gek_114406d
Short Description
GE L250...
Description
GE Transportation
L250 Diesel Engine Maintenance Document No. GEK-114406, Rev. D
GEK-114406D L250 Diesel Engine Maintenance © 2012 General Electric Company. All rights reserved. The information contained in this publication is the property of General Electric Company and is disclosed in confidence. This publication is intended for use by GE customers solely for purposes of operating and performing routine maintenance of purchased or licensed GE products, and it shall not be reproduced, redistributed, retransmitted, translated, abridged, adapted, condensed, revised or otherwise modified, in any form, in whole or in part, or used for any other purpose, or disclosed to third parties, without the express written consent of GE. GE and Customer agree that the information contained herein does not purport to cover all details or variations in GE products or to provide for every possible contingency with installation, operation or maintenance. Should further information be desired or should particular problems arise that are not covered sufficiently for the user’s purposes, the matter should be referred to General Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any information or instructions given in the Technical Documentation. GE has no obligation to keep the material up to date after the original publication. GENERAL ELECTRIC COMPANY EXPLICITLY DISCLAIMS ALL WARRANTIES OF ACCURACY, MERCHANTABILITY OR FITNESS FOR ANY PURPOSE IN CONNECTION WITH THIS PUBLICATION AND USE THEREOF. If you are not an authorized recipient of this publication, you are hereby notified that any perusal, use, distribution, copying or disclosure is strictly prohibited. If you have received this publication in error, please immediately return to GE at the following address: GE Transportation, Technical Publications Department, Building 14, 2901 East Lake Rd., Erie, PA 16531.
ii
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance Revision History Rev
Date
By
Description
NEW
DEC-2008
REB
A
DEC-2009
ACM
B
JUN-2011
MRT
Added lube oil suction strainer service requirement to lube oil pump maintenance instructions, per M. Mendoza.
C
SEP-2011
KMS
Revised to remove mention of checking/setting the fuel pump timing. Added power assembly weight information and caution.
D
APR-2012
KMS
Edited text in Figure 21
Initial release.
GE Proprietary and Confidential Information
iii
GEK-114406D L250 Diesel Engine Maintenance This page intentionally left blank.
iv
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
TABLE OF CONTENTS Section
Page
1. 1.1.
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1
2.
ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3. 3.1. 3.2. 3.3. 3.4. 3.5. 3.6.
POWER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARE TO REMOVE POWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE SHORT POWER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL SHORT POWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOUNT/ADJUST POWER ASSEMBLY AFTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . BREAK-IN PROCEDURE FOR NEW POWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESETTING THE ADAPTIVE FUEL LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 4 7 9 10 12 13
4. 4.1. 4.2.
EXHAUST MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE EXHAUST MANIFOLD SECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL EXHAUST MANIFOLD SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 13 14
5. 5.1. 5.2. 5.3. 5.4.
FUEL INJECTION PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORM POP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE FUEL INJECTION PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESETTING THE ADAPTIVE FUEL LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 17 17 19 22
6. 6.1. 6.2. 6.3. 6.4.
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARE TO INSTALL FUEL INJECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESETTING THE ADAPTIVE FUEL LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 23 25 25 26
7. 7.1. 7.2.
FLYWHEEL INSTALLATION AND REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLYWHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 26 27
8.
CHECK/ADJUST CRANKSHAFT WEB DEFLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
9. 9.1. 9.2.
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 32 33
10. 10.1. 10.2. 10.3. 10.4.
LUBRICATING-OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE LUBRICATING-OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE OIL PUMP GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL OIL PUMP GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL LUBRICATING-OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 35 36 36 36
11. 11.1.
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURBOCHARGER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 39
GE Proprietary and Confidential Information
v
GEK-114406D L250 Diesel Engine Maintenance
11.2. 11.3.
TURBOCHARGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 43
12. 12.1. 12.2. 12.3. 12.4. 12.5.
COALESCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE COALESCER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL COALESCER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVE COALESCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALL COALESCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COALESCER MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43 43 44 44 44 45
13. 13.1.
DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 46
vi
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
1. INTRODUCTION This publication covers component replacement procedures that may be required to service the General Electric (GE) L250 diesel engines.
1.1.
SAFETY PRECAUTION
Safety precautions which must be observed when working on the L250 diesel engine appear throughout this publication.
WARNING
Indicates the potential for personal injury.
CAUTION
Indicates the potential for equipment damage.
All local safety requirements should be reviewed before beginning maintenance work, and followed. GE recommends that the engine cranking system be de-energized for any major maintenance task.
1.1.1. Personal Protective Equipment (PPE) The following precautions must be taken to ensure the safety of all persons: • • • • •
Safety glasses must be worn at all times. Appropriate PPE must be worn when working on the diesel engine. Latex gloves must be worn to protect the hands when working with fuel, oil, and other lubricants or fluids. Suitable ear plugs must be worn to prevent hearing damage when using air-operated tools. Knee pads should be worn when kneeling for extended periods of time.
1.1.2. Engine Barring-over Safety When using an engine barring-over device, the following precautions must be taken to ensure the safety of all persons: • • • • •
Do not reach into or bend into the engine crankcase while barring-over the engine. Keep hands away from pinch points. Keep loose clothing away from moving parts. Ensure barring-over device/motor is properly secured. Warn fellow workers of engine movements.
WARNING
Prior to starting ensure that the barring-over device is not attached to the engine. Starting the engine without removing the barring-over device could result in serious personal injury and/or damage to the engine.
Revisions are indicated by margin bars. GE Proprietary and Confidential Information
1
GEK-114406D L250 Diesel Engine Maintenance
1.1.3. Tool Safety And Use To ensure the safety of all workers, the following care must be taken when using all hand tools: • • • •
Watch finger clearance when using hand tools. Pull hand tools (ratchets, wrenches, etc.) towards yourself for better control. If unable to pull hand tools, push with an open palm. Do not use torque wrenches to break bolts loose.
1.1.4. Hydraulic Tool Safety Hydraulic tools often times use very high pressure. The following precautions must be taken when using hydraulic tools: • • • • •
Do not stand directly in front of hydraulic lines. Do not check for possible leaks with hands. Watch placement of hands and avoid pinch points. Be careful when walking near hydraulic tools as hydraulic supply lines could pose possible tripping hazards. Ensure hydraulic supply lines are securely attached.
2. ENGINE DATA Table 1. L250 DIESEL ENGINE DATA. Item Cylinders
6L250
8L250
6
8
Rated BMEP, Bar (PSI)
21.2 (308)
Max BMEP, Bar (PSI)
23.5 (341)
Peak Firing Pressure (bar)
220
Stroke Cycle
4
Cylinder Arrangement
In-Line
Bore, mm (in.)
250 (9.8)
Stroke, mm (in.)
320 (12.6)
Compression Ratio
16.8:1
Displacement/Cylinder, Liters (in3)
15.7 (958)
Idle Speed (RPM)
330
Rated Speed (RPM)
1050
1000
900
1050
1000
900
Rated Power (MCR) BHP (kW)
2344 (1748)
2232 (1665)
2009 (1498)
3125 (2330)
2976 (2219)
2679 (1997)
Maximum Power BHP (kW)
2604 (1942)
2480 (1850)
2232 (1665)
3472 (2589)
3307 (2466)
2976 (2219)
Firing Order (CCW, std)
6-2-4-1-5-3
8-6-2-4-1-3-7-5
Firing Order (CW, rev)
6-3-5-1-4-2
8-5-7-3-1-4-2-6
0-120-240-360-480-600-(720=0)
0-90-180-270-360-450-540630(720=0)
Firing Angle (°CA)
2
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
3. POWER ASSEMBLY Table 2. POWER ASSEMBLY TOOLS. 12-point Box Wrench: 10 mm, 12 mm
—
Allen Key Set: 8 mm and 10 mm
TESCO T219957P13
Basic Standard Tool Kit
—
Box End Adapter: 24 mm, 30 mm
Included in TESCO T17801
Cylinder Head Lifting Device
TESCO T85320
Feeler Gages: 0.45 mm tip and 0.95 mm tip
TESCO T85220
Hex Socket: 15 mm, 16 mm, 18 mm, 9/16 in.
TESCO T219957P4
Fuel Pump Horseshoe Retainer
TESCO T85630
Hydraulic Tensioning Kit
TESCO T81731M
Open Flat Wrench: 9/16 in, 1-1/2 in.
—
Piston Centering Saddles
TESCO T81130
Piston Holding Tool
TESCO T85080
Power Assembly Lifting Device (head, strongback, liner, with or w/o piston/rod)
TESCO T85330
Strongback, Cylinder Liner, and Piston and Rod Lifter
TESCO T85310
Piston Ring Compressor
TESCO T80101
Power Assembly Bench
PSB 222254
Rocker Arm Torque Kit (used with 25:1 verifier from T85711)
T86430LV
Roller Retainer
TESCO T81201
Roll Pins and O-rings required for Reaction Tool
—
Socket and Ratchet Wrench: M24
TESCO T219957P41
Socket Head Bolts (4): M10 x 35 mm
—
Stud Driver: 36 x 2 mm
TESCO T80160
Stud Remover: 36 x 2 mm
TESCO T80160R
Torque Wrench: 100 Nm (74 lb.-ft.)
TESCO T22520
WARNING
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed.
The power assembly can be removed or installed in either of two configurations, long or short. A long power assembly consists of the cylinder head, strongback with cylinder liner, piston with rings, and connecting rod. A short power assembly consists of the cylinder head and strongback with cylinder liner. This publication covers the removal and installation procedures for the short power assembly. To remove or install the long power assembly, contact your GE representative.
