.

NOTE!

Removing of the cylinder head before dismantling of t

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Connections:

A

A Air inlet

Air inlet

NOTE!

A general

condition of

engine is i

ndicated w

ith the test device,

but more i

mportant is the

operation data records.

The overhauls must be made according to

recommended overhaul intervals and not only when

The pressure test shows a

big blow-by

.



Che

Check cyl

ck cyl inder tightness (valves,

inder tightness (valves, piston

piston rings) w

rings) w ith a pneumatic test.

ith a pneumatic test.



In general, the location of leakage can be found by listening when the air

In general, the location of leakage can be found by listening when the air valve is open

valve is open



Measure the time in seconds it takes for the pressure dropping to 0.5 bar.



If the pressure from the beginning was 6 bar and

If the pressure from the beginning was 6 bar and it takes more than 10 sec.

it takes more than 10 sec. for the

for the

pressure to drop to 0.5 bar, the result is acceptable.



If the pressure drops directly to 0 bar, it

If the pressure drops directly to 0 bar, it is possible that one or

is possible that one or more valves are sticki

more valves are sticking

ng

or the valve(s) are burnt.



Carbon particl

Carbon particles trapped between the valve and the seat causing a dir

es trapped between the valve and the seat causing a dir ect pressure

ect pressure

drop.



Blow

Blow-by bet

-by between the cylinder liner and piston

ween the cylinder liner and piston could be noticed from f

could be noticed from fast fouling of

ast fouling of filters

filters

or high crankcase pressure.



Alw

Always replace the gasket

ays replace the gasket ring w

ring when spark plug removed.

hen spark plug removed. (Alternative)

(Alternative)

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

Components:

01 End flange, 05 O-ring, 06 Retaining ring, 08 Tube stack, 0

01 End flange, 05 O-ring, 06 Retaining ring, 08 Tube stack, 0 9 Cooler

9 Cooler

housing, 10 O-ring



Spare pa

Spare part

rt sets

sets



Sealing set for lube oil module



Remove lubricati

Remove lubricating

ng oil module.

oil module.



Dismantle the oil cooler.



Clea

Clean oil si

n oil si de of tu

de of tu be stack.

be stack.



Due to the design, the tube stack cannot

Due to the des

ign, the tube stack cannot be cleaned mechanically on the out

be cleaned mechanically on the outside. Sli

side. Slight

ght

fouling can be removed by blowi

fouling can be removed by blowing

ng steam through the tube stack.

steam through the tube stack.



If the amount of dirt is

If the amount of dirt is considerable, use chemical cl

considerable, use chemical cleaning solutions available on the

eaning solutions available on the

market.



Clea

Clean water side of

n water side of tube stack.

tube stack.



If the deposits are soft, tubes can be

If the deposits are soft, tubes can be cleaned mechanical

cleaned mechanically. Use special nylon brushes.

ly. Use special nylon brushes.



The cleaning should be carried out

The cleaning should be carried out wi

without ca

thout causing damage to the na

using damage to the natural protective

tural protective

layer on the tubes.



If the deposit in the tubes is hard

If the deposit in the tubes is hard, e.g. calcium carbonate, it can be removed chemically

, e.g. calcium carbonate, it can be removed chemically

by using commercial agents.



Cleaning the cooler hydraulically



Spray w

Spray water to

ater to the inner surface of the tubes until the

the inner surface of the tubes until the deposits are removed.

deposits are removed.



Spray w

Spray water to

ater to the outer surface of the tubes using a

the outer surface of the tubes using a 3 mm diameter nozzle. Apply 120

3 mm diameter nozzle. Apply 120

bar pressure at 2 m distance from the fin surface. The

bar pressure at 2 m distance from the fin surface. The water jet has to attack the sur

water jet has to attack the surface

face

of tubes in vertical direction, parallel to the fins.



Clean oil and water sides of the

Clean oil and water sides of the module.

module.



Clean and inspect thermostatic valves.



Test the cooler by hydraulic pressure.

