Cat Engine Type GCM34 operating instructions Manual – PDF DOWNLOAD
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Cat Engine Type GCM34 operating instructions Manual – PDF DOWNLOADCat Engine Type GCM34 operating instructions Manual – PDF DOWNLOAD
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Cat Engine Type GCM34 operating instructions Manual – PDF DOWNLOAD
Introduction :
The present operating instructions include notes and guidelines for proper handling of the engine plant. It is matched with the equipment condition and the type of fuel sold.
With regard to operation and maintenance of the engine including the necessary work to be carried out, the operating instructions are subdivided into the following chapters:
With the respective information contained in the individual chapters, the technical personnel is able to maintain the engine in such a manner that regarding its output, reliability, economy and service life optimum operating results can be achieved. If you need further information or if you have any other questions, we kindly ask you to contact our department service technology.
The operating instructions do not release the personnel in charge of this engine plant from their duty to take care. The recognized rules of technology are to be observed, taking into account overriding regulations, observance of the general safety measures and locally applicable accident prevention regulations.
Data or explanations assumed to be the basic knowledge of trained technical and engine room personnel, are not contained. Caterpillar is not responsible for damage caused by improper operation and maintenance.
TABLE OF CONTENTS:
Cat Engine Type GCM34 operating instructions Manual – PDF DOWNLOAD
Initial operation........................................................................................................... 18
Operational supervision..................................................................................................... 39
Removal from operation...................................................................................................... 42
Danger of frost............................................................................................................. 43
The following measures are to be implemented after a light or heavy preservation........................................ 49
Running-in.................................................................................................................. 51
Fault tracing............................................................................................................... 52
Emergency operation......................................................................................................... 54
Regulations and care........................................................................................................ 59
• Suitable fresh water.................................................................................................. 65
• effective corrosion inhibiting agent.................................................................................. 65
- corrosion inhibiting oil, soluble..................................................................................... 65
- chemical corrosion inhibiting agent (chemicals)....................................................................... 65
• exact dosing of the corrosion inhibiting agent........................................................................ 65
1. Treatment of cooling water with corrosion inhibitors............................................................. 67
1. Adjust valve bridge.............................................................................................. 92
1.1 Establish air supply to the turning device.................................................................. 92
1.2 Remove cylinder cover hoods without damaging the gaskets.................................................... 92
1.3 Turn the crankshaft until the piston of the cylinder to be adjusted comes into the ignition d............... 92
1.4 Adjust sufficient clearance "S" (approx. 2 mm) between rocker arm (Fig. 1/1) and valve bridge............... 93
1.5 Loosen counternut (Fig. 2/3) and unscrew adjusting screw (4). Press down valve bridge until i............... 93
1.6 In this position screw in adjusting screw(4) at "Y"........................................................ 93
1.7 Counter adjusting screw (4)................................................................................. 93
2. Adjust valve clearance........................................................................................... 93
2.1 Measure the clearance (Fig. 1/S) with a feeler gauge. Thereby press the pushrod down........................ 93
2.2 Correct clearance "S"....................................................................................... 93
2.2.1 Loosen counternut..................................................................................... 93
2.2.2 Turn the valve adjusting screw (2) until the stipulated clearance has been attained................... 93
2.2.3 Tighten the counternut in order to fix the position of the adjusting screw............................ 93
2.2.4 Check clearance again after countering................................................................ 93
2.2.5 Interrupt air supply to the turning device............................................................ 93
1. Disassembly.................................................................................................. 94
1.1 Establish air supply to the turning device.............................................................. 94
1.2 Dismount the cylinder head cover........................................................................ 94
1.3 Turn piston to TDC. Inlet and exhaust valves are closed, rocker arms are unloaded. It must be........... 94
1.4 Remove fastening nuts (1)............................................................................... 94
1.5 Remove rocker arm bracket (3) with rocker arm shaft (2) and inlet and exhaust valve rocker.............. 94
2. Reassembly................................................................................................... 94
2.1 Clean the supporting surfaces of the rocker arm bracket (3)............................................. 94
2.2 Blow through oil overflow holes with compressed air..................................................... 94
2.3 Place rocker arm bracket (3) with rocker arm shaft (2) and rocker arms by means of stud bolts........... 94
2.4 Apply a thin film of Molykote paste "G-Rapid Plus" to thread and nut contact face and tighten........... 95
2.5 Adjust valve clearance (01.01.01.nn).................................................................... 95
2.6 Check the oil flow...................................................................................... 95
2.7 Interrupt air supply to the turning device.............................................................. 95
2.8 Mount cylinder head cover (check gasket!)............................................................... 95
1. Disassembly...................................................................................................... 96
1.1 Remove securing rings (Fig. 1/4) and thrust washers (5) from the rocker arm shaft (3)....................... 96
1.2 Remove the intake valve rocker arm (1) and the exhaust valve rocker arm (2) from the rocker a............... 96
2. Clean all parts and check for damage. Blow out oil bores with compressed air and check to ensu................... 96
3. Check the bearing surfaces of the ball pin (Fig. 2/10) and the adjusting screw (12) for wear a................... 97
4. Measure the rocker arm bush (Fig.2/ 13) and shaft (Fig. 1/3) and replace the bush when the c................... 97
5. Assembly......................................................................................................... 97
