Maintenance Procedures

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

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Tighten B1, B2, simultaneously sim ultaneously with stated hydraulic pressure.

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

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Tighten the nuts if possible.

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

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Components: 01 Adjusting screw for rocker arm, 02 Counter nut. nut.  Adju  Ad ju st in g th e valve val ve clearanc clear ance e 

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

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

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Hold the adjusting screw and tighten the counter nut. Check that the clearance has not changed while tightening.

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 Adju  Ad ju st in g the th e PCC v alv e clearance clearan ce

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Put a feeler gauge corresponding to the valve clearance between the surface of the valve stem and the adjusting screw (1) at the rocker arm. Tighten the screw until the feeler gauge can be moved to and fro only with slight force.

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Hold the adjusting screw and tighten the counter nut.

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Check that the clearance has not changed while tightening.

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Components: 01 Filter ring, 02 Tension ring, 03 Trap cover, 04 Cover panel, 05 Cover panel, 06 Fleece segment.

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Components: 01 Top cover, 02 O-ring, 03 Filter cover, 04 Fastening plate, 05 O-ring, 06 Spring, 07 Spindle, 08 Upper filter cartridge, cartridge, 09 Spindle, 10 Shim, 11 Lower filter cartridge, cartridge, 12 Filter plate, 13 Spring.

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

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Spare part sets Sealing set

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Components: 01 Filer body, 02 Filter cap cover, 03 Filter insert, 04 Filter basket, 05 Filter mesh with rubber rings, 06 O-ring, 07 Plastic ring, 08 Half pipe, 09 Sealing screw, 10 Magnetic insert.

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System components: 01 O-ring, 02 O-ring, 03 Flange, 04 Screw, 05 Sealing sleeve, 06 Oring, 07 Ignition coil, 08 Spark plug, 09 Gasket ring (Alternative) (Alternative)

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Spare parts: Spark plug with gasket ring, r ing, O-rings.

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Replace Replace spark plug s 

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

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

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Mark the spark plug with the cylinder number to clarify the location for later visual checks. A possible operation malfunction malfunction on a cylinder is often seen on the spark plug.

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Clean Clean and and check the conditi on of the igni tion c oil  Clean and check the condition of the extension if the engine is started/stopped daily or more often.  Clean and check the condition of the ignition coil if the engine is running more or less continuously at 2000 h.  

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 Always  Always replace the gasket ring when when spark plug removed. (Alternative)

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The ignition ignition coil should be replaced by a new coil in the event of malfunction. Replace O-rings.

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

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Clean Clean centrifugal f ilters It is very important to clean the filter regularly as it collects considerable quantities of dirt. If it is found that the f ilter has collected the maximum quantity quantity of dirt (correspond ( corresponds s to a 18 mm thick layer) at the recommended cleaning intervals, it should be cleaned more frequently.

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System components: 01 Main gas filter, 02 Main gas piping, 03 PCC gas piping, 04 Gas manifold,05 Main Main gas admission admission valve, 06 PCC gas channels in Hot-box, 07 PCC gas delivery piping, piping, 08 Main gas ga s venting valve, 09 Actuator for main gas venting valve, 10 PCC gas venting valve, 11 Non-return valve, 12 Gas venting piping.

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Pipe connections:  A 108 Gas inlet, inlet, B 110 PCC gas inlet, C 727 Gas system vent,

D PCC venting gas, E 311 Control air air to main gas venting valve. 

Testing Testing t he gas system for leak leak WARNING!

Release the system pressure before disassembli disassembling ng any connections. If a leak is detected, det ected, shut off the supply of gas immediately. NOTE! Release the air pressure in the t he system before disassembling.

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Disassemble the leaking leaking connection, examine the O-rings and sealing faces. Replace worn parts. Repeat the leak test for the repaired connection(s).

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

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Components: 01 Adjusting screw for rocker arm, 02 Counter nut. nut.  Adju  Ad ju st in g th e valve val ve clearanc clear ance e 

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

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

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Hold the adjusting screw and tighten the counter nut. Check that the clearance has not changed while tightening.

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 Adju  Ad ju st in g the th e PCC v alv e clearance clearan ce

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Put a feeler gauge corresponding to the valve clearance between the surface of the valve stem and the adjusting screw (1) at the rocker arm. Tighten the screw until the feeler gauge can be moved to and fro only with slight force.

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Hold the adjusting screw and tighten the counter nut.

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Check that the clearance has not changed while tightening.

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

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Cleanin Cleanin g of charge air cool ers 

Remove the cooler.

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Look carefully for corrosion. Check for possible leakage.