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

Components:

03 03 Positioner;

Positioner; 031

031 Pil

Pilot valve

ot valve in

in positioner,

positioner, 032

032 Lever,

Lever, 033

033 Cam,

Cam, 034

034 Adjusting

Adjusting screw, 035

screw, 035 Adjusti

Adjusting screw

ng screw



Connections:

A

A Control air from

Control air from external sy

external system, B

stem, B Connections to

Connections to and from actuator,

and from actuator, C

C

Control air from I/P converter



Spare pa

Spare part

rt sets

sets



Pil

Pilot v

ot valve

alve



Spare part kit



Diaphragm, complete



Che

Check the functio

ck the functio n of

n of air thrott

air thrott le valve

le valve and actuator

and actuator

1.

1. Check of wear of the waste gate system.

Check of wear of the waste gate system.



Check for wear of

Check for wear of the key connection between the actu

the key connection between the actuator and the positioner.

ator and the positioner.



Check for possible w

Check for possible wear inside actuato

ear inside actuator by moving the shaft.

r by moving the shaft.

2.

2. Change of positioner pilot valve.

Change of positioner pilot valve.



Pay attention to the pilot valve stem and the lever (13

Pay attention to the pilot valve stem and the lever (13 ), remove the pilot valve

), remove the pilot valve

carefully.



Replace the positioner pilot valve.



Adjust the

Adjust the wastegate

wastegate positioner.

positioner.



Calibrate the wastegate I/P converter.



Check the function of the valve by followi

Check the function of the valve by following

ng the positioners movement w

the positioners movement when t

hen the

he

engine is re-started and runs on load.

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

 Components:Components: 01 01 Pair Pair of friction of friction rings, rings, 02 02 Clamping Clamping ring, ring, 03 03 ScrewScrew 

 Spare paSpare part rt setssets



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

 Spare paSpare part rt setssets 



 ReReplace lubricating oil place lubricating oil filtfilt er candleer candless 

 Check filter and connections for leaks.Check filter and connections for leaks. 

 Drain the filter housing.Drain the filter housing. 

 Remove entire filter element.Remove entire filter element. 

 Clean the parts and check the overflow valves. Replace worn parts if necessary.Clean the parts and check the overflow valves. Replace worn parts if necessary. 

 Clean the wire gauze.Clean the wire gauze. 

 Replace the O-rings and seals.Replace the O-rings and seals. 

 Replace the filter candles.Replace the filter candles.



 Check the ease of movement of the worm gear unit, the turbine including gear with flushing arm.Check the ease of movement of the worm gear unit, the turbine including gear with flushing arm.

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 Components:Components: 01 01 Pressure Pressure regulating regulating valvvalve, e, 02 02 DrivDriving ing spindle, spindle, 03 03 Idler Idler spindle, spindle, 04 04 Gasket, Gasket, 05 05 BallBall

bearing,

bearing, 06 06 Circlip, Circlip, 07 07 Circlip, 0Circlip, 08 8 non-retunon-return rn valve, valve, 09 09 Gasket.Gasket.



 Connections:Connections: A A Suction Suction connecconnection, B tion, B Pressure Pressure conneconnection, ction, C C Pressure Pressure from pre-lubricatfrom pre-lubricating ing oiloil

pump. pump.



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 Components:Components: 01 01 Pair Pair of friction of friction rings, rings, 02 02 Clamping Clamping ring, ring, 03 03 ScrewScrew



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 Components:Components: 01 01 DrivDriving ing gear, gear, 02 02 DrivDriven en gear, gear, 03 03 Shaft Shaft seal, 0seal, 04 4 Retaining Retaining ring, ring, 05 05 Bearing Bearing bush,bush,

6

6 Pin, Pin, 07 07 O-ring, O-ring, 08 08 Screw, Screw, 09 09 Key.Key.



 Connections:Connections: A A Pressure cPressure conneconnection, tion, B B Suction Suction connecconnection.tion.

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 Components:Components: 01 01 CartridgCartridge e group, group, 02 02 Gas Gas inlet inlet casing, casing, 03 03 Nozzle Nozzle ring, ring, 04 04 Gas Gas outlet outlet casing, casing, 0505

Turbine

Turbine diffuserdiffuser, , 06 06 Foot, Foot, 07 07 ComprCompressor essor casing, casing, external external part, part, 08 08 ComprCompressor essor casing, casing, internalinternal part,

part, 09 09 Wall Wall insert, insert, 10 10 Diffuser.Diffuser.