GE Proprietary and Confidential Information
3
GEK-114406D L250 Diesel Engine Maintenance
3.1.
PREPARE TO REMOVE POWER ASSEMBLY
Procedures in this section must be performed prior to removing the power assembly (Figure 1) in either the short or long configuration. NOTE: The numbers in parentheses ( ) in this section refer to items found in Figure 1 in this publication, unless otherwise noted. 1.
Secure the engine so that it cannot be started. Remove the barring-over cover.
2.
Open all compression relief valves (11).
3.
Ensure the fuel system has been depressurized.
4.
Remove the exhaust manifold section per the procedure in section 4.1., REMOVE EXHAUST MANIFOLD SECTIONS, in this publication.
5.
Drain the engine coolant.
6.
Open the low pressure fuel filter drain back valve located under the fuel filter housing.
7.
Unscrew the bolts in the cylinder water outlet flange.
8.
Detach the low pressure fuel line (Figure 2) and drain back line at the high pressure (HP) pump and leak-off block. Collect the fuel that drains out.
9.
Disconnect the cabling at the solenoid valve for the fuel injection pump.
10. Remove the cylinder cover (13), crankcase inspection cover, and cam cover for the power assembly being removed. 11. Remove the plug (located just behind the fuel pump) from the cam cover and slowly bar the engine over until the desired cylinder number on the side of the cam journal aligns with the center of the hole. 12. Loosen the adjusting screws at both rocker arms and back them off several turns. 13. Lift and rotate the valve bridges to gain access to the push rods. Then, remove the push rods (Item 6, Figure 3). 14. Install the cam follower retainer (TESCO T81201) to secure the cam followers (2). 15. Install the fuel pump horseshoe retainer (TESCO T85630) (12) to secure the fuel pump roller. 16. Remove the seven strongback installation bolts (8) securing the strongback to the mainframe. 17. Obtain the correct procedure for removing nuts from the cylinder head hold-down nuts (Item 1, Figure 3) from your GE representative. NOTE: Do not install the bolts that secure the strongback to the cylinder head until after the cylinder head hold-down nuts are loose. 18. Bolt the strongback (3) to the cylinder head with four M10 x 1.50 x 35 mm socket head bolts and hand tighten these bolts in a diagonally opposite sequence (these screws are used only for power assembly movement purposes).
4
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
2
1
10
2
7
13
6
4 X 4 9
9 11
3
8 12 3
5
REF. 1 2 3 4 5 6 7 8 9 10 11 12 13
X
DESCRIPTION DEVICE FOR SECURING CAM FOLLOWERS (TESCO T81201) CAM FOLLOWERS STRONGBACK CYLINDER HEAD CYLINDER LINER EXHAUST PORT CAM STRONGBACK INSTALLATION BOLT SOCKET-HEAD SCREW (M10 X 1.5 X 35) BOLT AND SPACER (M12 X 1.75 X 60) COMPRESSION RELIEF VALVE FUEL PUMP HORSESHOE RETAINER (TESCO T85630) CYLINDER COVER
E-46636
Figure 1. Power Assembly. (E-46636)
GE Proprietary and Confidential Information
5
GEK-114406D L250 Diesel Engine Maintenance
Figure 2. High And Low Pressure Fuel Lines. (E-49728)
6
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
8
4 5
2 7
3
REF. 1 2 3 4 5 6 7 8
DESCRIPTION CYLINDER-HEAD HOLD-DOWN NUT INLET VALVE ROCKER ARM ROCKER-SHAFT SCREW ROCKER SHAFT PUSH ROD VALVE BRIDGES ADJUSTING SCREW
1 6
E-45423B
Figure 3. Cylinder Head. (E-45423B)
3.2.
REMOVE SHORT POWER ASSEMBLY
A short power assembly consists of the cylinder head and strongback with cylinder liner. The connecting rod and piston assembly remain in the diesel engine when the power assembly is removed in this configuration. Refer to related procedures in this publication where shown. 1.
Complete all procedures in section 3.1., PREPARE TO REMOVE POWER ASSEMBLY, in this publication.
2.
Bar the engine over to position the piston (for the power assembly being removed) near Top Dead Center (TDC)
3.
Disconnect workshop air from the barring-over device.
4.
Attach the power assembly lifter (TESCO T85330, Figure 4).
5.
CAUTION
The short power assembly weighs approximately 345 kg (760 lbs.). Ensure that the lifting device, cables, and straps are adequate. Failure to do so may result in equipment damage and/or personal injury.
CAUTION
Use caution when lifting the short power assembly from the mainframe so not to damage the cylinder hold down studs.
Slowly lift power assembly until the liner is a couple of inches above the main frame, but still on the piston (use caution so not to damage the cylinder hold down studs).
GE Proprietary and Confidential Information
7
GEK-114406D L250 Diesel Engine Maintenance
TESCO T85330 OR PSB PART NO. P5601 22.5-DEGREE LIFTING POINT
STRAIGHT-UP LIFTYING POINT
E-45421A
Figure 4. Power Assembly Lifter. (E-45421A)
CAUTION
Ensure that the piston centering saddles are inserted correctly and do not allow the piston to fall over by its own weight.
6.
Insert the three piston centering saddles (TESCO T81130) with the larger section outboard and the two smaller sections inboard near the cylinder head hold-down studs.
7.
Continue to lift the short power assembly until it is completely clear of the engine. Then, place the assembly onto the PSB-PA bench.
8.
Remove the gasket from the main frame. If necessary, clean the main frame surface carefully with a plastic abrasive pad to remove gasket residues.
NOTE: The gasket on the mainframe can be reused if it is not damaged. 9.
Carefully clean the piston, then cover the piston. Remove barring-over device for safety reasons.
CAUTION
As components are removed, cover all openings with tape or protective caps/plugs to prevent dirt or other foreign material from entering the engine.
10. Cover the main frame bore and surrounding holes to prevent dirt or other foreign matter from entering the diesel engine.
8
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
3.3. 1.
INSTALL SHORT POWER ASSEMBLY
Ensure mainframe mounting surface is clean, then install the gasket on the mainframe.
NOTE: The gasket on the mainframe can be reused if it is not damaged. NOTE: Saddle devices supporting piston may have to be lifted slightly (one at a time) to properly install gasket. 2.
Replace all other disturbed gaskets/O-rings with new gaskets/O-rings during installation.
3.
Apply stud driver (TESCO T80160 or PSB P1845) or double nuts and re-seat all four cylinder head hold-down studs to 200 Nm (148 lb.-ft.).
NOTE: Make sure washer is free of dirt and residual paint, for these will break down over time affecting the clamping force of the studs. 4.
Apply a GE recommended lubricant to the O-ring to keep it in place. Insert it into the groove of the air-intake manifold making sure that it is not twisted.
5.
The water jumper O-ring should be changed at this time. Once the power assembly is set in place, the water jumper O-ring cannot be accessed.
CAUTION
Use only a GE recommended water soluble lubricant on the cylinder liner O-rings. The two upper O-rings are EPDM and will be damaged by petroleum based lubricant.
6.
Lubricate the cylinder liner exterior surface and O-rings (Figure 5).
7.
Install the lifting device on the short power assembly.
CAUTION
The short power assembly weighs approximately 345 kg (760 lbs.). Ensure that the lifting device, cables, and straps are adequate. Failure to do so may result in equipment damage and/or personal injury.
Obtain the correct procedure for replacing the piston rings from your GE representative. It is not required to remove the piston to do this.
CAUTION 8.
Verify that piston rings are installed correctly. Oil Scraper Ring’s gap and its expander spring joint should be 180° apart. Also verify that the ring compressor is installed correctly and rotates with some resistance.
Apply fresh engine oil to the inside bore of the ring compressor. Then, wrap the ring compressor around the piston and rings. Engage the wing nut catch and tighten until the rings are compressed. The ring compressor should be tight enough that it supports its own weight. However, it must be concentric with the piston and free to rotate with some resistance.
Lubricate the cylinder liner bore with clean engine oil. 9.
Using the straight–up lifting point, lift the short power assembly over the piston crown.
GE Proprietary and Confidential Information
9
GEK-114406D L250 Diesel Engine Maintenance
LOWER O-RING
NOTE: ALWAYS REFER TO THE PARTS CATALOG FOR THE LATEST PART NUMBERS WHEN ORDERING PARTS. E-45537A
Figure 5. Cylinder Liner O-rings. (E-45537A)
CAUTION
If for any reason, the ring compressor slides off the piston rings before they are inside the cylinder liner, lift the short power assembly off from the piston, reinstall the ring, reinstall the ring compressor then lower it over the piston and piston rings again.
10. Start to lower the liner over the piston crown, but stop prior to contacting the ring compressor. At this time, remove the three saddle devices. If the saddles are not removed at this time, the ring compressor will not have enough clearance to drop off the piston rings in the next step. NOTE: It will be necessary to have an assistant support the piston until the crown enters the cylinder liner. 11. Once the crown is started into the liner and the saddle devices are removed, lower the short power assembly in one quick and steady motion until the ring compressor falls to the main frame and all of the rings are in the liner. Remove the ring compressor.
3.4.
MOUNT/ADJUST POWER ASSEMBLY AFTER INSTALLATION
NOTE: The numbers in parenthesis ( ) in this section refer to items found in Figure 1 in this publication, unless otherwise noted. 1.
Remove the power assembly lifting device.
2.
Remove the four socket head screws securing the cylinder head to the strongback (these screws are used only for power assembly movement purposes).
3.