5.1 Oil the contact surfaces of the intake (Fig. 1/1) and exhaust rocker arms (2) and the rocker ............... 97
5.2 Reinstall the rocker arm bracket and rocker arms on the cylinder cover (01.02.01.nn) and chec............... 97
1. Measure the rocker arm bush (1) and (01.02.02.nn)................................................................ 98
2. Replace.......................................................................................................... 98
2.1 Drive out the bush (1) with the proper copper punch (W1).................................................... 98
2.2 Oil the new bush lightly and press into rocker arm.......................................................... 98
1. Replacement of oil scraper rings (O-rings)....................................................................... 99
1.1 Dismount valve cone, clean stem thoroughly.................................................................. 99
1.2 Remove the O-ring (1) from the groove with a sharp-angled wire.............................................. 99
1.3 Clean groove................................................................................................ 99
1.4 Lubricate new O-ring slightly and carefully place in groove. The ring must not be twisted in ............... 99
2. Measurement of the valve guide clearance.........................................................................100
2.1 Measure the outside diameter of the valve stem in the guide zone of the bush................................100
2.2 Measure the inside diameter of the guide bush in traverse direction of the engine...........................100
2.3.............................................................................................................100
3. Replacement of the valve guide...................................................................................100
1. Turn the respective piston to ignition TDC, remove the cylinder head cover.......................................101
2. Drain the coolant: Close the shut-off valves for the corresponding coolant supply lines and op...................101
3. Open the screw plug (Fig. 1/3) of the respective coolant distributor housing, drain the remain...................102
4. Remove the main fuel line (1) with the manifold (2) of the respective cylinder head..............................102
5. Remove the ignition fuel line (4)................................................................................102
6. Remove the connection and sensor plugs (ignition sensor (5), fuel valve plug (SOGAV) (5), etc.)..................102
7. Remove the rocker arm lubrication line (7).......................................................................102
8. Remove the shroud between the exhaust line (8) and the cylinder head. Loosen the exhaust line ...................102
9. Loosen the six cylinder head nuts with the hydraulic clamping elements...........................................103
9.1 Slide the hydraulic clamping elements (Fig. 2/W3) with the support rings (W5) and tapped bush...............103
9.2 Screw the tapped bush (W6) onto the cylinder head bolt (11) until the base ...............103
9.3 Slide the hydraulic clamping elements (Fig. 2/W3) with the support rings (W7) and tapped bush...............103
9.4 Screw the tapped bush (W8) onto the cylinder head bolt (11) until the base ...............103
9.5 Connect the hydraulic clamping element (Fig. 4/W3) and distributor (W4) to the high-pressure ...............103
9.6 Close the valve (Z) on the high-pressure pump (W1) and apply pressure gradually to all 6 cyli...............104
9.7 Depressurize the clamping elements, remove the hydraulic clamping elements and remove the rou...............104
9.8 Mount the cylinder head lifting rig (Fig. 5/W10) and attach to the crane....................................105
9.9 Lift the cylinder head slowly with the crane, moving the crane as needed. Watch the valve lif...............105
9.10 Place the cylinder head on a wood surface and secure if necessary..........................................105
1. Disassembly......................................................................................................106
1.1 Dismantle cylinder head (01.06.01.nn).......................................................................106
1.2 Dismantle rocker arm (01.02.01.nn) and lift valve bridge....................................................106
1.3 Screw off clamping sleeve (5) by hand until it can be placed on valve stem (9)..............................107
1.4 Screw down by hand clamping sleeve (5)......................................................................107
1.5 Coat the contact surface (X) of the valve spring clamping device (W1) with „G-Rapid Plus“Moly...............107
1.6 Place valve spring clamping device (W1) on spring plate (2) and with the clamping screw (6) f...............107
1.7 Compress valve spring (3) and remove cone clamp halves (4). Carefully unload valve spring (3)...............107
1.8 Lift off valve spring clamping device (W1), spring plate (2), valve spring (3) as well as the...............107
1.9 Pull valve cone out of cylinder head........................................................................107
2. Reassembly.......................................................................................................107
2.1 Check valve guide clearance, renew O-rings (01.05.01.nn)....................................................107
2.2 Lubricate burr-free valve stem before fitting and put in valve cone screwing so that the O-ri...............107
2.3 The re-assembly is effected in a reverse dismantling sequence...............................................107
2.4 After putting in the cone clamp halves, slowly unload the valve springs and make sure that th...............107
1. Checking of condition........................................................................................108
1.1 Valves may be reused without refinishing when...........................................................108
1.2 The valves cannot be reused in the following cases......................................................109
2. Cleaning.....................................................................................................110
3. Repairing (refinishing of the sealing surface)...............................................................110
3.1 Regrind sealing surface in accordance with the prescribed angle (Fig. 3). Do not refinish exi...........110
3.2 The appropriate information of the grinding machine manufacturer is to be observed when grind...........110
3.3 The dimension between the visible edge of the base metal arm ring "X" and the outer edge of t...........110
3.4 Outer edge rounded with stone...........................................................................110
4. Maintenance (Checking contact reflexion/grinding)............................................................111
4.1 Apply small dots of diamond paste Dp30/10 - 15 µm with a syringe to the fitting surface of t...........111
4.2 Insert the lubricated valve stem into the guide. Fasten the device (Fig. 5/W1) to the valve h...........111
4.3 When the contact reflexion is poor, the valve must not be reground anymore, however, both sea...........112
4.4 Ensure that the components (valve cone and seat ring) refaced to one another stay together..............112
5. Final check..................................................................................................112
5.1 Ensure that the refinishing limits are maintained.......................................................112
5.2 Clean valve cone/seat thoroughly and check the sealing surfaces with an illuminated magnifyin...........112
1. Checking of condition........................................................................................114