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

 Components:Components: 01 01 CartridgCartridge e group, group, 02 02 Gas Gas inlet inlet casing, casing, 03 03 Nozzle Nozzle ring, ring, 04 04 Gas Gas outlet outlet casing, casing, 0505

Turbine

Turbine diffuserdiffuser, , 06 06 Foot, Foot, 07 07 ComprCompressor essor casing, casing, external external part, part, 08 08 ComprCompressor essor casing, casing, internalinternal part,

part, 09 09 Wall Wall insert, insert, 10 10 Diffuser.Diffuser.

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

Inspe

Inspect

ct camshaft bearings.

camshaft bearings.



Replace bearings if necessary.

1.

1. Remove camshaft bearing journal.

Remove camshaft bearing journal.

2.

2. Measure inner diameter of bearing bush.

Measure inner diameter of bearing bush.



Measure three diamete

Measure three diameters in a position 120°

rs in a position 120° from each other. The average diamet

from each other. The average diameter to

er to

be compared wi

be compared with

th wear limit. The wear limit

wear limit. The wear limit is stated in

is stated in chapter clearance and wear

chapter clearance and wear

limits.



If the wear limit for one

If the wear limit for one camshaft bearing bush is reached, all camshaft bearing bushes

camshaft bearing bush is reached, all camshaft bearing bushes

should be replaced.

3.

3. For visual inspection of the camshaft bear

For visual inspection of the camshaft bearing bush has the camshaft piece

ing bush has the camshaft piece and bearing

and bearing

journal to

journal to be removed.

be removed.

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

 Components:Components: 01 Crankshaft gear, 02 Bigger intermediate gear, 03 Smaller intermediate gear, 0401 Crankshaft gear, 02 Bigger intermediate gear, 03 Smaller intermediate gear, 04

Camshaft gear Camshaft gear



 Inspect inInspect in termediate getermediate gearsars

An

An early deearly detection tection of anof any tooth y tooth damage damage can prevent can prevent serious serious damage. damage. Checking Checking intermediate, intermediate, camshaftcamshaft gears and other parts condition.

gears and other parts condition.

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

 ReReplace conneplace connectinctin g rod g rod screwsscrews 

 Replace connecting rod screws by new ones at every second overhaul when doing pistonReplace connecting rod screws by new ones at every second overhaul when doing piston overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer intervals than 16 000 h.

intervals than 16 000 h.



 The nuts for the connecting rod screws do not need changing, unless they appear damage.The nuts for the connecting rod screws do not need changing, unless they appear damage.

Clean and examine the nuts carefully at every overhaul Clean and examine the nuts carefully at every overhaul



 ReReplace place connecting rod connecting rod shimsshims



 Replace connecting rod shims by new ones at every second overhaul when doing pistonReplace connecting rod shims by new ones at every second overhaul when doing piston overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer intervals than 16 000 h.

intervals than 16 000 h.



 Replace Replace big end bbig end b eaearinrin gsgs 

 Replace big end bearings.Replace big end bearings. 

 Inspect mating surfaces.Inspect mating surfaces. 

 Measure the big end bore, use measurement record.Measure the big end bore, use measurement record. 

 When measurinWhen measuring, upper and lower screws must bg, upper and lower screws must be tightened to the stated pressure.e tightened to the stated pressure. 

 Inspect the small end bearingsInspect the small end bearings 

 Inspect the small end bearings clearance byInspect the small end bearings clearance by

measuring the gudgeon pin diameter and small end bearing bores separately. measuring the gudgeon pin diameter and small end bearing bores separately.



 Replace if necessary.Replace if necessary.

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

 Tools:Tools: 

 Hydraulic toolsHydraulic tools



 Turning tool of main bearingTurning tool of main bearing 

 Inspect main bearings.Inspect main bearings.

1.