Install strongback (3) into the mainframe using the strongback installation bolt (8). Torque to 125 Nm (92 lb.-ft.).
10
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance NOTE: Apply Cyprina RA Grease to the cylinder head mounting stud threads for about 51 mm (2 in.) up from the head surface and on the washer face of the cylinder head prior to installing the washers and nuts. After tensioning the studs, apply Cyprina RA Grease to the cylinder head mounting stud threads for about 13 mm 0.5 in.) up from the nut prior to installing the rubber cap. 4.
Install washers and tighten the nuts on the cylinder head mounting studs until they are hand tight. Obtain the correct procedure for hydraulically tensioning them from your GE representative.
5.
Turn the engine until the cam (7) overlap is at the top most position. Then, remove the securing device (1) from the cam followers (2).
6.
Turn the engine until the fuel cam is at its top most point. Then, remove the fuel pump roller horseshoe retainer (12). This may require the use of pliers.
7.
Lift and rotate the valve bridges (Item 7,Figure 3) sideways.
8.
Insert the pushrods (Item 6, Figure 3) into their cam followers. Then place the valve bridges back in position. Verify that the outboard is properly engaged with the valve stem.
9.
Torque the fuel injection nozzle and high pressure fuel line. Refer to section 6.3., INSTALL FUEL INJECTOR, in this publication.
10. Prior to reinstalling the camshaft cover, cylinder head cover, and crankcase inspection cover, obtain the correct procedure for adjusting the valve clearance from your GE representative.
CAUTION
When reinstalling covers/components and fuel, coolant, or exhaust connections, inspect gaskets and O-rings. If in good condition, reuse the gasket or O-ring, otherwise replace it with a new one.
11. Reinstall the camshaft cover, crankcase inspection cover, and appropriate corresponding gaskets.
CAUTION
Do not allow the low pressure fuel lines to twist during installation.
12. Reinstall low pressure fuel and drain lines (Figure 2) with new gaskets. 13. Complete installation of water outlet flange with new O-ring and torque to 60 Nm (44 lb.-ft.). 14. Reinstall the exhaust manifold section. Refer to section 4.2., INSTALL EXHAUST MANIFOLD SECTIONS, in this publication. 15. Top off the engine coolant and vent the cooling system. Add the required corrosion inhibitor if necessary.
3.4.1. Fuel System Air Release In the case that multiple Power Assemblies are replaced at one time, the air may need to be released from the fuel system. This is not necessary all the time. Release the air on the new Power Assemblies as follows: 1.
Loosen high pressure (HP) Fuel line at the fuel pump connection by 1/4 turn.
2.
Completely loosen the diamond plate. This plate supports the HP fuel line and is held in place by two bolts into the cylinder head.
GE Proprietary and Confidential Information
11
GEK-114406D L250 Diesel Engine Maintenance 3.
Loosen HP fuel line at the cylinder head connection by 1/4 turn.
4.
Begin priming the fuel system.
5.
Wait to see if fuel drips out of the fuel line cavity in the cylinder head. If it does not, loosen another 1/4 turn. If it does, tighten the HP fuel line at the cylinder head.
6.
Tighten the HP fuel line at the fuel pump.
7.
Start engine.
8.
Allow all of the fuel to leak out of the fuel line cavity in the cylinder head.
9.
Retighten the diamond plate located in step 2.
3.5.
BREAK-IN PROCEDURE FOR NEW POWER ASSEMBLY
When a new power assembly has been installed, it must be broken in as follows:
WARNING
Prior to starting ensure that the barring-over device is not attached to the engine. Starting the engine without removing the barring-over device could result in serious personal injury and/or damage to the engine.
1.
Run the engine at IDLE for five minutes.
2.
Shut down the engine and check the following components through the crankcase opening (if any component is exhibiting any serious heating or noise find the cause and eliminate it):
NOTE: Bar the engine over when performing a crankcase inspection to get a clear view of each cylinder liner’s surface. a.
The piston skirt
b.
The applicable connecting-rod bearings (connecting rod should be movable with a small pry bar)
c.
Lower cylinder-liner surfaces for scoring (check from both sides of the engine)
3.
Run the engine unloaded at IDLE for 30 minutes.
4.
Check bearings and crankcase.
5.
Run the engine, gradually increasing the value by increments of 25 percent. The engine should run for 30 minutes at each increment, but one full hour in at full speed.
6.
Repeat Step 2 after the engine has been shut down and then proceed to Step 7 if Step 2 has no problems.
7.
Recheck valve lashes and valve-bridge lashes. Readjust as necessary. Re-torque the jam nut on the bridge to 80 Nm (60 lb.-ft.) and the jam nut on the rocker shaft to 100 Nm (80 lb.-ft.).
8.
Re-torque the bolts to the rocker bracket to 290Nm(214lb.-ft.), and the longer rocker shaft bolts to 560Nm (413 lb.-ft.).
12
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance 9.
Re-torque the exhaust-clamps hex nut to 38 Nm (32 lb.-ft.) and then assemble the second nut as a jam nut to the clamp and counter-torque it to the same value.
3.6.
RESETTING THE ADAPTIVE FUEL LIMIT
The Adaptive Fuel Limit reset procedure must be performed after the change out of the Power Assembly. 1.
Shutdown the engine.
2.
Go to the Engine Monitor Screen and verify that the Engine State reads STATIONARY.
NOTE: The Engine Monitor reading should take approximately 30 seconds from the time the Engine stops rotating. 3.
Go to the Self Test screen and initiate the fuel pump relay self test.
4.
When the fuel pump relay has been picked up, go to the Engine Tests screen and press the Pop Test softkey.
5.
When the Pop test is complete, the adaptive fuel limit is reset.
4. EXHAUST MANIFOLD Table 3. EXHAUST MANIFOLD TOOLS. Exhaust Manifold Torque Adapter
TESCO T85700
Prybar
TESCO T219957P11
Torque Wrench, 100 Nm (74 lb.-ft.)
TESCO T22520
4.1.
WARNING
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed.
CAUTION
When removing the turbocharger, support the exhaust manifold transition section by blocking it up if not being removed with the turbocharger. It is recommended to remove the transition section with the turbocharger to reduce the potential of damage to the exhaust bellows.
REMOVE EXHAUST MANIFOLD SECTIONS
CAUTION
Replace all exhaust manifold gaskets and manifold bolts where joints are loosened or removed. Failure to do so may result in premature equipment failure.
NOTE: The transition section and any main section of the exhaust manifold may be replaced without removing the water header. 1.
Secure the engine so it cannot be started.
GE Proprietary and Confidential Information
13
GEK-114406D L250 Diesel Engine Maintenance 2.
Loosen the band clamps on both ends of the exhaust manifold section to be removed (Figure 6). Use a large screwdriver or small prybar, and pry up against the main casting at the end of each clamp. After engine operation, it is normal for the clamps to remain tight on the flanges when the nuts are loosened.
3.
Unscrew the bolts and spacers and remove the exhaust manifold assembly.
4.2.
INSTALL EXHAUST MANIFOLD SECTIONS
NOTE: Lubricate all bolts, bolt-head washer faces and threads, and the tapped holes with the GE recommended high-temperature anti-seize thread compound. NOTE: The numbers in parenthesis ( ) refer to items found in Figure 7 in this publication, unless otherwise noted. 1.
Install the exhaust section (if necessary), to the end nearest the turbocharger first. Be sure to assemble the clamps with the “T bolt” downward. a.
Ensure that the gasket (4) is properly positioned between the exhaust section (1) and the turbocharger turbine inlet flange.
b.
Apply anti-seize compound to the bolts (5) and spacers (7) and attach the exhaust section.
c.
Torque the bolts (5) and spacers (7) in a crisscross pattern initially to 40 Nm (30 lb.-ft.). Repeat crisscross pattern torque sequence and torque the bolts and spacers to 100 Nm (74 lb.-ft.).
1
2
3
1
2
REF. 1 2 3
DESCRIPTION INTEGRATED BELLOWS CLAMP EXHAUST MANIFOLD SECTION
E-45418B
Figure 6. Type I Exhaust Manifold Section. (E-45418B)
14
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
6 5 4
1
2
FLOW DIRECTION 2 MM MAX 3 PLACES 120° APART 3
A
A
6 8 7
REF. 1 2 3 4
SECTION A-A
DESCRIPTION
REF.
EXHAUSTER MANIFOLD SECTION EXHAUSTER MANIFOLD END SECTION FLEX GASKET FLEX GASKET
5 6 7 8
DESCRIPTION CLAMP, V-BAND COMPOUND, FELPRO C5-A SPACER BOLT, 12 POINT M12 X 1.75 X 60 E50667-
Figure 7. L250 Exhaust Manifold. (E-50667) 2.
Ensure that the exhaust section assembly to be installed is oriented with the bellows section pointed towards the turbocharger end of the engine. a.
Apply anti-seize compound and attach the exhaust section assembly (1 or 2) and gasket (3) to the cylinders using new bolts (8) and spacers (7).
b.
Start the bolts at this time, but do not tighten. The manifold must be free to align to the adjacent manifold assembly as the clamps are applied.
NOTE: Apply a thin coat of anti-seize compound on the manifold, exhaust bellow tip, and taper face at any time before clamps are positioned or installed on them. 3.
Position the band clamps with the bolts and nuts oriented towards the left side of the engine. Place the clamps (5) loosely over the ends of the exhaust manifold section being replaced. Rest the clamps behind the flanges.
GE Proprietary and Confidential Information
15
GEK-114406D L250 Diesel Engine Maintenance 4.
