Beruflich Dokumente
Kultur Dokumente
DISASSEMBLY
1.1
2.1 PISTONS
2.1.1 Put the pistons in cleaning solution of washing
2.1.2
2.1.3
2.1.4
1.
PISTON
Record the type of piston, piston No, manufacturing date and
name of the manufacturer.
Check visually for any damage, pit marks, scratch mark or
cracks on it. If found condemn it.
Check the ring groove width of piston ring in the following
manner
Insert the outside edge of compression ring in groove in four
different position and measure side clearance with a feeler gauge
Maintain the following clearance for each groove
Limit
Ring clearance in compression groove 0.008 to 0.012
Ring clearance in 1st groove
0.006- 0.016
Ring clearance in 2nd groove
0.006- 0.012
Ring clearance in oil scrapper groove 0.001- 0.0045
Limit
0.006
Check the lifting hole threads and tap the threads.
3.2
3.3
3.4
3.5
3.6
3.7
Match the cap srl Nos. with connecting rod srl nos.
1.2
Put the con. Rod with shell bearing on crankshaft crank pin
fixture and assemble the cap with bearing, apply bolts and
nuts tighten it evenly in cross wise manner for proper
elongation.
1.3 Check the bolt elongation with elongation gauge it should be
with in 0.015 to 0.018.
1.4 Check the running clearance between crank pin big end bore.
It should be 0.004 to 0.008
1.5Loosen the nuts, remove the bearing cap and shell bearing.
Remove con rod.
1.6 Check visually for any wear and tear of little end bush of
con. rod. If there is any wear and tear, replace it with new
one.
1.7 Check the parallelism between piston pin bore and crank pin
bore on parallelism fixture assembled with Cap , in case of
any doubt or abnormality observed in 1.2 to 1.4 .
1.8 Do D.P. test for any surface cracks.
1.9 If found OK in DP test, place the connecting rod and cap in
a tray and do final cleaning with fresh diesel oil.
2.0 Blow air through that drilled lub oil passage to ensure that it
is fully clean, and the Con Rod is free from any dirt etc.
1.1
Permissible Range
1. Compression
2. Oil Scrapper Ring
0.050 0.085
0.020 0.045
1. Check clearance between piston pin and con rod little end bush
before assembly. It should be 0.003 to 0.005 and keep it as
matching pair.
1.1 Place piston on the assembly fixture.
1.2 Align rod bore with piston pinhole. Apply lube oil coat to all
mating surfaces.
1.3 Apply piston pin to piston through Con. Rod little end bush.
1.4 Check clearance between the piston pin to bore. Inserts the
piston pin into the piston bore. Check the clearance with feeler
gauge.
The clearance should be within 0.0005-0.0025. Limit 0.0035
1.5 Using special nose pliers, press snap ring on both sides of
Piston pin.
1.6 Use new piston rings from bottom groove to Top groove by
using ring expander.
1.7 Check the clearance between groove and ring by inserting ring
out side edge in piston groove at three or four point and
measure the clearance with filler gauge between rings & groove
on piston.
a) Compression ring, Side gap: 0.006-0.012. Limit: 0.016
b)Oil scrapper ring, Side gap 0.001-0.0045. Limit : 0.006
PISTON
3.
1R-TDC CHECKING
a) Mount the magnetic base dial indicator on the bloc nearer to 1Rcylinder liner on which piston fitting and big end elongation is
completed.
b) Mark a Dot Punch on the dowel of crank shaft at generator end
flange.
c) Bar the crank shaft over until the needle of the dial indicator
moves, when 1R piston reaches TDC needle of the indicator will
stop & it will move in opposite direction. Stop the barring and set
the dial indicator to Zero-reading.
d) Bar the crankshaft in any direction until the dial indicator needle
reaches to 0.050 and stop the barring.
e) Put one pointer of special trammel on Dot Punch on the crankshaft
dowel and make an arc with other end of trammel pointer on the
face of the block at generator end.
f) Bar the crankshaft in opposite direction until the needle of the dial
indicator reaches to zero and comes back to 0.050 again.
g) Make another arc with trammel pointer on the face of the block.