1. Dismantle side screws and mDismantle side screws and m ain bearing nuts.ain bearing nuts. 2.

2. Lower the main bearing cap by hydraulic jack.Lower the main bearing cap by hydraulic jack. 3.

3. Remove the lower bearing shell.Remove the lower bearing shell. 4.

4. Insert the turning tool into the main bearing journal radial oil hole.Insert the turning tool into the main bearing journal radial oil hole. 5.

5. Turn the crankshaft carefully until the bearing shell hTurn the crankshaft carefully until the bearing shell has turned 180°as turned 180° and can be and can be removed. Removeremoved. Remove turning tool.

turning tool.



 Clean the bearing shells and check for wear, scoring and other damages.Clean the bearing shells and check for wear, scoring and other damages. 

 The main bearing journals should be inspected for surface finish. Damaged journals, i.e. roughThe main bearing journals should be inspected for surface finish. Damaged journals, i.e. rough surface, scratches, marks of shocks etc., should be polished.

surface, scratches, marks of shocks etc., should be polished.



 No scraping or other damage of bearing shells, caps and saddles is allowed. Burrs should beNo scraping or other damage of bearing shells, caps and saddles is allowed. Burrs should be

locally removed, only. locally removed, only. WARNING!

WARNING!

Never re-install a bearing with the nickel-barrier exposed in any part of the bearing shell. Never re-install a bearing with the nickel-barrier exposed in any part of the bearing shell. WARNING!

WARNING!

Mark the new bearings with the bearing numbers. Mark the new bearings with the bearing numbers.

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

 Sealing set for cylinder head replacementSealing set for cylinder head replacement



 Sealing set for cylinder head overhaulSealing set for cylinder head overhaul



 Overhaul of cylOverhaul of cyl inder headinder head 

 Pressure test cylinder head water side.Pressure test cylinder head water side.



 Dismantle and clean the underside,Dismantle and clean the underside,



 Dismantle, clean and check condition of inlet and exhaust valves and ports.Dismantle, clean and check condition of inlet and exhaust valves and ports. 

 Inspect cooling spaces and clean, if necessary.Inspect cooling spaces and clean, if necessary.



 Grind the valves and seat rings.Grind the valves and seat rings.



 Inspect the valve rotators.Inspect the valve rotators.



 Check rocker arms.Check rocker arms.



 Pressure test cylinder head water side.Pressure test cylinder head water side. 

 Replace the O-rings in the valve guides.Replace the O-rings in the valve guides. 

 Replace the O-rings at bottom of cylinder head screws at every overhaul.Replace the O-rings at bottom of cylinder head screws at every overhaul.



 Fill cylinder head screw pocket with engine oil.Fill cylinder head screw pocket with engine oil.

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

 ToolsTools 

 Honing equipmentHoning equipment



 ReReplaceplacement coment co mponmpon entsents 

 Anti-polishin Anti-polishing g ringring



 InspeInspect tct t he cylinder linhe cylinder lin ersers Always

Always hone hone the cylinthe cylinder lineder liner when r when new piston new piston rings arings are mountre mounted.ed. Normally a light honing is sufficient.

Normally a light honing is sufficient.

If the honing is done when the cylinder liner is on its place in the engine block, the crankshaft under the If the honing is done when the cylinder liner is on its place in the engine block, the crankshaft under the cylinde

cylinder liner concerned must be r liner concerned must be covered by plastic filmcovered by plastic film..

Honing rests must be prevented from falling into the oil sump of the engine. Honing rests must be prevented from falling into the oil sump of the engine.



 InspeInspect tct t he cylinder linhe cylinder lin ersers

1.

1. Measure the cylinder liner diameter using measurement record.Measure the cylinder liner diameter using measurement record. 2.

2. Replace liner if wear limits are exceeded.Replace liner if wear limits are exceeded. 3.

3. Hone the liners.Hone the liners.



 The honing is to be carried out by means of Plateau honing.The honing is to be carried out by means of Plateau honing. 

 Only ceramic hones wOnly ceramic hones with a coarseness of 80 and 400 shoulith a coarseness of 80 and 400 should be used.d be used. 

 The pitch angle of the honing lines in the cross hatch pattern should be about 30°.The pitch angle of the honing lines in the cross hatch pattern should be about 30°.