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Clean the air side of the cooler. Clean the water side of the cooler.

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Replace parts if necessary.

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 Air  Ai r s id e clean c lean ing in g Clean the air side of the cooler by immersing the air cooler in a chemical cleaning bath for at least 24 hours. Use approved cleaning detergents. The best cleaning effect is achieved if the cleaning tank is equipped with perforated pipes. During cleaning, steam or  pressurized air is fed through the pipes. When cleaning is completed, the cooler should be flushed thoroughly with water. NOTE! The use of a high pressure water jet for flushing, should should be avoided because:because:- it will pack the dirt into the middle of the cooler- the cooler fins will be damaged. This This will cause lowered air cooling efficiency.

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

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Components: 01 Measuring unit, 02 Cable, 03 Transducer, 04 Cable holder, I Operating Operating side II Rear side (as seen from flywheel flywheel end)

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Check Check cr ankshaft ankshaft h ot deflection 

Check of deflection, use measurement record.

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The crankshaft deflection measurement is is always done on a thoroughly thor oughly warm warm engine, after the engine is stopped.

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The measurement should be carried out rapidly but carefully. carefully. If mounted on rubber not necessary to perform.

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Only the crankcase cover for the cylinder being measured should be opened and it should be closed immediately after measuring.

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It is recommended to switch switch off of f any forced ventilation close to the engine. NOTE!

During the deflection procedure the crankshaft should be turned in the direction of rotation, only. 

Check Check t hrust bearing bearing axial axial clearance clearance   

Lubricate the bearings by running the pre lubricating pump for a few minutes.  Apply a measure gauge, for instance, against the plane end surface of the flywheel flywheel.. Move the crankshaft by a suitable lever in either direction until contact is established with with the thrust bearing.

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Set the measure gauge at zero.

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Move the crankshaft in the opposite direction, and read the axial clearance from the measure gauge. NOTE!

Repeat the movement of crankshaft to ensure that correct clearance is measured. 22

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System compo nents: 01 Valve cotter, 02 Spring retainer, 03 Spring, 05 Washer,08 Washer ,08 Extension Extens ion piece, 09 Rod, 11 Valve guide, 12 O-ring ,13 Valve, 14 Valve seal, 15 Nozzle, 16 Sealing ring, 17 Sealing ring, 18 Grommet, Gromm et, 19 Spring, 20 Boot. Connections: C Gas from connection channel

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Spare Spare part kit : Spare part kit for ignition coil

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Replace the pr e-chamber nozzle and and O-rin gs

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Protect the bore in the cylinder head. Clean and check the condition of the pre-chamber.

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Replace the pre-chamber nozzle.

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Check the sealing faces on the bottom of the pre-chamber. Renew O-rings, sealing ring of nozzle and bottom sealing ring.

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Pressure test the cylinder head water side after mounting.

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Clean Clean and check th e pre-chamber valve  

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Drain the cooling water system. Remove the pre-chamber. pr e-chamber.

Dismantle and clean the valve and check for wear. Carefully Carefull y clean the valve and the upper body and body and inspect the sealing surfaces.

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The valve should be lapped if needed. The valve and the seat should either be machine grinded or renewed if deep pitting has occurred in the sealing surface. Renew the valve if the measure Y exceeds exceeds 1.5 mm ,

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Renew O-rings and renew parts if necessary.

Maintenance of ignit ion coi l  The spring, boot and grommet of the ignition coil should be replaced according to the maintenance schedule. The ignition ignition coil should be replaced by a new coil in the event of malfunction. 

NOTE!

Removing of the cylinder head before dismantling of t he pre-chamber is recommended. 24

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Connections:  A Air inlet

NOTE!

 A general condition of engine is indicated indicated with with the test device, but more important important is the operation data records. The overhauls must be made according to recommended overhaul intervals and not only when The pressure test shows a big blow-by. blow-by. 

Check Check cyl inder tightness (valves, piston rings) w ith a pneumatic test. 

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

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

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If the pressure from the beginning was 6 bar and it takes more than 10 sec. for the pressure to drop to 0.5 bar, the result is acceptable.

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If the pressure drops directly to 0 bar, it is possible that one or more valves are sticking sticking or the valve(s) are burnt. Carbon particles particles trapped between the valve and the seat causing a dir ect pressure drop.

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Blow-by Blow-by between bet ween the cylinder liner and piston could be noticed from fast f ast fouling of filters or high crankcase pressure.  Always  Always replace the gasket ring when when spark plug removed. (Alternative)

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Components: 01 End flange, 05 O-ring, 06 Retaining ring, 08 Tube stack, 0 9 Cooler housing, 10 O-ring

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Spare part part sets

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Sealing set for lube oil module

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Remove lubricating lubricating oil module.