1.1 The valve seat rings are re-usable without refinishing when.............................................115
1.2 The valve seat rings are not re-usable when.............................................................115
2. Cleaning.....................................................................................................115
3. Maintenance (refinishing of valve seat rings)................................................................115
3.1 Remilling of the valve seat.............................................................................115
3.1.1 Clean the valve seat ring thoroughly in the contact area (3) of the centering disk (4) in o.......115
3.1.2 Insert centering disk (4) with guide mandrel (5) and tighten with star handle (6).................115
3.1.3 Place cutter head (Fig. 6/2) on greased guide mandrel, screw in knurled screw(1) until res.......116
3.1.4 Rotate valve seat clockwise uniformly and slowly and remill the seat in one operation pass........116
3.1.5 Prior to finishing the cutting process, slowly unscrew the knurled screw (1), at the same t.......116
3.1.6 Maximum permissible dimension Ø (x) for refinishing (Fig. 7):.....................................116
3.1.7 When the milling cutters are blunt, the cutter head is to be sent to Caterpillar for refini.......117
3.1.8 Dismount the milling device. Grind sharp edges with fine emery cloth..............................117
4. Checking of contact reflexion/grinding.......................................................................117
4.1 Apply small dots of diamond paste Dp 30/10 - 15 µm with a syringe to the seat face of the new...........117
4.2 Insert the lubricated valve stem into the guide bush. Fasten the device (W1) (01.08.01.nn) to...........117
4.3 When the contact reflexion is poor, the valve must not be reground anymore, however, both sea...........117
4.4 Ensure that the components (valve cone and seat ring) reface to one another stay together...............117
5. Final check..................................................................................................117
5.1 Check whether the refinishing limit dimensions are observed.............................................117
1. Cut off the unusable valve cone at the shaft end (Fig. 1/1) and bevel the resulting cutting su...............118
2. Insert the valve cone into the valve seat ring and hold in the shown position. Connect cone an...............118
3. Drive the valve seat ring out by striking the valve spindle forcefully. Clean the bore where t...............118
4. Shrink the new seat ring in..................................................................................118
4.1 Cool the seat ring to at least -20 C, heat the cylinder head to 130 C.................................118
4.2 Carefully insert the seat ring with the help of a valve cone to the bottom of the cylinder he...........119
5. Slightly refinish the seat ring, e.g. with valve seat grinding machine or valve seat milling m...............119
6. Fit valve cone...............................................................................................119
1. Check the gasket between the cylinder head, cylinder liner and cooling water distributor housi...............120
2. Check cylinder head externally for leakage...................................................................120
2.1 In case of lubeoil leakage, check the retaining screws of the cylinder head cover for tightne...........120
1. Wash the cylinder head with a cold cleaner.......................................................................121
2. Clean the inlet and outlet ports and the cylinder head underside (not the valve seats!) of car...................121
3. Clean cooling water inlet ports and cooling water outlet.........................................................121
4. Check underside of cylinder head, especially at the valve webs, for cracks.......................................121
5. Clean the sealing surface for the gas valve and prechamber.......................................................121
1. Turn piston to ignition TDC......................................................................................122
2. Clean the sealing and contact surfaces of the cylinder head and cylinder liner thoroughly and ...................122
3. Replace the following O-rings: upper O-ring on the cylinder liner collar (Fig. 1/2), between t...................123
4. Lower the cylinder head carefully with the cylinder head lifting rig (W10). Move the crane as ...................124
5. Lower the cylinder head further, align on the cylinder dowel pin (Fig. 1/6) and set onto coola...................124
5.1 Install the exhaust line clamp and hook the chain links (06.01.01.nn). Apply high temperature...............124
6. Tighten the six cylinder head bolts at the same time with the hydraulic clamping unit............................124
6.1 Mount the hydraulic clamping elements (Fig. 2/W3) with the support rings (W5/ W7) into place ...............124
6.2 Slide the hydraulic clamping elements (Fig. 2/W3) with the support rings (W5,W7) over the rou...............125
6.3 Screw the tapped bushes (W6,W8) onto the cylinder head bolts (11) hand tight................................125
6.4 Connect the hydraulic clamping elements (Fig. 4/W3) and the distributor to the high-pressure ...............125
6.5 Close the valve (Z) on the high-pressure pump and gradually apply force to all 6 cylinder hea...............125
6.6 Tighten the round nuts (Fig. 3/12) with a pin (W9). Make sure that the nuts can be turned eas...............125
6.7 Make sure that the round nuts seat properly.................................................................125
6.8 Open the valve (Fig. 4/Z) on the high-pressure pump to depressurize the clamping elements...................125
7. Wait until the pressure drops completely, remove the tapped bushes (Fig. 3/W6,W8) and remove t...................126
8. Tighten the exhaust line clamp. The clamp is locked into place by means of the locking screw i...................126
9. Reinstall the connecting flange with a new gasket. Make sure that the dowel pins are seated co...................126
9.1 Close the screw plug on the coolant distributor ring........................................................126
9.2 Close the shut-off valves in the drain lines, open the shut-off valves in the coolant supply ...............126
9.3 Fill the engine coolant system (with permanent venting) completely..........................................126
10. Set the valve clearance (01.01.01.nn), install the cylinder head cover and the pump cover.......................126
11. Check all connections for leaks after starting the engine.......................................................126
1. Removal:.....................................................................................................127
1.1 Remove the ignition wire (1)............................................................................127
1.2 Remove the ignition coil (3) mounting bolts (2).........................................................127
1.3 Remove the ignition coil (3) with the spark plug extension (4) from the pre-chamber (5).................127
1.4 Place the installation and removal tool (W1) onto the spark plug (6) and screw out......................127
2. Inspection:..................................................................................................128
2.1 Visually inspect the plug for cracks or damage to the ceramic insulator, the threading or the...........128
2.2 Check the electrode gap with the feeler gauge set (W3). Electrode gap: 0.29 +/- 0.04 mm.................128
3. Installation:................................................................................................129
3.1 Place the spark plug (6) onto the removal tool (1) and slide carefully into the pre-chamber (5).........129