 As coo As coolant a lant a honinhoning oil is preferredg oil is preferred.. 

 When honing the liner fitted to the engine the used honing oil must be directed from the engineWhen honing the liner fitted to the engine the used honing oil must be directed from the engine

with e.g. a tarpaulin or similar. with e.g. a tarpaulin or similar.



 The honing time depends on the condition of the bore surface. Usually only a few minutes'The honing time depends on the condition of the bore surface. Usually only a few minutes' honing is required.

honing is required. 4.

4. After After honinhoning, clean g, clean bore cbore carefully.arefully. 5.

5. Check the cylinder liner diameter.Check the cylinder liner diameter. 6.

6. Clean the cylinder liner cooling bores.Clean the cylinder liner cooling bores. 7.

7. Renew the anti-polishing ring after piston mounting.Renew the anti-polishing ring after piston mounting.

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

 System System compocompo nents:nents: 01 01 Gas maniGas manifold, fold, 02 02 Bellow, Bellow, 03 03 Main Main gas agas admission dmission valve, valve, 04 04 Safety Safety filter,filter,

05 O-ring 05 O-ring



 Pipe Pipe connectionsconnections :: A A Gas sGas supply, B upply, B Charge Charge air , C air , C ExhauExhaust gas.st gas.



 Replace Replace the main gas admisthe main gas admis siosio n valvesn valves 

 Check that the gas supply valves are closed, the gas ventilation valve is in open position and gasCheck that the gas supply valves are closed, the gas ventilation valve is in open position and gas pressure is drained out from the gas lines.

pressure is drained out from the gas lines.



 Dismantle flexible pipe Dismantle flexible pipe connecconnection.tion. 

 DisconneDisconnect the cable of ct the cable of admission valve and remove the gas admission valve.admission valve and remove the gas admission valve. 

 Replace the main gas admission valve with new one.Replace the main gas admission valve with new one.



 Replace O-rings with new ones.Replace O-rings with new ones.



 CleClean the main gas admission an the main gas admission valve filter insertvalve filter insert 

 Clean the main gas admission valve filter insert.Clean the main gas admission valve filter insert.



 Replace if needed.Replace if needed. 

 Replace O-ring with new ones.Replace O-ring with new ones.

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

 System System compocompo nents:nents: 01 01 Main Main gas filter, gas filter, 02 02 Main Main gas piping, gas piping, 03 03 PCC PCC gas piping, gas piping, 04 04 Gas Gas manifold,manifold,

05

05 Main gas Main gas admission valve, admission valve, 06 06 PCC gas PCC gas channels channels in Hot-box, in Hot-box, 07 07 PCC gas PCC gas delivery piping,delivery piping, 08

08 Main gas Main gas venting valve, venting valve, 09 09 Actuator for Actuator for main gas main gas venting valve, venting valve, 10 10 PCC PCC gas venting gas venting valvvalve,e, 11

11 Non-return Non-return valve, valve, 12 12 Gas ventiGas venting png piping.iping.



 Pipe Pipe connectionsconnections :: A A 108 G108 Gas inleas inlet, B t, B 110 PCC 110 PCC gas inlet, gas inlet, C C 727 727 Gas systeGas system vent, m vent, D D PCC ventinPCC ventingg

gas, E

gas, E 311 Control 311 Control air to main gas air to main gas venting valveventing valve



 TeTestst ing the gas systing the gas syst em for leakem for leak 

 Connect compressed air/nitrogen, of 3 bar to the inlet flange of the gas system on the engine.Connect compressed air/nitrogen, of 3 bar to the inlet flange of the gas system on the engine. 

 Check all connections with soap water or leakage spray, beginning from the inlet flange andCheck all connections with soap water or leakage spray, beginning from the inlet flange and

continuing through the gas line. continuing through the gas line.



 Growing bubbles on the connection indicates leakage.Growing bubbles on the connection indicates leakage.

NOTE!

Release the air pressure in the system before disassembling.

Release the air pressure in the system before disassembling. 

 Disassemble the leaking connection, examine the O-rings and sealing faces. Replace wornDisassemble the leaking connection, examine the O-rings and sealing faces. Replace worn

parts. parts.