Place gaskets (4) into the grooves of the manifold section assembly (1 or 2). Apply anti-seize compound at three positions to help hold the gaskets in place while handling. Ensure the bellows gaskets are placed correctly before clamping the joint.
5.
The bellows flange and mating exhaust manifold flange must be concentric to each other. Realign the joint if a radial offset of more than 1 mm (0.039 in.) is observed.
NOTE: While tightening the band clamps, observe the alignment of the adjacent flanges. More than 1.0 mm (0.039 in.) misalignment indicates that improvement of the alignment is needed. 6.
Apply anti-seize compound to the threads and nut face of the band clamps, place them in position and press them firmly into the flanges by hand. Install the nuts and hand tighten. Torque the band clamps and main sections to the cylinder head as follows: a.
Torque the first nut on the clamps to 38 Nm (28 lb.-ft.).
b.
Pre-torque the main section assembly mounting bolts to 40 Nm (29 lb.-ft.).
c.
Final torque the main section assembly mounting bolts to 100 Nm (74 lb.-ft.).
CAUTION
Ensure all bellows convolutions are parallel and not touching each other. This condition may cause overheating and possible equipment damage.
7.
Before starting the engine, add coolant as necessary; position the circuit breakers for engine operation and vent the system.
8.
Start and run the engine for a minimum of twenty minutes at full load after replacing any exhaust manifold gasket.
CAUTION 9.
The exhaust manifold metal must cool below 94°C (200°F) before re-torquing.
After the load test, perform the following: a.
Re-torque all exhaust manifold assembly bolts to 100 Nm (74 lb.-ft.).
b.
Re-torque the first nut on the band clamps to 38 Nm (28 lb.-ft.).
c.
Apply a second nut to each clamp and (while holding the first nut in place) torque it to 40 Nm (29 lb.-ft.) in a jamming action.
5. FUEL INJECTION PUMP Table 4. FUEL INJECTION TOOLS. 12 mm 12-point Bolts (4)
—
12-point Socket set: 10 mm, 12 mm
TESCO T85280
Barring-over Device
TESCO T58440
Flat Open-End Wrench: 1-1/2 in.
—
HP Fuel Pump Thread Adapter
HP Fuel Pump Thread Adapter
Low Pressure Fuel Block
—
16
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance Table 4. FUEL INJECTION TOOLS. (Continued) Open-End Torque Adapter: 30 mm
—
Sliding Hammer
TESCO T80481
Socket Set: 6 mm, 16 mm, 18 mm, 24 mm
TESCO T219957P4
Torque Wrench
—
WARNING
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed.
WARNING
When working with any component of the fuel system, there is always a fire risk. Extra care should be taken to ensure that no open flame or spark emitting device is present when working with these components.
Each cylinder has a high pressure fuel injection pump, which is used to supply each injector with a properly timed burst of metered fuel at the required pressures.
5.1.
PERFORM POP TEST
The L250 diesel engines have the capability to run a pop test as a first pass diagnostic to determine if a cylinder is firing. The pop test sequentially increases the fuel duration to each cylinder, one at a time. When the fuel duration is increased to a given cylinder, it responds by firing louder than the others. This can be useful in determining if a particular cylinder is firing properly. To run the pop test, the throttle must be at idle. The pop testis initiated from the Self Test screen of the L250 Smart Display. After initiating the test, the engine speed goes to 330 RPM. The pop test will terminate if a speed over 340 RPM is commanded, or if the actual engine speed goes over 500 RPM. After the engine speed is set to 330 RPM, the fuel duration is increased on L6/L8 for ten seconds. After popping for ten seconds, the engine returns to normal firing for ten seconds. This sequence is repeated along the left bank of the engine, through L1. After L1 finishes popping, there is a thirty second period of normal firing. This allows the operator to safely walk around to the other side of the engine. After thirty seconds, the pop test sequence resumes on R1. The pop test then continues down the right side of the engine through R6/R8.
5.2.
REMOVE FUEL INJECTION PUMP
NOTE: Record the engine position of the fuel injection pump being removed and the serial number of the fuel injection pump being installed. Remove the applicable low pressure fuel line covers before beginning. 1.
With the engine shut down and secured so that it cannot be started, drain the LP fuel systems.
NOTE: Have a container for collecting fuel drainage available and collect the drained fuel. 2.
Disconnect the wires from the fuel injection pump solenoid.
GE Proprietary and Confidential Information
17
GEK-114406D L250 Diesel Engine Maintenance 3.
Clean the HP fuel line connections between the fuel injection pump and cylinder head with a stiff-bristle brush and fuel oil before disconnecting to prevent dirt from entering the fuel system (Figure 8).
4.
Loosen the first fuel line nut slowly to vent off any fuel that may still be in the HP fuel line, then unscrew the HP fuel line nuts at each end, and remove the fuel line (collect any fuel drainage).
NOTE: Immediately clean up any fuel that may spill out of the line as it is removed. 5.
Remove the two different length M10 x 1.5 spacers from the mounting studs of the LP fuel block at the fuel injection pump (collect fuel drainage from the flange and the pump).
CAUTION
As components are removed, cover all openings with tape or protective caps/plugs to prevent dirt or other foreign material from entering.
Figure 8. Cylinder Fuel Lines. (E-49730)
18
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance 6.
Discard the two O-rings from the LP-block openings and cover the LP-block openings after the fuel oil has drained from the header (collect fuel drainage). Apply protective plugs from the new fuel injection pump to the pump fuel inlet and outlet to avoid contamination with dirt.
NOTE: If the fuel injection pump begins to raise when the mounting bolts are loosened, bar the engine over until the fuel cam follower at the cylinder being worked on is no longer in contact with the camshaft fuel lobe. 7.
Carefully loosen and remove the four fuel injection pump mounting bolts.
CAUTION 8.
Lift the fuel injection pump out of the strongback with the nozzle/HP-pump knocker, with the HP-adapter. Cover the area from where it was removed to prevent foreign matter from entering the engine unless the replacement fuel injection pump is to be installed immediately.
5.3.
INSTALL FUEL INJECTION PUMP
CAUTION 1.
Handle the fuel pump with care, and take measures to prevent dirt from entering the pump. Return pumps for repair protected in the same manner as new pumps are received.
When installing a fuel injection pump, ensure that no dirt or foreign matter enters the fuel lines, connections and the engine. Keep the plugs and caps in place until the connections are to be made.
Verify that the fuel lobe is still at a base circle position before installing the fuel injection pump (Figure 9).
POWER TERMINALS
12 MM 12 PT MOUNTING BOLT
O-RINGS
PERMANENT SET SCREW
E-45560
Figure 9. Fuel Injection Pump. (E-45560)
GE Proprietary and Confidential Information
19
GEK-114406D L250 Diesel Engine Maintenance NOTE: If a new Fuel Injection pump is installed, new O-rings may be already be installed in place. If the same Fuel Injection pump is being reinstalled, grease the new O-rings to prevent the O-rings from sticking to the surface of the strongback while the fuel injection pump is being installed. 2.
Install new O-rings to the upper and lower grooves around the fuel injection pump, and coat the sealing surfaces of the O-rings with a GE recommended lubricant.
3.
Verify that the alignment groove is on the same side of the pump as the terminal block.
CAUTION
Be careful not to damage the fuel injection pump solenoid while tightening the mounting bolts.
4.
Install the four 12 mm, 12-point fuel injection pump mounting bolts, and hand-tighten all four bolts, then torque the mounting bolts in a diagonally-opposite sequence to 102 Nm (75 lb.-ft.).
5.
If removed, reapply the high pressure fuel line flange at the head and torque to 40 Nm (30 lb.-ft.).
NOTE: Ensure that no dirt gets into the connections.
CAUTION 6.
7.
If low pressure hoses have been removed for any reason, assemble as instructed and torque to 150 Nm (115 lb.-ft.) Assemble them stress free without any twist.
Install the LP fuel block as follows: a.
Install two new O-rings to the LP fuel block (Figure 10). (A GE recommended lubricant may be used on the O-rings to ensure they do not fall out during installation of the LP fuel block).
b.
Place the LP fuel block onto the two M10 x 1.5 studs and secure to the fuel injection pump with two different length M10 x 1.5 spacers and torque these to 66 Nm (50 lb.-ft.).
c.
Do not squeeze the low pressure hoses into place between two fixed fuel headers. The hose will exceed the permissible bending radius resulting in inner delaminating, distortions, and later fuel leaks. To avoid this, loosen one header, attach both free line ends hand tight to the next fixed header, then the other. Assemble both free ends hand tight. If the hose starts to twist, release immediately, hold it in place, and torque again.
Install the HP fuel line as follows: a.
Remove the protective caps from the ends of the HP fuel line, from the fuel injection pump, and from the cylinder head connections (Figure 11).
b.
Insert the fuel injection line in the cylinder head, hand-tightening the fittings at each end.
c.
Ensure that the line has seated properly into the fittings at the fuel injection pump and cylinder head, then torque fittings to 105 Nm (77 lb.-ft.).
8.
Connect the wires to the fuel injection pump solenoid studs and torque the connections to no more than 1.2 Nm (0.9 lb.-ft.).
9.
Remove the barring-over device and install the barring-over cover.