3.2 Place the torque wrench (W2) onto the removal tool (W1) and tighten the spark plug (6) to : M...........129
3.3 Place the ignition coil (3) with the spark plug extension (4) into the cylinder head (5)................129
3.4 Screw the mounting bolts (2) into place.................................................................129
3.5 Attach and secure the ignition wire (1).................................................................129
1. Removal:.....................................................................................................130
1.1 Remove the combustion sensor wire (1)...................................................................130
1.2 Remove the connecting piece (2) with O-ring (3).........................................................130
1.3 Remove the spark plug extension (4) with both spacer washers (5)........................................130
1.4 Place the installation and removal tool (W1) onto the combustion sensor (6) and screw out...............130
2. Installation:............................................................................................................131
2.1 Slide the new combustion sensor (6) into the combustion sensor bore carefully with the instal.......................131
2.2 Place the torque wrench (W2) onto the removal tool (W1) and tighten the combustion sensor (6).......................131
2.3 Slide the spark plug extension (4) with both spacer washers (5) onto the combustion sensor (6.......................131
2.4 Install the connecting piece (2) with O-ring (3), making sure that the O-ring (3) seats prope.......................131
2.5 Tighten the connecting piece (2) to M = 35 Nm.......................................................................131
2.6 Attach and secure the combustion sensor wire (1)....................................................................131
1. Remove the spark plug (A5.05.01.15.01.00)............................................................................132
2. Remove the valve cover...............................................................................................132
3. Remove the pre-chamber valve (A5.05.01.22.01.00).....................................................................132
4. Drain the coolant: Close the shut-off valves for the corresponding coolant supply lines and op.......................132
5. Open the screw plug (Fig. 1/1) of the respective coolant distributor housing, drain the remain.......................132
6. Removal:.............................................................................................................133
6.1 Remove the sleeve nuts (Fig. 2/2) and remove the resilient sleeves (3)..........................................133
6.2 Position the installation and removal rig (W1) and screw both threaded rods (4) into the pre-...................133
6.3 Connect the installation and removal rig (W1) to the crane......................................................133
6.4 Lift the pre-chamber (5) slowly with the crane, moving the crane as required....................................133
6.5 Lower the pre-chamber (5) carefully and remove the installation and removal rig (W1)............................133
6.6 Remove the cylinder bolts (7) and remove the lower pre-chamber section (8)......................................133
6.7 Remove the O-rings (9/10/11/12) and seal (13)...................................................................133
6.8 Clean the injector housing (14) thoroughly......................................................................134
7. Installation:........................................................................................................134
7.1 Apply a light coat of Vaseline to the new O-rings (9/10/11/12) and insert without twisting......................134
7.2 Place the lower pre-chamber section (8) onto the injector housing (14). Apply a light coat of...................134
7.3 Apply „Dag S 5080“ to the seal (13) and install on the lower pre-chamber section................................134
7.4 Slide the installation and removal rig (W1) into the pre-chamber (5) and connect to the crane...................134
7.5 Place the pre-chamber (5) into the cylinder head (6)............................................................134
7.6 Slide the resilient sleeves (3) onto the stud bolts (15) and tighten the sleeve nuts (2) even...................134
8. Install the pre-chamber valve (A5.05.01.22.01.00)....................................................................134
9. Install and secure the cylinder head cover...........................................................................134
10. Install the spark plug (A5.05.01.15.01.00)..........................................................................134
11. Close the drain plug (1)............................................................................................134
12. Open the shut-off valves of the respective coolant supply lines and close the shut-off valves.......................134
1. Removal:.............................................................................................................135
1.1 Remove the ignition wire (1)....................................................................................135
1.2 Remove the ignition coil (3) mounting bolts (2).................................................................135
1.3 Remove the ignition coil (3) with the spark plug extension (4) from the pre-chamber (5) (or c...................135
1.4 Screw the spark plug extension (4) out of the ignition coil (3).................................................135
2. Installation:........................................................................................................136
2.1 Screw the spark plug extension (4) into the new ignition coil (3) hand tight....................................136
2.2 Place the ignition coil (3) with the spark plug extension (4) into the pre-chamber (5) (or cy...................136
2.3 Screw the ignition coil (3) mounting bolts (2) into place.......................................................136
2.4 Attach and secure the ignition wire (1).........................................................................136
1. Establish air supply to the turning device...........................................................................137
2. Open the crank case cover approximately 10 minutes after engine shutdown.............................................137
3. Touch the crankshaft and connecting rod bearings to see whether they are of uniform and normal.......................137
4. Check all screws and nuts for locking................................................................................137
5. Check the degree of fouling in the crankcase (sludge, corrosion, bearing metal deposits), loos.......................137
6. Check the appearance of the cylinder liner surface. Check the lubeoil flow and oil outlet at t.......................137
7. Remove camshaft cover. Check the screws of the camshaft section pieces and the lower valve dri.......................137
7.1 Turn engine and check the running surfaces of the camshafts and rollers. Replace defective ca...................137
7.2 Check lubeoil flow for camshaft bearings and valve drive........................................................137
8. Check wheel drive (04.08.01.nn)......................................................................................137
9. Check the sump and crankcase for left behind tools, rags etc. Check the seals of all crankcase.......................137
1. Turn the crank pin from bottom dead center in the direction of the exhaust side so that the me...................139
2. Set the pointer to the scale value 20 on the measuring gauge: 1st measuring point (initial pos...................139
3. Turn the crankshaft, so that the crank pin turns in the direction of the exhaust side and the ...................139
