THE PROCEDURE FOR DISMANTLING OF CYLINDER UNIT FROM THE ENGINE ARE AS FOLLOWS:
1.Safety precautions
-Stopped engine
-Shut-off starting air
-Shut-off cooling water
-Shut-off fuel oil
-Stopped lub. oil circul.
-Press Blocking - Reset
-Engine stopped and cooled down.
2.Disassembly of cyl.head - water jacket, cyl. liner and piston Fuel injection valve
-Preparation before Dismantling
1) Drain off the water from the engine.
2) Remove the top cover.
3) Remove the side covers on both sides of the engine.
4) Remove the exhaust gas cover.
-Disassembly of Connections
5) Remove the clamp for connecting cylinder head and exhaust gas receiver.
6) Remove the fuel oil high pressure pipe.
7) Remove the 4 clamps securing the fresh water(FW) connection between the cylinder heads by unscrewing the locking bolts for the clamps.
8) Push the FW connections inside the cylinder heads, which are to be removed.
9) Remove the 2 clamps securing the charge air connections by unscrewing the locking bolts for the clamps.
10) Push the charge air connections, inside the cylinder head which are to be removed.
11) Turn the piston to top position.
-Removal of Bearing Cap
12) Loosen the connecting rod nuts by means of thehydraulic jacks.
13) Remove the connecting rod nuts and bearing cap by hand.
-Mounting of Support Tools
14) Mount the fixing part for locking the connecting rod to the cylinder liner.
15) Remove the cylinder head nuts by means of the hydraulic jacks,
16) Mount the lifting tool on the cylinder head
-Removal of Cylinder Unit from Engine
17) Lift the cylinder unit just enough for removing the upper connecting rod bearing shell by hand
18) Lift carefully the cylinder unit out of the engine after the upper connecting rod bearing shell is
removed.
19) Land and fasten the cylinder unit upon thespecial work table, or on the floor upon wooden supports and remove the lifting tool.
-Removal of Piston and Connecting Rod
1) Remove the fixing part from the cylinder liner and connecting rod.
2) Turn the unit 180° in the table.
3) Pull out the piston and connecting rod with theaid of the tool.
Removal of Cylinder Head
4) Remove the five allen screws in the cylinder head.
5) Remove the cylinder head by means of the lifting tool.
-Removal of Water Jacket and Cylinder Liner
6) Loosen two positioning pins in the water jacket and remove the two roller guides.
7) Lift the cylinder liner out of the water jacket by means of the lifting tool.
8) Remove the flame ring from the cylinder liner by means of the tool.
-Separation/Assembly of Piston and Connecting Rod
and fitting of Piston Rings
1) Take out the securing ring (seeger circlips) with the plier . Push out the piston pin and lift the connecting rod away.
-Assembly of Piston and Connecting Rod
2) Lubricate the piston pin before assembling.
3) For assembly of piston and connecting rod,see point 1, but in the opposite direction.
-Fittings of Piston Rings
The piston rings should only be fitted to the piston by the use of a special tool; the so called piston ring opener. If the rings are opened further than necessary there is a risk of over stressing, which means that rings will become permanently distorted and will not confirm
to the cylinder inner running surface. The piston rings should be installed with the identification mark, which is stamped into the ring close to the ring joints, facing up words, .Before fitting the coil spring loaded scraper ring, the coil spring is dismantled from the ring by removal of the joint pin. The coil spring is placed and assembled in the ring groove then the scraper ring is fitted in the groove in such a way that the ring joint is approximately 180° offset to the spring joint.Ascertain correct assembling by checking the back clearance.The back clearance is sufficient when the face of the ring is below the groove edge when the ring is pressed against the bottom of the groove.When installed on the piston the rings should be pushed back and forth in the grooves to make sure
that they can move freely. It is also advisable to insert
a feeler gauge of adequate thickness between ring and groove. Adequate clearance is present so the feeler gauge can be moved all the way round. To prevent gas leakage through coinciding ring joints the piston rings should be turned into positions offsetting the ring joint 180° to each other.
-Dismantling of Inlet and Exhaust Valve Spindles
1) Land and fasten the cylinder head upon a special work table and remove the lifting tool.
Or as an Alternative:
Land the cylinder head on the floor upon wooden supports and remove the lifting tool.
2) Turn back the rocker arm and remove the valve bridge over the valve spindles.
3) Install the tool for mounting of valves (B), see fig 1.
4) Compress valve springs by tightening nut A, see fig 2.
5) Press valve up to access cone ring, see fig 3
6) Remove cone rings, see fi g 3.
7) Release springs again.
8) Loosen nut A and extractor plate B, see fig1.