h) Draw a straight horizontal line and join both the arcs, this line will
intersect the arcs.
i) Bisect the straight line, putting divider on inter section points of arc
& straight line.
j) Mark with dot punch at bisecting point.
k) Put the trammel on crankshaft dowel and bar the crankshaft in
opposite direction till the trammel pointer coincides with the center
point on horizontal line.
l) The dial indicator needle must show Zero-reading. This is correct
IR- TDC.
m)Set the TDC trammel on the punch mark on crankshaft web and
other pointer on the base door of the crank case. If it coincides with
previous punch mark on 8L base door then it is OK. If it is not
coinciding then punch mark a new one on 8L base door and
eliminate the old punch mark on 8L base door.
4. CYLINDER HEAD
a)Check the straightness of cylinder head studs with a
template from the tools locker.
b)Fit the inlet and exhaust push rod grommets. Apply
holdtite between engine bock and grommet and on the
upper surface of the grommet.
c)Clean the face of head and liners and piston crowns
before loading the cylinder heads.
d)Apply graphite powder on the cylinder heads stud
before fitment of nuts on studs.
e)Mount all the cylinder heads with the help of EOT
crane and align with a straight edge.
Tight the nuts with torque wrench at 550 ft-Ib as per
tightening sequence
Responsibility: Concerned Staff & JE.
5.
6.
9. TSC SUPPORT
a)Clean the TSC support with HSD oil and water jet.
b)Check the threaded holes provided for mounting of after
cooler on it.
c)Clean the Engine Block mounting surface of TSC support.
d)Check the threaded holes on the TSC support-mounting
surface on the engine block free end as well as on sump.
e)Apply gasket of size 1/16 of thickness on the Engine
sump and Block.
10. AFTER COOLER AND TSC
a)Clean the inside of after cooler housing with dry clean
cloth.
b)Apply suitable gasket on the after cooler mounting face.
c)Mount the after cooler with the help of EOT crane.
d)Fasten the mounting bolts and tight it properly.
e)Place gasket of size 1/8 thickness on either side of the
support and mount the TSC on it with the help of EOT
crane.
f) Fasten the TSC mounting bolts and tight properly.
11. LUBE OIL SECONDARY HEADER
a)Clean lube oil secondary header with HSD oil and water.
b)Blow out with dry compressed air.
c)Fit the headers on the block on both sides using clamps
and tight properly.
Apply screw to jacking hole of key and tighten the screw. The key will
come out from keyway of crankshaft.
2.9
4.2
4.3
Conduct DP test for split gear, socket head bolts & key.
5.0 CLEANING
5.1
Clean the entire crankshaft with Diesel oil. (Including oil holes)
5.2
Polish the crank journal and main journal after applying diesel with the help of
400/320 silicon papers.
5.3
Place the crank pin no:2 & 7 on top position. Place the crankshaft on surface table.
Do not turn the crankshaft.
6.2
Measure the vertical and horizontal Dia of crank pins with outside micrometer (the
measurement should not be less than 5.996)
6.3
The difference of dia. between vertical and horizontal dia should not exceed 0.002.
If it exceeds, it is out of round then matching to be done by polishing with 400/320silicon paper.
6.4
6.5
Take the measurement keeping crank pin in same position as mentioned above.
Record the above measurement in the Register below.
Measure vertical and horizontal dia on either side of oil hole &1 away.
7.2
The minimum dia should not be less than 8.496, new dia 8.500
7.3
7.4
Conduct DP Test on all the crank pin & main journal of the crankshaft to detect any
surface crack.
Conduct magna-flux test on all crank pin & journal for any sub surface crack.
If any crack is detected, either surface or sub surface, withdrawal the crankshaft from
service.
10.0FITMENT OF KEY
Check the split gear keyway on the crankshaft. Key should have interference fit of
0.000-0.005 both in shaft & split gear.
11.2 Check the side clearance on the both sides of the split gear, the clearance
should be between 0.007 to 0.023.
11.3 Check the total split gear split line clearance, it should be 0.0015
11.4 Record the measured clearances in the Format No. DS/PP/0108
11.5 Seal wire the pairs of bolts.
Record Format No : DS/PP-0104