4. Watch the gauge continuously and read the values at the measuring points2 -5 . If a ...................139
1. Remove piston (02.06.01.nn)..........................................................................................149
2. Turn the connecting rod, the round nuts (Fig. 1/2) must be freely accessible.........................................149
3. Loosen the round nuts (2) with the hydraulic rig.....................................................................149
3.1 Place the hydraulic clamping elements (W3) over the round nuts (2) with the support rings. En...................149
3.2 Screw the tapped bushes (W5) onto the connecting rod bolts (1) securely and then loosen one 3...................149
3.3 Connect the hydraulic clamping elements (Fig. 2/W3) and the distributor (W7) to the high- pre...................150
4. Close the valve (Fig. 2/6) on the high-pressure pump (W1) gradually apply pressure to both con.......................150
5. Loosen the round nuts (Fig. 1/2) with the pin (W6). Turn the round nuts back at least 8 holes........................150
6. Open the valve (Fig. 2/6) on the high-pressure pump (W1) to depressurize the clamping elements.......................151
7. Allow the hydraulic rig (W3, W4, W5 and W7) to depressurize completely and dismantle.................................151
8. Turn the connecting rod (Fig. 3/10) horizontal with the connecting rod shank towards the middl.......................151
9. Install the suspension rig (Fig. 3/25) with spacers (26) and suspension (20).........................................151
10. Place the slide rail (Fig. 3/22) with the draw spindles (21) into the crankcase, lift and pla.......................152
11. Align the slide rail (22) with the draw spindles (21). It must lie flat on the connecting rod.......................152
12. Install the stopper (24) and bolt the connecting rod to the stopper.................................................152
13. Remove the piston rod clamping rings (W9)...........................................................................152
14. Remove the round nuts (2) and pull the big-end bearing cap (11) approx. 160 mm from the bearing.....................152
15. Remove the lower big-end bearing shell (12) from the crank journal..................................................152
16. Loosen the lateral stopper bolts (23) so that the stopper can slide in the elongated holes..........................152
17. Pull the connecting rod (10) approx. 60 mm from the bearing.........................................................152
18. Turn the upper big-end bearing shell (13) 180° on the crank journal and remove from the crank.......................152
19. Inspect the big-end bearing shells (02.03.03.nn and 02.03.07.nn)....................................................152
20. Remove the connecting rod (10) if necessary:........................................................................152
20.1 Install the suspension rig (28) and mount the slide rail (27)..................................................152
20.2 Connect the connecting rod to the crane with a sling and remove the lateral stopper support ...................152
20.3 Slide the connecting rod out of the engine, keeping the sling tight............................................152
20.4 Remove the stopper (24), lift the connecting rod and place on a suitable surface...............................152
1. Reassembly of the bearing shells.................................................................................153
1.1 Clean and lubricate the crank pin...........................................................................153
1.2 If necessary, attach the disassembled con-rod (fig. 2/10) to a crane by means of a sling....................153
1.2.1 Place the con-rod on the slide rail (27) of the mounting / extraction device (W8) in such a...........153
1.2.2 Mount the con-rod bolts (1) and stopper (24) on the con- rod (10).....................................153
1.2.3 Push the con-rod to approx. 60 mm in front of the crank pin. Do not remove the sling!.................153
1.2.4 Preassemble the lateral stopper fixing device (23). Do not tighten it.................................153
1.3 Lubricate the bearing shells on the inside and outside......................................................153
1.4 Place the upper bearing shell (a, without holes) on the crank pin and turn it under the con- ...............154
1.5 Carefully press the con-rod against the bearing shell. The locating projection on the bearing...............154
1.6 Mount the con-rod clamping devices (W9). Remove the sling from the con-rod..................................154
1.7 Insert the lower bearing shell (fig. 1/b) paying attention to the locating projection (x). Al...............153
1.8 Carefully push the big-end bearing cover (fig. 2/11) against the bearing shell and the foot o...............154
1.9 Mount the round nuts (fig. 3/2) and tighten finger-tight....................................................155
1.10 Dismantle the mounting / extraction device for the big-end bearing [(fig. 2/W8), slide rails...............155
1.11 Check the con-rod shells on the exhaust side for any offset in an axial direction. Eliminate...............153
2. Tighten the round nuts (fig. 3/2) by means of the hydraulic device...............................................155
2.1 Turn the con-rod with the con-rod division downwards by approx. 15-30°, see position illustra...............155
2.2 Place the hydraulic tension elements (fig. 4/W3) together with the support rings (W4) above t...............154
2.3 Screw the threaded sleeves (W5) hand-tight onto the con-rod bolts (1).......................................156
2.4 Connect the hydraulic tension elements (fig. 5/W3) and distributor (W7) to the high pressure ...............156
2.5 Close the valve (fig. 5/6) on the high pressure pump (W1) and extend both con-rod bolts simul...............156
2.6 Firmly tighten the round nuts (fig. 4/2) with the pin (W6). Pay attention to easy action....................156
2.7 Check firm seating on the round nuts • Reduce the pressure by 50 bar. • It must no longer be ...............157
2.8 Open the valve (fig. 5/6) of the high pressure pump (W1). The tension elements are relieved.................157
2.9 Wait until the pressure has dropped completely and then remove the hydraulic devices (W3, W4,...............157
3. Mount the piston (02.10.01.nn)...................................................................................157
1. Remove the crankshaft bearing....................................................................................159
1.1 Remove the respective coupling-side crankcase cover on both sides of the engine (cylinder ban...............159
1.2 Turn the crankshaft into a convenient position; the round nuts (Fig. 1/23) on the crankshaft ...............159
1.3 Loosen the round nuts (7) on the lateral uniform strength bolts (6) with the hydraulic rig..................159
1.3.1 Remove the protective caps (8)........................................................................159
1.3.2 Slide the hydraulic clamping elements (Fig. 2/W4) over the round nuts (7) with the support ...........159
1.3.3 Screw the tapped bushes (W8) onto the uniform strength bolts (6) tightly and then loosen 1/...........159
1.3.4 Connect the hydraulic clamping elements (Fig. 3/W4) and the distributor (W10) with the high...........160
1.3.5 Close the valve (Fig. 3/13) on the high-pressure pump (W1) and apply force gradually to bot...........160
1.3.6 Loosen the round nuts (Fig. 2/7) with the pin (W3). Turn the round nuts back at least 8 holes.........160
1.3.7 Open the valve (Fig. 3/13) on the high-pressure pump (W1) to depressurize the clamping elem...........161
1.3.8 Wait until the pressure drops completely, remove the tapped bushes (Fig. 2/W8) and dismantl...........161
