Beruflich Dokumente
Kultur Dokumente
Introduction
Intended f ~ ...r
Table of contents
Intended for
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Numbering
The ordinal number of the work cards - on top at the right - is composed of
the three-digit subassembly group number (or of a neutral numerical
combination) and a counting number, for example:
I
How to find the work cards
required
The work cards are contained in the lists of Section 2 and 3. The list, Part
1 is a summary of work cards by subjectslkey words, the list, Part 2
contains working instructions arranged in an order following the
subassembly group system of the engine.
Access to the ordinal system of the list, Part 3 is ensured by the
subassembly group list. Illustrated by a cross section and a longitudinal
section of the engine, it lists the subassembly group numbers in tabulated
form, respresenting the order in which the work cards of this section have
been arranged.
Safety notes
AA
General
Table of contents
001
000.16
Replacement
Pipes
Cleaning, Acid Bath Treatment and Preservation
000.18
002
000.04
Lubricating oil
Assessing and Treating
Lube oillfuel
Cany out drop test
Cooling water
000.05
000.07
000.14
Engine or components
Preservation treatment
003
Machine elements
000.11
Galvanized bearings
Assessing
Bimetal bearings (without a third layer)
000.11
000.25
000.40
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Categories of information
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Cleanins
The cooling water system has to be checked for contamination at the
specified intervals. If heavily fouled, immediate cleaning is necessary. This
work should preferably be done by a specialist firm which will provide the
cleansers suitable for the particular type of deposits and materials used in
the cooiing system. Only in the event that procurement d the services of a
specialist firm is not possible, the cleaning should be performed by the
engine operator.
Oil sludge produced by lube oil entering the cooling system or by an
excessive concentration of anti-corrosion agents can be removed by
flushing with frssh water, with some cleaning agent being added. Table 1
lists appropriate agents in alphabetical order. Products of other
manufacturers may be used provided their properties are comparable. The
manufacturer's instructionsfor use are to be strictly observed.
Oil sludge
Manufacturer
Drew
Nalfleet
Uilitor
Vecom
Product
Concentration
HDE - 777
Nalfleet 9 - 010
Aquabreak
Ultrasonic
Muiti Cleaner
4 - 5%
2-5%
0.05 - 0.5%
4%
Calcareous and rust deposits may form if excessively hard water or too
low a concentration of anti-corrosion agent has been used in operation. A
thin layer of scale need not be removed as, according to experience, this
provides protection against corrosion. Calcareous layers of > 0.5 mm in
i
.
L
Pipes
Cleaning, Acid Bath Treatment and
Preservation
Pumose of iobs to be done
Keeping operating systems free from contamination and residues,
ensuring/restoring of operational reliability.
Preliminary remarks
All pipes to be mounted on the engine as replacements require mechanical
or chemical cleaning on completion of manufacture. If there is a longer
period between cleaning and mounting (replacement pipes), the pipes
must be preserved and their ends must be closed. Plastic plugs or caps in
vivid colours are most suitable for this purpose because they will not be
overlooked.
Pipes for cooling water, heating, exhaust gas and combustion air systems
are normally cleaned mechanically. Pipes for lube oil, fuel oil, compressed
air, gas, steam and condensation systems must be cleaned mechanically
and chemically. Shut-off and regulating elements as well as other units are
not to be fitted to the individual systems before the latter have been
cleaned.
Pipes to be bent in the hot state must be filled with fine-grained sand
exclusively, which must be completely dry. If the sand used is damp,
steam can develop involving accident hazards. Either the entire pipe
systems or parts of them are to be subjected to a pressure test. The entire
lube oil, fuel oil and compressed air systems must be thoroughly flushed
before the engine is put into operation.
Mechanical cleanina
Scale and welding pearls rr~ustbe carefully removed from the welds with
the aid of a chisel, file or grinding wheel. The entire pipe section is to be
tapped with a hammer and, if possible, compressed air is to be passed
through simultaneously so that even minor particles (sand filled in for hot
bending) are removed.
All pipe conncetions must be closed and must stay closed until they are
installed.
General
Solderless screwed pipe unions are preferably used where pipes of minor
diameters can be bent in cold state. In this case, the pickling and
neutralising process can be dispensed with.
The worWsteps include:
proper processing and
proper installation.
No.
Quant Denomination
Availability
000.002
1 Pipe cutter
lnventory
1 Spot facer
lnventory
1 Machinery oil
Inventory
e
Advantaaes of solderless screwed ~ i o unions
Solderless screwed pipe unions are preferably used where pipes of minor
diameters can be bent in cold state, i.e. which have not to be submitted to
heat treatment for this purpose. In this case, the pickling and neutralizing
process which otherwise is usually necessary can be dispensed with.
Copper pipes have to be provided with reinforcing sleeves on the inside.
Please refer to work card 000.18.
Seauence of o~erations
Loctite Products
Use
Pumose of iobs to be done
Preliminary remarks
Operating Sequence 1
Steps
- Assembly
1. Carefully clean ,thejointing surfaces using LOCTITE 706 quick
cleaner (evaporation time approximately 3 minutes) or any other
appropriate cleaning agent to remove dirt and grease.
2. If necessary, apply accelator T by means of a spray bottle and allow
it to dry for about 3 minutes. The filling compound will cure more
quickly if the accelerator is used (see the Table).
Table of contents
List of Assemblies
Work cards, arranged by s~~bassembly
groups
3.2
...
009
000.09
012.01
012
012.02
012.03
020
Crankshaft/Coupling bolts
000.10
020.01
Crankshaft
Measure the crank web deflection
Balance weight bolts
020.02
020.03
020.04
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021
027
030
Cor~nectingrod/Big-end bearing
034
Piston/piston rings
034.01 Piston
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Prelubricating pump
Lubricating oil, therrr~ostaticvalve
Lubricating oil cooler
Centrifugal bypass filter
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Foundationhesilient mounting1
alignment of the engine
CrankcaseKie rod/solts
CrankshaftlCoupling bolts
Main bearinchrust bearinplange bearing
Torsional vibration damper
Connecting rodlsig end bearing
PistonlPiston rings
Cylinder linermop land ring
Cylinder headlsafety valve
Dead centre indicatorlSpeed pick-up
Crankcase coverlCovering
Camshaft drive
Camshaftrrhrust bearing
Torsional vibration damper
Rocker armmocker arm casing
Cam follower/Push-rod
Inlet and exhaust valve
Camshaft adjusting device
Operating device
Speed control
Starting air pilot valvelStarting valve1
Main starting valve
Fuel injection pumplControl linkage
Fuel injection valve
Charge air and exhaust pipe
Lube oil and cooling water pipe
Charge air cooler
Fuel injection pipe