10. Reinstall the plug with O-ring (located just behind the fuel pump) into the cam cover and torque the plug to 59 lb.-ft. (80 Nm). (Figure 8 shows cylinder 4). 20
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
MOUNTING HOLES FOR 10MM BOLT/STUD
O-RING
E-49731
Figure 10. Low Pressure Fuel Block. (E-49731)
10 MM MOUNTING BOLT/STUD HOLES
PROTECTIVE CAP PLACEMENT
E-49732
Figure 11. Low Pressure Fuel Block Attachment Point. (E-49732)
GE Proprietary and Confidential Information
21
GEK-114406D L250 Diesel Engine Maintenance 11. Tighten all compression release valves, then start the engine and immediately check for fuel leaks. Run the engine at full speed for thirty minutes. Shut down the engine and re-torque the HP fuel line connections. 12. Reinstall the low pressure fuel line cover(s).
5.4.
RESETTING THE ADAPTIVE FUEL LIMIT
The Adaptive Fuel Limit reset procedure must be performed after the installation of the fuel injection pump. Refer to section 3.6., RESETTING THE ADAPTIVE FUEL LIMIT, in this publication for instructions on resetting the Adaptive Fuel Limit.
6. FUEL INJECTOR Table 5. FUEL INJECTOR TOOLS. 12-point Socket Set: 10 mm
TESCO T85280
Breaker Bar:3/4 in.
—
Bucket
—
Flashlight
—
Fuel Line Torque Wrench
TESCO T54931
Injector Alignment Tool
TESCO T81310
Injector Sleeve Torquing Tool
TESCO T81330
Nozzle Carbon Cleaner
TESCO T81230
Open-End Torque Adapter: 30 mm, 110 Nm (81 lb.-ft.)
—
Injector Puller (also M16 x 2 mm adapter, TESCO T80480N) (For use with T80480 puller TESCO T80481 Socket Set: 16 mm, 24 mm
TESCO T219957P45, P50
Torque Wrench: 200 Nm (147 lb.-ft.)
TESCO T22520
WARNING
WARNING
22
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed. When working with any component of the fuel system, there is always a fire risk. Extra care should be taken to ensure that no open flame or spark emitting device is present when working with fuel system components.
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
6.1.
REMOVE FUEL INJECTOR
NOTE: Remove the applicable low pressure fuel line cover before beginning. Remove the Fuel Injector (Figure 12) as follows: 1.
Secure the engine so that it cannot be started, then remove the cylinder head cover.
2.
Clean the joint between the high pressure (HP) fuel line and the fuel injection pump with a clean rag.
CAUTION 3.
As components are removed, cover all openings with tape or protective caps to prevent dirt or other foreign material from entering.
Unscrew the HP fuel line nuts at the HP pump end and remove the 10 mm bolts on the HP fuel line oval flange.
NOTE: Immediately clean up any fuel that may spill out of the line as it is removed. 4.
Remove the fuel line and oval flange.
5.
Remove the valve cover.
CAUTION
Any time after assembly is complete and the engine has been run, if the injector clamp nut is loose or torqued to the wrong value, replace the injector and torque the clamp nut to the correct value. Check that all other injectors on the engine have the clamp nut properly torqued. Replace all injectors where the clamp nut is loose or not properly torqued. Do not just re-torque the clamp nut and reuse the same injector. The injector is most likely damaged and should be replaced.
6.
Remove the nut which secures the fuel injector clamp, then remove the clamp washer and clamp.
7.
Remove the fuel injector from the cylinder head using the injector puller.
NOTE: Ensure the copper sealing ring is on the fuel injector nozzle when the fuel injector is removed. If it is not on the fuel injector nozzle, check the nozzle bore for the copper sealing ring.
CAUTION
Handle the fuel injector with care, and take measures to prevent dirt from entering the injector. Do not bump the tip or clean the tip with a wire brush. Place a protective cover over the tip end. Return injectors for repair protected in the same manner as new injectors are received.
GE Proprietary and Confidential Information
23
GEK-114406D L250 Diesel Engine Maintenance
INJECTOR CLAMP NUT
CYLINDER HEAD
INJECTION TUBE
INJECTOR CLAMP WASHER
INJECTOR
INJECTOR CLAMP
HIGH-PRESSURE FUEL-OIL LINE
INJECTOR SEALING RING FUEL-OIL INJECTION PUMP
E-43624
Figure 12. Fuel Injector Assembly. (E-43624)
24
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
6.2.
PREPARE TO INSTALL FUEL INJECTOR
If difficulty was encountered while removing the fuel injector nozzle from the cylinder head, the nozzle bore in the cylinder head is probably packed with carbon, scale, etc. Clean this material from the recess before installing a new nozzle, as follows: 1.
Inspect fuel injector bore in the cylinder head and check the fuel injector sleeves. Torque the fuel injector sleeves to 150 Nm (111 lb.-ft.) using the sleeve socket tool (TESCO T81330).
NOTE: The entire length of the recess should be cleaned, but the seat is of particular importance. 2.
Clean the recess using the 3M conical rubberized seat and bore cleaning tool or similar. This will clean the seat as well as the bore.
WARNING 3.
When blowing with compressed air, personal injury may result if proper eye protection is not worn. To prevent personal injury when using compressed air, observe all Standard Operating Procedures.
Blow out loosened debris or remove it with a greased rag on a pin, then cover the opening until reassembly.
6.3.
INSTALL FUEL INJECTOR
NOTE: Verify that the upper O-ring has a white stripe and is thicker than the lower two O-rings. 1.
Pre-grease and install three new O-rings into the grooves around the fuel injector and grease them with a GE recommended lubricant.
2.
Visually align the fuel injector HP threaded connection with the HP fuel line bore in the cylinder head.
3.
Press the fuel injector down by hand for initial seating.
4.
Look into the HP fuel line bore in the cylinder head (use a flashlight) to ensure that the HP connection in the fuel injector is centered in the bore. Use the fuel injector alignment tool to center the injector as needed.
NOTE: No excessive force should be required to seat the fuel injector. If a fuel injector does not seat and align vertically, it may be an indication that the copper sealing ring has fallen off of it. Remove the fuel injector and begin the installation procedure again.
CAUTION
Do not use a nozzle knocker to tap the nozzle into place. Doing so may jar loose the copper sealing ring.
CAUTION
Make sure that the dome steel washer is in the correct position to the clamp, not upside down, beveled side should mate with the clamp. Also, make sure the injectors clamp ends are properly engaged and aligned to the cylinder heads step.
5.
Assemble the fuel injector clamp onto the stud and over the fuel injector, install the clamp washer and nut, and then tighten the fuel injector clamp nut to press the injector onto the copper sealing ring.
6.
Loosen the clamp nut.
GE Proprietary and Confidential Information
25
GEK-114406D L250 Diesel Engine Maintenance 7.
Remove the protective caps or tape from the ends of the HP fuel line and from the fuel injection pump and cylinder head connections. Be careful not to allow any dirt to enter opening during the reassembly process.
8.
Install the HP fuel line into the cylinder head hand-tight. Ensure that the line has threaded properly into the fuel injector. Use the alignment tool (TESCO T81310) if necessary.
9.
Lightly secure the opposite end of the HP fuel line fitting to the fuel injection pump. Ensure that the line has threaded properly onto the fitting. Assemble both connections hand-tight.
10. Torque the injector clamp nut 200 Nm (148 lb.-ft.). 11. Torque the high--pressure fuel line connection to 105 Nm (77 lb.-ft.). 12. Install the oval flange bolts and hand tighten. Torque the oval flange bolts to 40 Nm (30 lb.-ft.). 13. Wipe the cylinder head cover sealing surfaces clean and install the cylinder head cover and mounting bolt. 14. Torque cylinder head cover mounting bolts to 77 Nm (57 lb.-ft.). 15. Start the engine and immediately check for fuel leaks. Run the engine at full speed/full load for 30 minutes. Shutdown the engine and re-torque the HP fuel line connections and the fuel injector clamp nut. 16. Reinstall the low pressure fuel cover(s). NOTE: Fuel mist or vapor escaping from the fuel tank vent is an indication that the fuel injector nozzle is not seated properly.
CAUTION
6.4.
Any time after assembly is complete and the engine has been run, if the injector clamp nut is loose or torqued to the wrong value, replace the injector and torque the clamp nut to the correct value. Check that all other injectors on the engine have the clamp nut properly torqued. Replace all injectors where the clamp nut is loose or not properly torqued. Do not just re-torque the clamp nut and reuse the same injector. The injector is most likely damaged and should be replaced.
RESETTING THE ADAPTIVE FUEL LIMIT
The Adaptive Fuel Limit reset procedure must be performed after the installation of the Fuel Injector(s). Refer to section 3.6., RESETTING THE ADAPTIVE FUEL LIMIT, in this publication for instructions on resetting the Adaptive Fuel Limit.
7. FLYWHEEL INSTALLATION AND REMOVAL 7.1.
FLYWHEEL REMOVAL
WARNING
26
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed. GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance 1.
Remove covers and guards around the flywheel.
2.
Remove the flywheel assembly from the crankshaft flange. Install a M24–3 swivel eye bolt into flywheel assembly and use a crane to take load lightly off crankshaft but not enough to put bind on the flywheel assembly.
3.
Loosen the bolt mounting the flywheel to the crankshaft.
4.
Use crane to take away the rest of the load.
5.
Use low profile hydraulic cylinder to push the flywheel off of the crankshaft flange in small increments. Use a 90 degree pattern to position the hydraulic power unit.
6.
Remove the flywheel assembly from the crankshaft flange.
CAUTION 7.2.
Do not contact the ring gear with any part while removing and setting the flywheel assembly into a safe position or it may result in damage to the ring gear.
FLYWHEEL INSTALLATION
1.
Visually inspect to ensure that there is no thread damage on the bolts or damage to the flywheel itself.
2.
Lubricate the bolts with lithium grease.
3.
Trial fit the bolts into the flywheel hole by hand.