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Dismantle the oil cooler.

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Clean Clean oil si de of tu be stack. 

Due to the design, des ign, the tube stack cannot be cleaned mechanically on the outside. out side. Slight Slight fouling can be removed by blowing blowing steam through the tube stack.

If the amount of dirt is considerable, use chemical cleaning cleaning solutions available on the market. Clean Clean water side of tube stack. 

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If the deposits are soft, tubes can be cleaned mechanically. mechanically. Use special nylon brushes.

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The cleaning should be carried out without without causing ca using damage to the natural na tural protective layer on the tubes.

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

Cleaning the cooler hydraulically 

Spray water water to the inner surface of the tubes until the deposits are removed.

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Spray water water to the outer surface of the tubes using a 3 mm diameter nozzle. Apply 120 bar pressure at 2 m distance from the fin surface. The water jet has to attack the surface sur face of tubes in vertical direction, parallel to the fins.

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Clean oil and water sides of the module.

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Clean and inspect thermostatic valves.

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Test the cooler by hydraulic pressure.

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Components: 03 Positioner; 031 Pilot Pilot valve in positioner, 032 Lever, 033 Cam, 034  Adjusting screw, 035 Adjusting Adjusting screw

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Connections:  A Control air from external system, system, B Connections to and from actuator, C Control air from I/P converter 

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Spare part part sets

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Pilot Pilot valve v alve

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Spare part kit Diaphragm, complete

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Check Check the functio n of air thrott le valve and actuator  1. Check of wear of the waste gate system. actu ator and the positioner.  Check for wear of the key connection between the actuator wear inside actuator actuato r by moving the shaft.  Check for possible wear

2. Change of positioner pilot valve. Pay attention to the pilot valve stem and the lever (13 ), remove the pilot valve  carefully. Replace the positioner pilot valve.    Adjust the wastegate positioner. Calibrate the wastegate I/P converter.   Check the function of the valve by following following the positioners movement when when the t he engine is re-started and runs on load.

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

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Spare part part sets Sealing set

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Spare part part sets

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Sealing set

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Replace Replace lubricating oil filt er candles candles  Check filter and connections for leaks.  Drain the filter housing.  Remove entire filter element.  Clean the parts and check the overflow valves. Replace worn parts if necessary.  Clean the wire gauze.  Replace the O-rings and seals.  Replace the filter candles.  Check the ease of movement of the worm gear unit, the turbine including gear with flushing arm.

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Components: 01 Pressure regulating valve, valv e, 02 Driving Driv ing spindle, 03 Idler spindle, 04 Gasket, 05 Ball bearing, 06 Circlip, 07 Circlip, 08 08 non-return non-return valve, 09 Gasket.

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Connections: A Connections: A Suction connection, connection, B Pressure connection, connection, C Pressure from pre-lubricating pre-lubricating oil pump.

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Spare part part sets

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Sealing set

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

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Spare part part sets

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Sealing set

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Components: 01 Driving Driv ing gear, 02 Driven Driv en gear, 03 Shaft seal, 04 04 Retaining ring, 05 Bearing bush,

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6 Pin, 07 O-ring, 08 Screw, 09 Key. Connections: A Connections: A Pressure connec connection, tion, B Suction connection. connection.

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Spare part part sets

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Sealing set

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Components: 01 Cartridge Cartridg e group, 02 Gas inlet casing, 03 Nozzle ring, 04 Gas outlet casing, 05 Turbine diffuser, diffuser , 06 Foot, 07 Compressor Compr essor casing, external part, 08 Compressor Compr essor casing, internal part, 09 Wall insert, 10 Diffuser.

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Components: 01 Cartridge Cartridg e group, 02 Gas inlet casing, 03 Nozzle ring, 04 Gas outlet casing, 05 Turbine diffuser, diffuser , 06 Foot, 07 Compressor Compr essor casing, external part, 08 Compressor Compr essor casing, internal part, 09 Wall insert, 10 Diffuser.

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Inspect Inspect camshaft bearings. 

Replace bearings if necessary.

1. Remove camshaft bearing journal. 2. Measure inner diameter of bearing bush. 

Measure three diameters diameters in a position 120° from each other. The average diameter diameter to be compared with with wear limit. The wear limit is stated in chapter clearance and wear limits.

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If the wear limit for one camshaft bearing bush is reached, all camshaft bearing bushes should be replaced.