9) Remove a valve rotator and springs
10) Repeat point 4 - 9 to remove other valve spindles
1.Safety precautions
-Stopped engine
-Shut-off starting air
-Shut-off cooling water
-Shut-off fuel oil
-Stopped lub. oil circul.
-Press Blocking - Reset
-Engine stopped and cooled down.
2.Disassembly of cyl.head - water jacket, cyl. liner and piston Fuel injection valve
-Preparation before Dismantling
1) Drain off the water from the engine.
2) Remove the top cover.
3) Remove the side covers on both sides of the engine.
4) Remove the exhaust gas cover.
-Disassembly of Connections
5) Remove the clamp for connecting cylinder head and exhaust gas receiver.
6) Remove the fuel oil high pressure pipe.
7) Remove the 4 clamps securing the fresh water(FW) connection between the cylinder heads by unscrewing the locking bolts for the clamps.
8) Push the FW connections inside the cylinder heads, which are to be removed.
9) Remove the 2 clamps securing the charge air connections by unscrewing the locking bolts for the clamps.
10) Push the charge air connections, inside the cylinder head which are to be removed.
11) Turn the piston to top position.
-Removal of Bearing Cap
12) Loosen the connecting rod nuts by means of thehydraulic jacks.
13) Remove the connecting rod nuts and bearing cap by hand.
-Mounting of Support Tools
14) Mount the fixing part for locking the connecting rod to the cylinder liner.
15) Remove the cylinder head nuts by means of the hydraulic jacks,
16) Mount the lifting tool on the cylinder head
-Removal of Cylinder Unit from Engine
17) Lift the cylinder unit just enough for removing the upper connecting rod bearing shell by hand
18) Lift carefully the cylinder unit out of the engine after the upper connecting rod bearing shell is
removed.
19) Land and fasten the cylinder unit upon thespecial work table, or on the floor upon wooden supports and remove the lifting tool.
-Removal of Piston and Connecting Rod
1) Remove the fixing part from the cylinder liner and connecting rod.
2) Turn the unit 180° in the table.
3) Pull out the piston and connecting rod with theaid of the tool.
Removal of Cylinder Head
4) Remove the five allen screws in the cylinder head.
5) Remove the cylinder head by means of the lifting tool.
-Removal of Water Jacket and Cylinder Liner
6) Loosen two positioning pins in the water jacket and remove the two roller guides.
7) Lift the cylinder liner out of the water jacket by means of the lifting tool.
8) Remove the flame ring from the cylinder liner by means of the tool.
-Separation/Assembly of Piston and Connecting Rod
and fitting of Piston Rings
1) Take out the securing ring (seeger circlips) with the plier . Push out the piston pin and lift the connecting rod away.
-Assembly of Piston and Connecting Rod
2) Lubricate the piston pin before assembling.
3) For assembly of piston and connecting rod,see point 1, but in the opposite direction.
-Fittings of Piston Rings
The piston rings should only be fitted to the piston by the use of a special tool; the so called piston ring opener. If the rings are opened further than necessary there is a risk of over stressing, which means that rings will become permanently distorted and will not confirm
to the cylinder inner running surface. The piston rings should be installed with the identification mark, which is stamped into the ring close to the ring joints, facing up words, .Before fitting the coil spring loaded scraper ring, the coil spring is dismantled from the ring by removal of the joint pin. The coil spring is placed and assembled in the ring groove then the scraper ring is fitted in the groove in such a way that the ring joint is approximately 180° offset to the spring joint.Ascertain correct assembling by checking the back clearance.The back clearance is sufficient when the face of the ring is below the groove edge when the ring is pressed against the bottom of the groove.When installed on the piston the rings should be pushed back and forth in the grooves to make sure
that they can move freely. It is also advisable to insert
a feeler gauge of adequate thickness between ring and groove. Adequate clearance is present so the feeler gauge can be moved all the way round. To prevent gas leakage through coinciding ring joints the piston rings should be turned into positions offsetting the ring joint 180° to each other.
-Dismantling of Inlet and Exhaust Valve Spindles
1) Land and fasten the cylinder head upon a special work table and remove the lifting tool.
Or as an Alternative:
Land the cylinder head on the floor upon wooden supports and remove the lifting tool.
2) Turn back the rocker arm and remove the valve bridge over the valve spindles.
3) Install the tool for mounting of valves (B), see fig 1.
4) Compress valve springs by tightening nut A, see fig 2.
5) Press valve up to access cone ring, see fig 3
6) Remove cone rings, see fi g 3.
7) Release springs again.
8) Loosen nut A and extractor plate B, see fig1.
9) Remove a valve rotator and springs
10) Repeat point 4 - 9 to remove other valve spindles
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