4.
If they fit correctly, remove the bolts.
5.
Install the M24–3 swivel eye bolt into the flywheel assembly.
6.
Visually inspect the mating surfaces of the flywheel and the crankshaft for damage.
7.
Apply lithium grease to the internal diameter of the flywheel assembly as shown in Figure 13.
8.
Lift the flywheel assembly into position.
9.
Install bolts and washers into the flywheel and crankshaft at twelve, three, six, and nine o'clock positions as shown in Figure 14.
10. Draw flywheel evenly into the crankshaft flange using bolts. Tighten the bolts in a cross-tightening pattern. 11. Once the flywheel is pulled into the crankshaft flange, apply the remainder of the bolts and washers. 12. Pre-torque the bolts to 100 Nm (74 lb.-ft.). 13. Final torque bolts to 1900 Nm (1401 lb.-ft.). 14. Check the total runout on the ring gear of the flywheel and record this number. Make sure the total runout is less than 0.508 mm (0.020 in.).
GE Proprietary and Confidential Information
27
GEK-114406D L250 Diesel Engine Maintenance
13 5
14
1
3 2
7 SEE DETAIL A 6 12 8 9 11
12
4 10
DETAIL A REF. 1 2 3 4 5 6 7
DESCRIPTION CRANKSHAFT CAM DRIVE GEAR FLINGER SCREW, METRIC CAP FLYWHEEL FLANGE PLUG FLYWHEEL OR FLEX PLATE
REF. 8 9 10 11 12 13 14
DESCRIPTION HARDENED WASHER, 1.25 IN. BOLT LOCKTITE 271 SHIM SHIM, T2 CRANKSHAFT RING GEAR (CW OR CCW) BOLT E-50669
Figure 13. Flywheel Assembly. (E-50669)
28
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
E-49591
Figure 14. Install Bolts into Flywheel. (E-49591)
8. CHECK/ADJUST CRANKSHAFT WEB DEFLECTION
WARNING
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed.
NOTE: When checking/adjusting the web deflection on the shop floor, it must be rechecked (and readjusted if necessary) after the engine has been installed and adjusted. 1.
Index crankshaft throw number 6 to position A (Figure 15). Hang deflection gage in the punch prick marks on crankshaft. Zero the gage and rotate the crankshaft to ensure it is seated. Re-zero the gage if necessary.
NOTE: When recording the deflection readings, use “+” to indicate web spread and “-” to indicate web compression. 2.
Index crankshaft to positions B, C, D, and E as shown in Figure 16. Record the deflection reading on the gage at each position.
GE Proprietary and Confidential Information
29
GEK-114406D L250 Diesel Engine Maintenance
10 3
5
8
7
1
2
9
6 4
E-46505
Figure 15. Flex Plate Flange Bolt Installation Pattern. (E-46505)
CRANK POSITION LOOKING FROM ALTERNATOR END OF THE ENGINE
INDICATOR
INDICATOR
INDICATOR
INDICATOR
INDICATOR
ROTATE
POSITION A
ROTATE
ROTATE
ROTATE POSITION B
POSITION C
ROTATE POSITION D
POSITION E
CRANK PIN TOP CENTER
E-45433
Figure 16. Crankshaft Position. (E-45433A)
30
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance 3.
It is common to monitor web deflections as part of regular maintenance. Web deflection limits are as follows: a.
Normally obtainable for new installations = 0.050 mm (0.002 in.)
b.
Realignment or investigation recommended = 0.075 mm (0.003 in.)
c.
Absolute maximum permissible under any condition = 0.100 mm (0.004 in.)
NOTE: When recording readings at crank positions E and C, use the following sign convention: • •
“+” reading indicates web spread ”-” reading indicates web compression
4.
Check the condition of the crankcase inspection cover and cover seals (replace any defective ones). Wipe off all mating and sealing surfaces.
CAUTION
Final torque at all fasteners with a torque wrench. Over-torquing the bolts with an impact wrench could result in the premature failure of the bolts.
5.
Close all cylinder compression relief valves. Torque to 60 Nm (44 lb.-ft.).
6.
Remove the pneumatic barring-over device.
9. WATER PUMP Table 6. WATER PUMP TOOLS. Adjustable Ring Wrench (Narrow 1 in. open end wrench) — Basic Standard Tool Kit
—
“C” Frame Manipulator
TESCO T57170
Feeler Gage: 0.05 mm to 40 mm
TESCO T52060
Oil and Water Pump Lifter (C-frame)
TESCO T80750A
Torque Wrench: 280 Nm (206 lb.-ft.)
TESCO T22520
Water Pump Adapter
TESCO T80750A
WARNING
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed.
NOTE: L250 diesel engines are equipped with special alignment rings for the oil and water pumps expressly for the purpose of adjusting the backlash of the pump gears with the auxiliary drive gear. The rings are installed and properly adjusted on the front cover. Removal and/or readjustment of these rings are not necessary for pump maintenance, and thus not recommended.
GE Proprietary and Confidential Information
31
GEK-114406D L250 Diesel Engine Maintenance
9.1.
REMOVE WATER PUMP
1.
Secure engine so that it cannot be started and remove the sensor from the water pump discharge pipe.
2.
Loosen and remove the M12 and M16 bolts that secure the discharge pipe to the water pump (Figure 17) and the front cover.
3.
Disassemble the discharge pipe from the water pump and front cover, then remove the two O-rings and Inlet pipe.
4.
Drain the coolant water system to a level below the lowest level in the water pump.
5.
Insert an M12 eyebolt into the water pump threaded hole and attach an adequate capacity lifting device to the eyebolt.
6.
Support the water pump and remove the M16 bolts and washers securing the water pump housing to the front cover.
7.
Remove the gear-end of the water pump from its boss on the front cover.
NOTE: The alignment ring comes out with the water pump. If the alignment ring needs to be removed, the gear will need to be removed from the front of the pump.
WATER PUMP
E-50556
Figure 17. Water Pump Assembly. (E-50556) 32
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
9.2.
INSTALL WATER PUMP
NOTE: Subassembly of water pump, adjustment ring and pump gear must already be completed with O-rings in place between the water pump and adjustment ring, and the adjustment ring and front cover water pump bore (Figure 18) 1.
Lubricate the O-rings with Victaulic lube.
2.
Install an M12 eye bolt, then lift and install the water pump sub assembly onto the front end cover (Figure 19).
NOTE: The pump must be supported until the mounting flange is fully engaged with the engine, and the screws securing the pump are tightened 3.
Install only three mounting bolts and washers and tighten the three bolts in a triangular pattern enough to hold the water pump in place without any movement.
NOTE: For measuring at the impeller, the needle on the indicator should be about 3-5 mm away from the outer edge of the impeller blades. There might be presence of rough casting on the outer edge of the blade due to which backlash value may be set incorrectly. 4.
Measure the backlash of the water pump drive gear either through the oil pump opening underneath the water pump, or at the water pump impeller (Figure 20). The acceptable backlash of the impeller at this location is 0.101 to 0.178 mm (0.004 to 0.007 in.), which corresponds to backlash at the gear being 0.28 to 0.54 mm (0.011 to 0.021 in.), which would be measured through the oil pump opening.
5.
Perform the following If the backlash is incorrect: a.
If it is necessary to rotate the alignment ring, loosen the three mounting bolts of the water pump assembly. Do not remove water pump mounting bolts from the mounting holes.
b.
Rotate the adjustment ring to clockwise (CW) increase backlash or counterclockwise (CCW) to decrease the backlash.
E-50664
Figure 18. Water Pump, Adjustment Ring, And Gear Assembly. (E-50664)
GE Proprietary and Confidential Information
33
GEK-114406D L250 Diesel Engine Maintenance
E-50665
Figure 19. Water Pump On End Cover. (E-50665)
E-50666
Figure 20. Measuring Pump Backlash. (E-50666) c.
Retighten the three pump mounting bolts when the adjustment ring is adjusted to the correct backlash.
d.
Recheck backlash after tightening the three mounting bolts and repeat if necessary to achieve correct backlash.
e.
Apply Loctite 242 must be applied to the two bolts that do not have an alignment ring support under them, then install the remaining three mounting bolts.
NOTE: Torque the four bolts where the alignment ring is beneath them first and then torque the remaining two bolts where the alignment ring is not beneath them. f.
Torque the four bolts under where the alignment ring is present to 190 Nm, +/-20 Nm (140 lb.-ft., +/-15 lb.-ft).
g.
Torque the remaining two bolts under where the alignment ring is not present are to 30 Nm (22 lb.-ft.).
NOTE: Mark the bolts as torqued to ensure none are missed. 34
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
10. LUBRICATING-OIL PUMP Table 7. LUBRICATING-OIL PUMP TOOLS. 24 mm Special Crow Foot (for installation/removal of M16X2 nuts onto/from stud bolts)
TESCO T85420
Adjustment Ring Wrench (This is a standard wrench -25 mm or 1 in. open end)
—
Basic Standard Tool Kit
—
“C” Frame Manipulator
TESCO T57170
Feeler Gage: 0.05 mm to 40 mm
TESCO T52060
Oil and Water Pump Lifter (C-Frame)
TESCO T80750
Torque Wrench: 280 Nm (206 lb.-ft.)
TESCO T22520
WARNING
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed.