3. For visual inspection of the camshaft bear ing bush has the camshaft piece and bearing  journal to be removed.

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

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Inspect in termediate gears gears  An early detection detection of any any tooth damage can prevent serious damage. Checking intermediate, camshaft gears and other parts condition.

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Replace Replace connectin connectin g rod screws  Replace connecting rod screws by new ones at every second overhaul when doing piston overhauls at 16 000 h intervals and at every overhaul when doing piston overhauls at longer intervals than 16 000 h. The nuts for the connecting rod screws do not need changing, unless they appear damage.  Clean and examine the nuts carefully at every overhaul

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

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Replace big end b earin earin gs Replace big end bearings.   Inspect mating surfaces.  Measure the big end bore, use measurement record.  When measuring, measuring, upper and lower screws must be b e tightened to the stated pressure.

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Inspect the small end bearings  Inspect the small end bearings clearance by measuring the gudgeon pin diameter and small end bearing bores separately.  Replace if necessary.

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Tools:

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Hydraulic tools Turning tool of main bearing

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Inspect main bearings.

1. Dismantle side screws and m ain bearing nuts. 2. Lower the main bearing cap by hydraulic jack. 3. Remove the lower bearing shell. 4. Insert the turning tool into the main bearing journal radial oil hole. 5. Turn the crankshaft carefully until the bearing shell has has turned 180° and can be removed. Remove turning tool. 

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

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

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No scraping or other damage of bearing shells, caps and saddles is allowed. Burrs should be locally removed, only.

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

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Spare part part sets

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Sealing set for cylinder head replacement Sealing set for cylinder head overhaul

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Overhaul of cyl inder head Pressure test cylinder head water side.   Dismantle and clean the underside,  Dismantle, clean and check condition of inlet and exhaust valves and ports.  Inspect cooling spaces and clean, if necessary.  Grind the valves and seat rings.  Inspect the valve rotators.  Check rocker arms. Pressure test cylinder head water side.   Replace the O-rings in the valve guides.  Replace the O-rings at bottom of cylinder head screws at every overhaul.  Fill cylinder head screw pocket with engine oil.

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Tools

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Honing equipment

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Replace Replacement ment co mpon ents

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 Anti-polishing  Anti-polishing ring

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Inspect Inspect t he cylinder lin ers  Always hone the cylinder cylinder liner liner when new piston rings are are mounted. mounted. Normally a light honing is sufficient. If the honing is done when the cylinder liner is on its place in the engine block, the crankshaft under the cylinder cylinder liner concerned must be covered by plastic film. film . Honing rests must be prevented from falling into the oil sump of the engine.

Inspect Inspect t he cylinder lin ers 1. Measure the cylinder liner diameter using measurement record. 2. Replace liner if wear limits are exceeded. 

3. Hone the liners.    

The honing is to be carried out by means of Plateau honing. Only ceramic hones with w ith a coarseness of 80 and 400 should shoul d be used. The pitch angle of the honing lines in the cross hatch pattern should be about 30°.  As coolant coolant a honing honing oil is preferred. preferred.

When honing the liner fitted to the engine the used honing oil must be directed from the engine with e.g. a tarpaulin or similar. The honing time depends on the condition of the bore surface. Usually only a few minutes'  honing is required. 4.  After honing, honing, clean bore carefully. carefully. 5. Check the cylinder liner diameter. 

6. Clean the cylinder liner cooling bores. 7. Renew the anti-polishing ring after piston mounting.

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System compo nents: 01 Gas manifold, manifold, 02 Bellow, 03 Main gas admission admission valve, 04 Safety filter, 05 O-ring

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Pipe connections : A Gas supply, supply, B Charge air , C Exhaust Exhaust gas.

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Replace the main gas admis sio n valves  Check that the gas supply valves are closed, the gas ventilation valve is in open position and gas pressure is drained out from the gas lines.  Dismantle flexible pipe connection. connection.  Disconnect Disconnect the cable of admission valve and remove the gas admission valve.  Replace the main gas admission valve with new one.  Replace O-rings with new ones.

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Clean Clean the main gas admission valve filter insert  Clean the main gas admission valve filter insert.  Replace if needed.  Replace O-ring with new ones.

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System compo nents: 01 Main gas filter, 02 Main gas piping, 03 PCC gas piping, 04 Gas manifold, 05 Main gas admission valve, 06 PCC gas channels in Hot-box, 07 PCC gas delivery piping, 08 Main gas venting valve, 09 Actuator for main gas venting valve, 10 PCC gas venting valve, valv e, 11 Non-return valve, 12 Gas venting venting piping. piping.