1.3.9 Loosen the uniform strength bolt (Fig. 1/6) and remove completely.....................................161
1.3.10 Loosen the uniform strength bolts (6) on the neighboring crankshaft bearing(s) with the hy...........161
1.4 Use the rig (Fig. 4/W11)....................................................................................161
1.4.1 Lower the rig to the lowest position (stop) with the threaded rod (Fig. 4/15).........................162
1.4.2 Remove the platform (20). Lift the rig (W11) into the crankcase at the corresponding cranks...........162
1.4.3 Mount the platform onto the bearing block (19). Slide the rig under the crankshaft bearing ...........162
1.5 Loosen the round nuts (23) on the crankshaft bearing bolts with the hydraulic rig...........................162
1.5.1 Place the hydraulic clamping elements (Fig. 4/W5) with the support rings (W7) flat onto the...........162
1.5.2 Raise the rig (W11) until the support rings (W7) rest against the crankshaft bearing cap (3...........162
1.5.3 Screw the tapped bushes (W9) onto the crankshaft bearing bolts (22) firmly from below throu...........162
1.5.4 Connect the hydraulic clamping elements (Fig. 7/W5) and the distributor (W10) with the high...........162
1.5.5 Close the valve (Fig. 7/30) on the high- pressure pump (W1) and apply force gradually to bo...........163
1.5.6 Loosen the round nuts (Fig. 6/23) with the pin (W3). Turn the round nuts back at least 8 ho...........163
1.6 Open the valve (Fig. 7/30) on the high-pressure pump (W1) to depressurize the clamping elements.............164
1.6.1 Wait until the pressure drops completely, remove the tapped bushes (W9)...............................164
1.6.2 Lower the rig carefully to the lower stop, remove the support rings and the hydraulic clamp...........164
1.7 Measure the gap, see procedure 2............................................................................164
1.8 Raise the rig to the crankshaft bearing cap, remove the round nuts. Lower the rig to the lowe...............164
1.9 Remove lower bearing shell..................................................................................164
1.10 Slide the carrier (Fig. 8/ W12) into the oil bore in the crankshaft until it stops.........................164
1.11 Turn the upper bearing shell towards the left side of the engine (cylinder bank A) and remove..............164
1.12 Inspect the bearing shells, see 02.03.03.nn and 02.03.07.nn................................................164
1.13 Check the thickness in the main wear zone at the indicated measurement points (Fig. 9/X) wit...............165
1.14 The bearing shells must be changed when the wear reaches >0.05 mm. Nominal size = 8.87- 0.0...............165
2. Measure the gap..................................................................................................165
2.1 Remove the uniform strength bolts (Fig. 10/6) from the respective crankshaft bearing on both ...............165
2.1.1 Loosen both round nuts (Fig. 10/23) hydraulically as described in steps 1.4 and 1.5. Lower ...........166
2.1.2 Loosen the round nuts further, but do not remove. Tighten the round nuts alternately by han...........166
2.1.3 Measure the gap „K“ between the crankcase and the crankshaft bearing cap on both sides of t...........166
1. Install the bearing shells...........................................................................................168
1.1 Oil the running surface of the upper crankshaft bearing shell thoroughly, dry the back of the...................168
1.2 Slide the carrier (Fig. 1/W12) into the oil bore until it stops.................................................168
1.3 Insert the installation rig (W13) into the crankshaft bearing cap. Make sure that the unit se...................168
1.4 Raise the rig (W11) slowly until the installation rig (W13) rests against the bearing block (x).................168
1.5 Tighten the round nuts (23) by hand, clamp the installation rig (W13). Lower the rig (W11)......................168
1.6 Turn the upper bearing shell into place. Make sure that the bearing shell is centered. The po...................168
1.7 Raise the rig (W11), remove the round nuts (23). Lower the rig (W11) and remove the carrier (...................168
1.8 Oil the running surface of the lower crankshaft bearing shell (Fig. 2/4). Dry the back of the...................169
1.9 Place lower thrust washer segments (1; only on the crankshaft thrust bearing) on the dowel pi...................169
2. Install the round nuts (Fig. 3/23) for the crankshaft bearing bolts..................................................169
2.1 Raise the rig (W11) with the crankshaft bearing cap (3) to the upper stop. Be careful not to ...................169
2.2 Screw the round nuts (23) onto the crankshaft bearing bolts (22) and tighten with the pin (Fi...................169
2.3 Loosen any flat-headed bolts (Fig.3/21) and remove..............................................................169
2.4 Lower the rig (W11) to the lower stop, do not remove............................................................169
3. Install the lateral uniform strength bolts (Fig. 4/6)................................................................170
3.1 Apply Molykote to the threads of the uniform strength bolts (6), screw in and tighten to T = ...................170
3.2 Screw the round nuts (7) onto the uniform strength bolts hand tight.............................................170
3.3 Slide the hydraulic clamping elements (Fig. 5/W4) over the round nuts (7) with the support ri...................170
3.4 Screw the tapped bushes (W8) onto the uniform strength bolts (6) hand tight.....................................170
3.5 Connect the hydraulic clamping elements (Fig. 6/W4) and the distributor on the operating side...................170
3.6 Close the valve (Fig. 6/13) on the high-pressure pump (W1) and apply force to the uniform str...................171
3.7 Tighten the round nuts (Fig. 5/7) with the pin (W3), making sure that the nut can be turned e...................171
3.8 Open the valve (Fig. 6/13) on the high-pressure pump (W1) to depressurize the clamping elements.................171
3.9 Connect the hydraulic clamping element (Fig. 5/W4) on the exhaust side to the high-pressure p...................171
3.10 Close the valve (13) on the high-pressure pump (W1) and apply force to both uniform strength...................171
3.11 Make sure that the round nuts seat properly • Lower the pressure by 50 bar. • The round nuts...................172
3.12 Open the valve (Fig. 6/13) on the high-pressure pump (W1) to depressurize the clamping eleme...................172
3.13 Wait until the pressure drops completely, remove the tapped bushes (Fig. 5/W8) and remove th...................172
3.14 Tighten the round nuts (Fig. 4/7) of the lateral uniform strength bolts (6) on the neighbori...................172
3.15 Screw the protective caps (8) onto the uniform strength bolts..................................................172
4. Tighten the round nuts on the crankshaft bearing bolts...............................................................172
4.1 Place the hydraulic clamping elements (Fig. 7/W5) with the support rings (W7) flat on the bea...................172
4.2 Raise the rig (W11) until the support rings (Fig. 7/W7) rest against the crankshaft bearing c...................172
4.3 Screw the tapped bushes (W9) onto the crankshaft bearing bolts (22) hand tight through the be...................172
4.4 Connect the hydraulic clamping elements (Fig. 8/W5) and the distributor (W10) with the high-p...................172
4.5 Close the valve (Fig. 8/30) on the high-pressure pump (W1) and apply force gradually tp notj ...................172
4.6 Tighten the round nuts (Fig. 7/23) with the pin (W3). Check to ensure that the nuts can be tu...................173