NOTE: Diesel engines are equipped with special alignment rings for the oil and water pumps expressly for the purpose of adjusting the backlash of the pump gears with the auxiliary drive gear. The rings are installed and properly adjusted on the front cover of the engine the first time the pumps are installed on the engine. Removal and/or readjustment of these rings is not necessary for pump maintenance, and thus not recommended. NOTE: If ELIP sensor is reading low and deltaP between ELIP and ELPP is low,; then drain oil, remove suction pipe, and then remove and clean oil pan strainer as detailed in section 10.1., REMOVE LUBRICATING-OIL PUMP.
10.1. REMOVE LUBRICATING-OIL PUMP NOTE: The pump must be properly supported during the removal process using the correct lifting tool (C-Frame or lifting bar). 1.
Secure the engine so that it cannot be started, drain oil, and remove the sensors from the oil pump discharge pipe.
2.
Remove the four bolts that fasten the oil outlet elbow to the top of the oil pump and the four bolts that fasten the oil suction pipe to the bottom of the oil pump.
3.
Properly support the pump, then remove the four M16 x 2 nuts and washers from the oil pump mounting flange that attaches the oil pump to the front cover of the engine.
4.
Pull the oil pump straight out of the front cover, careful not to drop the O-ring from the suction pipe flange into the suction pipe.
5.
Remove the four fasteners that mount the oil suction pipe to the oil pan.
GE Proprietary and Confidential Information
35
GEK-114406D L250 Diesel Engine Maintenance 6.
Remove the suction pipe.
7.
Remove the oil strainer, clean, and reinstall.
10.2. REMOVE OIL PUMP GEAR 1.
Properly support the oil pump with its gear held stationary, then remove the M16-2 x 80 bolt and washer that retains the oil pump gear onto the oil pump shaft (Figure 21).
2.
Remove the oil pump gear from the shaft using a gear puller.
10.3. INSTALL OIL PUMP GEAR 1.
Orient the oil pump gear so that the larger diameter of the tapered bore in the gear is facing the oil pump, then slide it onto the oil pump shaft.
2.
Install the oil pump gear retaining washer and M16-2 x 80 bolt into the end of the oil pump shaft (Figure 21).
3.
Properly support the oil pump with its gear held stationary, then torque the retaining bolt to 290 Nm (214 lb.-ft.).
10.4. INSTALL LUBRICATING-OIL PUMP NOTE: Subassembly of lubricating-oil pump, adjustment ring and pump gear must already be completed with O-rings in place between the lubricating-oil pump and adjustment ring, and the adjustment ring and front cover lubricating-oil pump bore (Figure 21 and Figure 22).
ALIGNMENT RING O-RING
BOLT, M16-2 X 80
GEAR WASHER
GEAR
O-RING
LUBE OIL PUMP E-50728A
Figure 21. Oil Pump Gear Section. (E-50728A) 36
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
E-50746
Figure 22. Lubricating-oil Pump, Adjustment Ring, And Gear Assembly. (E-50746) 1.
Verify the O-rings are installed in the adjustment ring of the lubricating-oil pump.
2.
Record the serial number of the lubricating-oil pump.
3.
Lubricate the O-rings with Victaulic lube.
4.
Install the lubricating-oil pump lifter, then lift and install the lubricating-oil pump assembly onto the front endcover (Figure 23).
NOTE: The pump must be supported until the mounting flange is fully engaged with the engine, and the screws securing the pump are tightened. 5.
Install only three mounting bolts and washers and tighten the three bolts in a triangular pattern enough to hold the lubricating-oil pump in place without any movement.
NOTE: The dial indicator needle should be at the edge of the internal drive gear which is directly connected to the oil pump drive shaft. This will give a more realistic value of the backlash at the pump gear. Do not place the needle at the driven gear (one which is not connected to the drive shaft of the pump). This would cause the backlash value to be set incorrectly. Figure 24 shows a standard rotation lubricating-oil pump; a reverse rotation pump will have the driven gear on the other side of the drive gear. 6.
Measure the backlash of the lubricating-oil pump drive gear either through the water pump opening (if water pump not installed) or as shown in Figure 24. The acceptable backlash at the gear is 0.28 to 0.54 mm (0.011 to 0.021 in.).
GE Proprietary and Confidential Information
37
GEK-114406D L250 Diesel Engine Maintenance
E-50747
Figure 23. Lubricating-oil Pump Attached To Front Cover. (E-50747)
E-50748
Figure 24. Measuring Lubricating-oil Pump Backlash. (E-50748) 7.
38
Perform the following if the backlash is incorrect: a.
If it is necessary to rotate the alignment ring, loosen the three mounting bolts of the lubricating-oil pump assembly. Do not remove lube pump mounting bolts from the mounting holes.
b.
Rotate the adjustment ring to clockwise (CW) increase backlash or counterclockwise (CCW) to decrease the backlash.
c.
Retighten the three pump mounting bolts when the adjustment ring is adjusted to the correct backlash.
d.
Recheck backlash after tightening the three mounting bolts and repeat if necessary to achieve correct backlash.
e.
Apply Loctite 242 must be applied to the two bolts that do not have an alignment ring support under them, then install the remaining three mounting bolts.
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance NOTE: Torque the four bolts where the alignment ring is beneath them first and then torque the remaining two bolts where the alignment ring is not beneath them. f.
Torque the four bolts under where the alignment ring is present to 190 Nm, +/-20 Nm (140 lb.-ft., +/-15 lb.-ft.).
g.
Torque the remaining two bolts under where the alignment ring is not present are to30 Nm. (22 lb.-ft).
NOTE: Mark the bolts as torqued to ensure none are missed.
11. TURBOCHARGER Table 8. TURBOCHARGER TOOLS. Box End Extension (for inner foot bolts)
TESCO T81370
Lifting Eyebolts
TESCO T80760
Turbocharger Installation Kit
250X1007
Turbocharger Speed Sensor Torque Tool
TESCO T85161
WARNING
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed.
These procedures cover removing and installing the turbochargers in a L250 Marine engine only. The turbocharger can be installed on either end of the 6L250 and 8L250 engines.
11.1. TURBOCHARGER REMOVAL At the specified maintenance intervals or when inspection establishes that a turbocharger is faulty, remove the turbocharger using the following procedure. Refer to the appropriate GEK-114366, MAINTENANCE AND OVERHAUL SCHEDULE, L250 ENGINES, publication for additional information concerning the maintenance intervals. 1.
Drain the cooling water system.
2.
Record the turbocharger serial number in engine documentation.
3.
Remove the exhaust components above the turbocharger, and remove the eductor hose
4.
Disconnect the water outlet hose fittings.
5.
Remove the bellows between the transition section and the exhaust manifold. Also, remove the PTT sensor from the transition section.
6.
Remove the four bolts and washers that secure the turbocharger to the flange and sleeve connector between the turbocharger air discharge and the intercooler.
GE Proprietary and Confidential Information
39
GEK-114406D L250 Diesel Engine Maintenance 7.
Remove the air filter connections at the compressor end of the turbocharger. Slide the duct onto the turbocharger inlet.
8.
If equipped, remove the turbocharger speed sensor by loosening the lock nut and carefully unscrewing the sensor. Refer to Table 8, for additional information on removing the speed sensor.
9.
Remove the eight mounting bolts and washers that secure the turbocharger to the turbocharger mounting bracket.
10. Remove the two nuts (front mounted turbocharger) or two bolts (rear mounted turbocharger) that come up from the bottom of the turbo shelf near the front. 11. For front mounted turbochargers, remove the four bolts and washers that secure the turbocharger to the saddle bracket.
CAUTION
Exercise care in removing the turbocharger to avoid damaging the exhaust manifold.
12. Lift the turbocharger from the engine using lifting eyebolts. Refer to Table 8 in this publication for additional information on lifting the turbocharger. 13. After positioning the turbocharger on the floor: a.
If the turbocharger was removed because of a failure (and not for a periodic replacement), thoroughly examine the turbocharger and determine the cause of the failure. Neglecting to do so may result in a repeat failure. If the failure was caused by foreign material, it is mandatory that all traces of this material be removed. It may be necessary to remove and clean the exhaust manifold, or it might be necessary to replace the air filters and clean and inspect the filter clean-air plenum. Also, inspect the inlet side of the intercooler for foreign material.
b.
Apply protective covers and pipe plugs to all openings in the removed turbocharger. Apply new covers and plugs, or transfer them from the replacement turbocharger.
11.2. TURBOCHARGER INSTALLATION If the turbocharger is being installed as a result of a failure and not for a periodic replacement, correct the cause of the failure (if caused by foreign object damage, for example). Apply new o–rings, seal rings and lock–washers, and install the turbocharger using the following procedure: NOTE: If installing the turbocharger on the opposite end of the diesel engine from which it was removed, contact your GE representative for the appropriate procedures for removing and installing the turbocharger intercooler to the appropriate side of the diesel engine. 1.
Remove all protective covers and pipe plugs from the replacement turbocharger. Ensure that no foreign material remains in the turbocharger and air delivery system.
2.
Install new O–rings into the grooves in the turbocharger shelf.
WARNING
40
Do not stand under the turbocharger. Ensure that the turbocharger mounting bolts are securely tightened before removing the crane hooks.
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance 3.
Lift the turbocharger. Ensure that the oil inlet orifice is installed, and that the bottom surface of the turbocharger is clean and smooth. Lower the turbocharger onto the turbocharger mounting bracket.
CAUTION 4.
Exercise care when installing the turbocharger to avoid damaging the exhaust manifold.