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Pipe connections : A 108 Gas Gas inlet, inlet, B 110 PCC gas inlet, C 727 Gas system system vent, D PCC venting venting gas, E 311 Control air to main gas venting valve

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Test Test ing the gas syst em for leak 

Connect compressed air/nitrogen, of 3 bar to the inlet flange of the gas system on the engine. Check all connections with soap water or leakage spray, beginning from the inlet flange and continuing through the gas line.

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Growing bubbles on the connection indicates leakage.

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NOTE! Release the air pressure in the system before disassembling. 

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Disassemble the leaking connection, examine the O-rings and sealing faces. Replace worn parts. Repeat the leak test for the repaired connection(s).

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

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Inspection Inspection of t he piston crown  Clean all the parts and all spaces carefully. Inspect combustion space for corrosion and/or b urning marks.   Check a deposit layers thickness in the cooling spaces.  Inspect all surfaces by crack detection test.  No cracks are allowed.  Measure the distance between the inner and outer support surfaces, see measurement record. Check the height of the ring grooves, use measuring record.   Replace complete set of piston rings. Note the running-in programme. The piston assembly must be dismantled for inspection of mating surfaces between piston skirt and piston crown and for inspection and cleaning of cooling oil spaces. Visual Visual inspectio n 



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



If marks deeper than 2 mm are found the piston crown should be replaced. Check a deposit layers thickness in the cooling spaces.

Deposits in the cooling oil space thicker than 0.5 mm is an indication of contaminated lubricating oil. Such extensive deposit layers can cause overheating of the piston crown. Crack Crack d etection etection test 



 A crack detection test by use use of liquid liquid penetrant penetrant or, preferably, magnetic particle detection method should be performed, comprising all surfaces.

No cracks are allowed. Measurements 



 

 Assessment of wear of the support surfaces to be made by measurement of the distance distance between the inner and outer support surfaces, see measurement record. Check the height of the ring grooves, use measuring record. Replace complete set of piston rings. Note the running-in programme.

NOTE! No repair welding is allowed. 48

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Inspection of the piston skirt Clean all the parts and all spaces carefully. Consequently cleaning with use of emery cloth or other abrasives is not allowed.   Inspect running surface for wear marks and/or scoring/seizure marks.  Inspect entire entire piston skirt by crack detection test. test.  Indications exceeding of normal “defects” 5 mm in length should be examined more in detail.  If a crack is confirmed, the piston skirt must be replaced with a new or reconditioned one. Measure the distance between the inner and outer support surfaces, see measurement record.   Check the retainer rings of the gudgeon pins. Visual Visual inspectio n  Inspect running surface for wear marks and/or scoring/seizure marks. The running surface of the skirt is coated with a graphite-phosphate layer. Consequently cleaning with use of emery cloth or other abrasives is not allowed. Excessive wear marks and/or scoring/seizure marks on the running surface may require replacement  of the skirt. Crack Crack d etection etection test  Crack detection test of the entire piston skirt with use of liquid penetrant must be made. Special attention must in this regard be given to the upper part of the piston skirt and to the gudgeon pin bore with its supports to the upper part and to the circumferential part part of the skirt, piston skirts are cast pieces a crack detection detection test may also also give indications indications for surface "defects" "defects"   As piston which are normal in castings. Indications exceeding 5 mm in length should be examined more in detail.  If a crack is confirmed, the piston skirt must be replaced with a new or reconditioned one. Measurement   Assessment of wear of the support surfaces to be made by measurement of the distance distance between the inner and outer support surfaces, see measurement record.  Check the retainer rings of the gudgeon pins. 

 

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 Ass  As s emb li ng of p is to ns If the inspections are resulting in a conclusion that a piston can be reused the same pair of crown and skirt must be assembled together again .

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



Spare part k it Spare part kit for valve tappet



Check Check valve mechanism mechanism parts. 1. Dismantle and inspect valve mechanism parts 





Clean the rocker arm bore and the shaft (01) and measure for wear. When cleaning, pay special attention to the oil holes. Clean and inspect all parts of the valve tappets. When cleaning, pay special attention to the oil holes.



Measure the valve tappet boring and the tappet (02) as well as the tappet roller (03) for wear. Clean the pre-chamber valve tappet and inspect for wear.

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

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2.  Assembling of valve mechanism 3. Check the valve clearances

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Replace int ermediate gear gear bearings  Measure tooth backlash and bearing clearances.  Check gears for damages.  Remove camshaft gear w heels.  Remove intermediate gear wheels. 

Check and clean trust bearing and parts.



Change bearings if necessary.

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