4.7 Make sure that the round nuts seat properly. • Lower the pressure by 50 bar. • The round nuts...................173
4.8 Open the valve (Fig. 8/30) on the high-pressure pump (W1) to depressurize the clamping elements.................173
4.9 Wait until the pressure drops completely, remove the tapped bushes (Fig. 7/W9)..................................173
4.10 Lower the rig (W11) to the lower stop, remove the hydraulic clamping elements and the suppor...................173
4.11 Remove the platform (Fig. 3/20)................................................................................173
4.12 Remove the rig (W11) from the engine and remount the platform..................................................173
4.13 Check the engine oil flow......................................................................................173
4.14 Install the crankcase covers on both sides of the engine (cylinder banks A and B) and the co...................173
1. Measure end play „s“.................................................................................................175
1.1 Open the covers under the timing gears and the first coupling-side crankcase cover on both si...................175
1.2 Measure the end play „s“ (s1 and s2) with the feeler gauge......................................................175
1.3 End play „s“:...................................................................................................175
2. Removing the crankshaft thrust bearing...............................................................................176
2.1 Turn the crankshaft to a convenient position, the round nuts (Fig. 2/23) on the crankshaft be...................176
2.2 Loosen the round nuts (7) on the lateral uniform strength bolts (6) with the hydraulic rig:.....................176
2.2.1 Remove the protective caps (8)............................................................................176
2.2.2 Slide the hydraulic clamping elements (Fig. 3/W4) over the round nuts (7) with the support ...............176
2.2.3 Screw the tapped bushes (W8) onto the uniform strength bolts (6) tightly and then loosen 1/...............176
2.2.4 Connect the hydraulic clamping elements (Fig. 4/W4) and the distributor with the high-press...............176
2.2.5 Close the valve (Fig. 4/13) on the high-pressure pump (W1) and apply force gradually to bot...............177
2.2.6 Open the valve (Fig. 4/13) on the high-pressure pump (W1) to depressurize the clamping elem...............177
2.2.7 Wait until the pressure drops completely, remove the tapped bushes (Fig. 3/W8), remove the ...............178
2.2.8 Loosen the uniform strength bolt (Fig. 2/6) and remove completely.........................................178
2.2.9 Loosen the round nuts (7) on the lateral uniform strength bolts (6) on the next crankshaft ...............178
2.3 Use the rig (Fig. 5/W11):.......................................................................................178
2.3.1 Lower the rig to the lowest stop with the threaded rod (15)...............................................178
2.3.2 Remove the platform (20). Lift the rig (W11) into the crankcase at the corresponding cranks...............178
2.3.3 Mount the platform on the bearing block (19). Slide the rig under the crankshaft thrust bea...............178
2.4 Loosen the round nuts (23) on the crankshaft bearing bolts with the hydraulic rig...............................179
2.4.1 Place the hydraulic clamping elements (Fig. 5/W5) with the support rings (W7) flat onto the...............179
2.4.2 Raise the rig (W11) until the support rings (W7) rest against the crankshaft bearing cap (3...............179
2.4.3 Screw the tapped bushes (W9) onto the crankshaft bearing bolts (22) firmly from below throu...............179
2.4.4 Connect the hydraulic clamping elements (Fig. 8/W5) and the distributor (W10) with the high...............179
2.4.5 Close the valve (Fig. 8/30) on the high-pressure pump (W1) and apply force gradually to bot...............180
2.4.6 Loosen the round nuts (Fig. 7/23) with the pin (W3). Turn the round nuts back at least 8 ho...............180
2.5 Open the valve (Fig. 8/30) on the high-pressure pump (W1) to depressurize the clamping elements.................180
2.5.1 Wait until the pressure drops completely, remove the tapped bushes (Fig. 7/W9)............................180
2.5.2 Lower the rig carefully to the lower stop, remove the support rings and the hydraulic clamp...............181
2.6 Measure the gap, see procedure 3................................................................................181
2.7 Raise the rig to the crankshaft bearing cap, remove the round nuts. Lower the rig to the lowe...................181
2.8 Remove the lower bearing shell..................................................................................181
2.9 Slide the carrier (Fig. 9/ W12) into the oil bore in the crankshaft until it stops..............................181
2.10 Turn the upper bearing shell towards the left side of the engine (cylinder bank A) and remove..................181
2.11 Inspect and evaluate the bearing shells, see 02.03.03.nn and 02.03.07.nn.......................................181
2.12 Measure the thickness in the main wear zone at the indicated measurements points (Fig. 10/X)...................181
2.13 The bearing shells must be replaced when the wear reaches >0.05 mm. Nominal size = 8.87- 0....................181
3. Measure the gap......................................................................................................182
3.1 Remove the uniform strength bolts (Fig. 11/6) from the crankshaft thrust bearing on both side...................182
3.1.1 Loosen both round nuts (23) hydraulically as described in 2.3 and 2.4. Lower the rig (W11),...............182
3.1.2 Loosen the round nuts further, but do not remove. Tighten the round nuts alternately by han...............182
3.1.3 Measure the gap „K“ between the crankcase and the crankshaft bearing cap on both sides of t...............182
1. Remove the crankcase cover for the respective cylinder on both sides and remove the cylinder h...................184
2. Turn the crank journal to the control side to approx. 20° before TDC.............................................184
3. Clean the carbon deposits from the area above TDC for the 1st piston ring up to the gauging ri...................184
4. Turn the upper piston edge below the gauging ring (Fig. 2/2).....................................................184
5. Insert the disassembly rig (W10) so that the recess is inside the gauging ring...................................184
6. Tighten the disassembly unit slightly by turning the spindle nut.................................................184
7. Press out and remove the gauging ring by turning the engine to raise the piston..................................184
8. Remove the disassembly rig (W10).................................................................................184
9. Turn the piston to TDC and retap the threaded holes (1; M12, 11 mm deep) in the piston crown.....................184
10. Bolt the crosspiece (Fig. 3/W1.2) onto the piston crown.........................................................184
11. Bolt the spacer blocks (W1.1) onto the crosspiece and mount the lever (W2) with the extension...................184
12. Attach the crane to the lever (W2) and bring the piston to BDC..................................................184
13. Split the connecting rod shank..................................................................................185
13.1 Bolt the flexible head wrench (Fig. 4/W8) to the piston rod cap on both sides with the holde...............185
13.2 Place the flexible head wrench on the uniform strength bolts (20). Secure the wrench above t...............185
13.3 Mount the piston rod clamping ring (W3) on the counterweight to secure the piston rod (22).................185