 Repeat the leak test for the repaired connection(s).Repeat the leak test for the repaired connection(s).

NOTE!

When the engine is running a portable gas leak detector can be used.

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Inspection of tction of t he piston crownhe piston crown



 Clean all the parts and all spaces carefully.Clean all the parts and all spaces carefully.



 Inspect combustion space for corrosion and/or bInspect combustion space for corrosion and/or b urning marks.urning marks. 

 Check a deposit layers thickness in the cooling spaces.Check a deposit layers thickness in the cooling spaces. 

 Inspect all surfaces by crack detection test.Inspect all surfaces by crack detection test.



 No cracks are allowed.No cracks are allowed. 

 Measure the distance between the inner and outer support surfaces, see measurement record.Measure the distance between the inner and outer support surfaces, see measurement record.



 Check the height of the ring grooves, use measuring record.Check the height of the ring grooves, use measuring record.



 Replace complete set of piston rings. Note the running-in programme.Replace complete set of piston rings. Note the running-in programme.



 The piston assembly must be dismantled for inspection of mating surfaces between piston skirt andThe piston assembly must be dismantled for inspection of mating surfaces between piston skirt and piston crown and for inspection and cleaning of cooling oil spaces.

piston crown and for inspection and cleaning of cooling oil spaces. Visua

Visual inspectiol inspectio nn



 The combustion space must be checked for corrosion and/or burning marks.The combustion space must be checked for corrosion and/or burning marks.

If marks deeper than 2 mm are found the piston crown should be replaced. If marks deeper than 2 mm are found the piston crown should be replaced.



 Check a deposit layers thickness in the cooling spaces.Check a deposit layers thickness in the cooling spaces.



 Deposits in the cooling oil space thicker than 0.5 mm is an indication of contaminated lubricatingDeposits in the cooling oil space thicker than 0.5 mm is an indication of contaminated lubricating

oil. Such extensive deposit layers can cause overheating of the piston crown. oil. Such extensive deposit layers can cause overheating of the piston crown. Cra

Crack dck d eteetection ction testtest



 A crack A crack detection detection test by ustest by use of liquie of liquid pend penetrant etrant or, or, preferably, preferably, magnetic magnetic particle particle detection detection methodmethod should be performed, comprising all

should be performed, comprising all surfaces.surfaces.



 No cracks are allowed.No cracks are allowed. Measurements

Measurements



 Assessment Assessment of wear of wear of the of the support support surfaces surfaces to be to be made by made by measurement measurement of the dof the distance istance between between thethe

inner and outer support surfaces, see measurement record. inner and outer support surfaces, see measurement record.



 Check the height of the ring grooves, use measuring record.Check the height of the ring grooves, use measuring record. 

 Replace complete set of piston rings. Note the running-in programme.Replace complete set of piston rings. Note the running-in programme.

NOTE!

No repair welding is allowed.

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Inspection of the piston skirt



 Clean all the parts and all spaces carefully.Clean all the parts and all spaces carefully. 

 Consequently cleaning with use of emery cloth or other abrasives is not allowed.Consequently cleaning with use of emery cloth or other abrasives is not allowed. 

 Inspect running surface for wear marks and/or scoring/seizure marks.Inspect running surface for wear marks and/or scoring/seizure marks.



 Inspect entiInspect entire piston skirt re piston skirt by crack by crack detection tesdetection test.t. 

 Indications exceeding of normal “defects” 5 mm in length should be examined more in detail.Indications exceeding of normal “defects” 5 mm in length should be examined more in detail. 

 If a crack is confirmed, the piston skirt must be replaced with a new or reconditioned one.If a crack is confirmed, the piston skirt must be replaced with a new or reconditioned one.



 Measure the distance between the inner and outer support surfaces, see measurement record.Measure the distance between the inner and outer support surfaces, see measurement record. 

 Check the retainer rings of the gudgeon pins.Check the retainer rings of the gudgeon pins. Visua

Visual inspectiol inspectio nn



 Inspect running surface for wear marks and/or scoring/seizure marks.Inspect running surface for wear marks and/or scoring/seizure marks.