Install the eight bolts and washers that secure the turbocharger to the turbocharger mounting bracket and initially torque to 95 to 110 Nm (70 to 80 lb.-ft), and then finally to 500 to 600 Nm (370 to 440 lb.-ft). Install the two nuts (front mounted turbocharger) or two bolts (rear mounted turbocharger) that come up from the bottom of the turbo shelf near the front. Tighten the bolts and nuts to a torque of 500 to 600 Nm (370 to 440 lb.-ft). Then, for front mounted turbochargers, install the four bolts and washers that secure the turbocharger to the saddle bracket and tighten to a torque of 250 to 310 Nm (185 to 229 lb.-ft). Tighten the mounting bolts evenly to the torque given in section 6.1., REMOVE FUEL INJECTOR, in this publication.
WARNING
Personnel performing cleaning operations must wear protective clothing, gloves, and eye protection to avoid injury. Follow all Railroad operating procedures when using compressed air.
5.
Install the air filter components.
6.
Ensure that the O-ring is in place, and assemble the air discharge to the intercooler flange and sleeve connection using four bolts and washers. Tighten the bolts evenly to a torque of 47 to 53 Nm (35 to 39 lb.-ft). Refer to section 13.1., TORQUE VALUES, in this publication for all torque values.
7.
Install the bellows between the turbine inlet and the exhaust manifold using new gaskets. Also, install the PTT sensor in the transition section.
NOTE: Assure that the exhaust manifold bellows are assembled with the flow arrow pointing toward the turbocharger. 8.
Record the turbocharger serial numbers in engine documentation.
9.
If equipped, carefully return the turbocharger speed sensor Figure 25. Refer to Table 8 for additional information on installing the speed sensor. Gap the speed sensor to the compressor wheel blade to 0.3–0.4 mm (0.013–0.015 in.). Tighten the lock nut to a torque of 5 Nm (4 lb.-ft). Refer to section 13.1., TORQUE VALUES, in this publication for all torque values.
10. Connect the water discharge hose Figure 26 fittings. Return the water outlet pipe, if previously removed. Tighten to a torque of 75 to 81 Nm (55 to 60 lb.-ft). Refer to section 13.1., TORQUE VALUES, in this publication for all torque values. 11. Install the exhaust manifold blankets to the transition section. 12. Install the stack transition piece, securing it with bolts and washers. Tighten the bolts evenly to a torque of 61 Nm (45 lb.-ft). Also, return the eductor hose. Refer to section 13.1., TORQUE VALUES, in this publication for all torque values. 13. Fill the cooling water system with properly treated water.
GE Proprietary and Confidential Information
41
GEK-114406D L250 Diesel Engine Maintenance
SPEED SENSOR
E-50547
Figure 25. Install Turbocharger Speed Sensors. (E-50547)
HOSE AND FITTINGS
E-50548
Figure 26. Hose And Fitting Connections. (E-50548)
42
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
11.3. OPERATIONAL CHECK After the turbocharger work has been performed and the engine is running, listen near the turbocharger and the exhaust for unusual noises, such as parts rubbing.
CAUTION
Do not allow the engine to idle for an extended period before warming up and loading. Extended idling could cause oil leakage at the seals, and engine souping would be aggravated.
If possible, load the engine and observe that the turbocharger is performing its function. This will be evident by a manifold air pressure above 276 kPa (40 psia), depending on the engine model and the stack should be clear. Check the installed turbocharger for water, oil, air, and exhaust leaks, and correct if found.
12. COALESCER Table 9. COALESCER TOOLS. Basic Standard Tool Kit
—
Torque Wrench, 190 Nm (140 lb.-ft.)
TESCO T22520
WARNING
To prevent personal injury and potential equipment damage, make sure the engine cannot be started before beginning to remove, install, or adjust any engine components. Open all related switches or circuit breakers for the battery, fuel pump, or other switches, circuit breakers, or controls that would initiate the engine start sequence. Apply a warning tag to the engine start control panel using standard shop procedures identifying that the engine is locked down and should not be started due to maintenance being performed.
The coalescer can be located on either end of the engine. Oil-saturated air from the crankcase is drawn into the coalescer by use of vacuum pressure provided by the exhaust system. Once the air is drawn into the coalescer, the oil is removed and directed back to the lubrication system.
12.1. REMOVE COALESCER HOSE NOTE: The coalescer has been designed to have no contact with the engine or components except for the coalescer hose connections. This decreases the chance for wear.
WARNING
Do not remove the hoses while the engine is running or hot.
1.
Loosen the 15 mm (9/16 in.) clamp bolts that secure the ends of the hose to their attachment pipes.
2.
Rotate each end of the hose back and forth at its attachment point just enough to break it free from any bonding that may have occurred between the hose and the attachment pipe.
3.
Pull the free ends of the hose off the pipes, taking care not to scrape the hose against other components that may damage it.
4.
Repeat the above process for both hoses.
GE Proprietary and Confidential Information
43
GEK-114406D L250 Diesel Engine Maintenance NOTE: For the longer hose, an additional 19 mm (3/4 in.) bolt must be removed from the P-clamp that supports the hose near its center (Figure 27).
12.2. INSTALL COALESCER HOSE NOTE: Before installing/reinstalling any hoses, be sure that the attachment pipes are clean and free of any debris. 1.
Apply anti-seize compound to the exterior of the attachment pipes.
2.
Ensure that the clamps are located loosely around the hose cuffs at both ends of the hose, then install the hose ends over the attachment pipes.
3.
Rotate the clamps around the hose such that the bolt is in a convenient position for adjustment.
4.
Position the hose so that it will not make contact with the engine or other engine components, then torque each 15 mm (9/16 in.) clamp bolt to 7 Nm (5 lb.-ft.).
NOTE: When installing the longer hose, upon completion of the installation of the end clamps, refasten the P-clamp around the center of the hose to the turbo flange with the 19 mm (3/4 in.) bolt and torque the bolt to 190 Nm (140 lb.-ft.).
12.3. REMOVE COALESCER NOTE: Before the coalescer can be removed from the engine, the oil drain hose and the short blow-by hose (Figure 27) must be disconnected.
WARNING
Do not remove the hoses while the engine is running or hot.
1.
Once the hoses are removed, support the coalescer to prevent it from falling.
2.
Remove the retaining strap bolts from the retaining straps (Figure 27).
3.
Remove the coalescer from its installed position.
12.4. INSTALL COALESCER NOTE: Proper orientation of the coalescer is important to ensure that the coalescer, hoses, and other components work properly and do not become damaged. 1.
Position the coalescer in its mounting bracket such that the inlet hose attachment is parallel to the turbocharger shelf.
2.
With the coalescer held in place, position the coalescer straps around the coalescer, replace the coalescer straps bolts, and torque to 23 Nm (17 lb.-ft.).
44
GE Proprietary and Confidential Information
GEK-114406D L250 Diesel Engine Maintenance
RETAINING STRAPS
P−CLAMP
OIL DRAIN HOSE
E−49634
Figure 27. Coalescer Clamp, Straps, And Hose. (E-49634)
12.5. COALESCER MAINTENANCE A poorly maintained coalescer/filter element may cause additional pressure loss through the coalescer system resulting in incorrect crankcase pressure, which may result in the engine shutting down due to crankcase overpressure faults. 1.
Remove the coalescer from the coalescer hoses. Refer to section 12.3., REMOVE COALESCER, in this publication.
NOTE: The inside of the coalescer and hoses and the filter element will likely be coated with dirty engine oil. 2.
Separate the top and bottom halves of the coalescer by rotating and pulling up on the top half of the coalescer with the bottom half supported.
3.
Remove the filter element from the coalescer shell and the sealing ring from the bottom half of the coalescer.
4.
The filter element and the coalescer halves may now be cleaned with solvents to remove the oil residue and contaminants that may have built up in/on them.
5.
Once the filter element and coalescer halves have been cleaned, replace the sealing ring and filter elements. Reassemble the coalescer halves.
6.
Ensure the proper orientation of the coalescer halves in relation to each other. Then, replace the clamp and torque the clamp nut to 6 Nm (4.4 lb.-ft.).
GE Proprietary and Confidential Information
45
GEK-114406D L250 Diesel Engine Maintenance 7.
The coalescer may now be reinstalled on the engine per the procedures in section 12.4., INSTALL COALESCER, in this publication.
13. DATA 13.1.
TORQUE VALUES Table 10. TORQUE VALUES. lb.-ft.
Nm
Bolts, air inlet to compressor casing
40
54
Bolts, air discharge to flange and sleeve
35 to 39
47 to 53
Bolts, diffuser to compressor casing
25 to 30
35 to 40
Bolts, transition piece to turbocharger
45
61
Bolts, shroud to turbine casing
55 to 60
75 to 81
Bolts, turbine–casing clean–out flange
43 to 54
58 to 73
Bolts, turbine casing to compressor casing
30 to 35
41 to 47
Initial
70 to 80
95 to 110
Final
370 to 440
500 to 600
Bolts, turbocharger to saddle bracket
185 to 229
250 to 310
Bolts, turbocharger turbine–casing clean–out cover
25 to 31
34 to 42
Bolts, water flange to turbocharger casing
45 to 50
61 to 68
Bolts, water outlet pipe to engine bracket
55 to 60
75 to 81
Initial
25 to 30
35 to 40
Final
16 to 20
21 to 27
Cap screws, compressor-end seal
7 to 9
10 to 13
Cap screws, turbine-end seal
7 to 9
10 to 13
Initial
100
136
Final
80
108
Nut, turbocharger speed sensor to mounting block
4
5
Nuts, transition section to shroud
25 to 30
35 to 40
Rotor stud to turbine disk assembly
60
81
Bolts and Nuts, turbocharger to turbocharger shelf
Bolts and nuts, nozzle–ring retainer to nose piece
locknut, rotor
46
GE Proprietary and Confidential Information
View more...
Comments