The running surface of the skirt is coated with a graphite-phosphate The running surface of the skirt is coated with a graphite-phosphate layer. Consequently cleaning with use of emery cloth or other abrasives layer. Consequently cleaning with use of emery cloth or other abrasives is not allowed.

is not allowed.



 Excessive wear marks and/or scoring/seizure marks on the Excessive wear marks and/or scoring/seizure marks on the running surface may require replacementrunning surface may require replacement of the skirt.

of the skirt. Cra

Crack dck d eteetection ction testtest



 Crack detection test of the entire piston skirt with use of liquid penetrant must be made. SpecialCrack detection test of the entire piston skirt with use of liquid penetrant must be made. Special

attention must in this regard be given to the upper part of the piston skirt and to the gudgeon pin bore attention must in this regard be given to the upper part of the piston skirt and to the gudgeon pin bore with its supports to the upper part and to

with its supports to the upper part and to the circumferential pathe circumferential part of the rt of the skirt,skirt,



 As pisto As piston skirts n skirts are cast are cast pieces a pieces a crack decrack detection tection test may atest may also give lso give indicationindications for s for surface "surface "defects"defects" which are normal in castings. Indications exceeding 5 mm in length should be examined more in detail. which are normal in castings. Indications exceeding 5 mm in length should be examined more in detail.



 If a crack is confirmed, the piston skirt must be replaced with a new or reconditioned one.If a crack is confirmed, the piston skirt must be replaced with a new or reconditioned one.

Measurement Measurement



 Assessment Assessment of wear of wear of the of the support support surfaces surfaces to be to be made by made by measurement measurement of the dof the distance istance between between thethe

inner and outer support surfaces, see measurement record. inner and outer support surfaces, see measurement record.



 Check the retainer rings of the gudgeon pins.Check the retainer rings of the gudgeon pins. 



As

Ass

semb

emb liling

ng of

of p

pis

is to

to ns

ns



 If the inspections are resulting in a conclusion that a piston can be reused the same pair of crown andIf the inspections are resulting in a conclusion that a piston can be reused the same pair of crown and skirt must

skirt must be assembled together again .be assembled together again .

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

 Components:Components: 01 01 Rocker Rocker arm arm shaft, shaft, 02 02 Tappet, Tappet, 03 03 Tappet Tappet roller, roller, 04 04 O-Ring, O-Ring, 05 05 Protecting Protecting pipe.pipe. 

 Spare Spare part kpart k itit



 Spare part kit for valve tappetSpare part kit for valve tappet



 CheCheck ck valve mechavalve mechanism nism parts.parts.

1.

1. Dismantle and inspect valve Dismantle and inspect valve mechanism partsmechanism parts



 Clean the rocker arm bore and the shaft (01) and measure for wear. When cleaning, pay specialClean the rocker arm bore and the shaft (01) and measure for wear. When cleaning, pay special attention to the oil holes.

attention to the oil holes.



 Clean and inspect all parts of the valve tappets. When cleaning, pay special attention to the oilClean and inspect all parts of the valve tappets. When cleaning, pay special attention to the oil

holes. holes.



 Measure the valve tappet boring and the tappet (02) as well as the tappet roller (03) for wear.Measure the valve tappet boring and the tappet (02) as well as the tappet roller (03) for wear.



 Clean the pre-chamber valve tappet and inspect for wear.Clean the pre-chamber valve tappet and inspect for wear. 

 Change the O-rings (04) and (06) if they are damaged or hard.Change the O-rings (04) and (06) if they are damaged or hard. 2.

2. Assembling Assembling of valve of valve mechanismmechanism 3.

3. Check the valve clearancesCheck the valve clearances

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

 Replace Replace intint ermediate geermediate gear bearingsar bearings 

 Measure tooth backlash and bearing clearances.Measure tooth backlash and bearing clearances.



 Check gears for damages.Check gears for damages.



 Remove camshaft gear wRemove camshaft gear w heels.heels. 

 Remove intermediate gear wheels.Remove intermediate gear wheels. 

 Check and clean trust bearing and parts.Check and clean trust bearing and parts. 

 Change bearings if necessary.Change bearings if necessary.

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