Attention: The engine may not be turned with the piston rod clamping rig (23) in place......................................186
13.4 Loosen the uniform strength bolts (20) with the torque wrench (W6) and reversible ratchet (W7).....................186
13.5 Remove the uniform strength bolts (20) with the segments (21)......................................................186
14. Place the holding device (Fig. 3/W5) for the piston rod eye (12) on the connecting rod shank .......................186
15. Pull the piston (4) carefully, moving the crane as required. Place the piston on a suitable s.......................186
Attention: Remove the connecting rod eye (Fig. 3/12) if the piston will be stored for a longer pe...........................186
16. Seal off the oil bore in the connecting rod shank with a protective cap.............................................186
17. Measure the wear of the cylinder liner (03.03.01.nn)................................................................186
1. Turn the piston......................................................................................................187
1.1 Attach the crane to the lever (fig. 1/W2) and lift the piston...................................................187
1.2 Extract holding device (W1.4) for con- rod eye. Mount with the opening towards the correspond...................187
1.3 Mount cross-piece (W1.3) on the con-rodeye (5) and attach to a second crane....................................187
1.4 Only rotate the piston around the tip of the lever (fig. 1/W2) in the direction shown...........................188
1.5 Mark the installation position of the lever (W2, extension to control side) on the piston.......................188
1.6 Dismantle the cross-piece (W1.2) with the spacers (W1.1) and lever (W2).........................................188
1.7 Place the piston on a suitable base and secure it!..............................................................188
2. Disassemble the piston pin...........................................................................................188
2.1 Mark the con-rod eye (fig. 2/ 5), piston (4) and piston pin (31) for assembly on the correct ...................188
2.2 Raise the con-rod eye slightly to relieve the piston pin........................................................188
2.3 Remove the locking rings (32) with Circlip pliers (W3)..........................................................188
2.4 Push the piston pin (31) out of the piston bore and small end bearing bush (30) without using...................188
2.5 Check the piston pin surface for cracks and damage..............................................................189
2.6 Measure the piston pin, small end bearing bush and piston pin bore in the piston (02.09.01.nn)..................189
3. Reassembly...........................................................................................................189
3.1 Fit a locking ring (fig. 2/32) in the piston bore with Circlip pliers (W3)......................................189
3.2 Insert the con-rod eye (5) in the piston (4) in such a way that the piston bore and small end...................189
3.3 Lubricate the piston pin (31) and push it into the piston and small end bearing bush accordin...................189
3.4 Secure the piston pin with the second locking ring (32).........................................................189
4. Turn the piston to the installation position.........................................................................189
4.1 Attach the crane to the cross-piece (fig. 2/W1.4) or to a second sling and raise the piston.....................189
4.2 Mount the cross-piece (W1.2) with spacers (W1.1) and lever (W2) according to the mark on the ...................189
4.3 Attach the crane to the shackle on the lever (fig. 1/ W2).......................................................190
4.4 Rotate the piston in the opposite direction shown in fig. 1.....................................................190
4.5 Extract the holding device (W1.4) for the con-rod eye. Mount it with the opening towards the ...................190
4.6 Dismantle the cross-piece (W1.3) and place the piston on a suitable base........................................190
1. Replace the piston rings if needed...................................................................................191
1.1 Remove the lever (Fig. 2/W2) with the crosspiece (W1.2) and spacer blocks (W1.1). Mark the po...................191
1.2 Install the piston rings with the gaps lengthwise respective to the engine, the ring gaps mus...................191
2. Loosen the tensioning screw (Fig. 1/1) enough that the piston installation guide (W12) is open.......................192
3. Apply Molykote paste „G-Rapid Plus“ to the threads and contact surface of the tensioning screw.......................192
4. Place the piston installation guide (Fig. 1/W12) over the piston rings and tighten the tension.......................192
5. Check that the piston installation guide (W12) can be turned around the piston.......................................192
6. Mount the piston installation ring (Fig. 2/W11)......................................................................192
7. Mount the piston installation/removal rig (W1) on the piston:........................................................192
7.1 Mount the crosspiece (W1.2) with spacer blocks (W1.1) and lever (W2) with extension on the pi...................192
8. Attach the crane to the lever (Fig. 2/W2) and lift...................................................................193
9. Check the position of the retainer (W5). It must sit closely in the piston on the control side.......................193
10. Slide the piston into the cylinder liner carefully..................................................................193
11. Lower the piston, it may not tilt and catch in the cylinder liner, adjust with the lever (W2).......................193
12. Place the piston installation guide (Fig. 1/W12) flat on the piston installation ring (Fig. 2.......................193
13. Place the piston with the connecting rod eye onto the connecting rod (22) carefully, remove t.......................193
14. Install the cylinder liner retainer (Fig. 4/W4) on the cylinder liner (3), screw the Allen sc.......................193
15. Install the piston and connecting rod...............................................................................194
15.1 Apply Molykote to the threads and contact surfaces of the uniform strength bolts (Fig. 3/ 20)..................194
15.2 Place the segments (21) on the connecting rod shank, insert the uniform strength bolts and t...................194
15.3 Mark the position of each of the uniform strength bolts with a chalk mark......................................194
15.4 Remove the piston rod clamping ring (Fig. 4/W3)................................................................194
15.5 Bolt the flexible head wrench (W8) to the piston rod cap on both sides with the holder. Use ...................194
15.6 Place the flexible head wrench on the uniform strength bolts (20). Secure the wrench above t...................195
15.7 Tighten the uniform strength bolts to T = ...................195
15.8 Check the marks on the uniform strength bolts, they must be at ...................195
15.9 Remove the flexible head wrench (Fig. 4/W8) and extension (W9) with the retainer and set col...................195
16. Turn the piston to TDC together with the crane......................................................................195
17. Remove the piston installation/removal rig (Fig. 2/W1) and lever (W2) with extension, piston .......................195
18. Clean the gauging ring contact surface (Fig. 5/2) onthe cylinder liner collar (3)..................................195
19. Lower the piston and install a new gauging ring (2).................................................................195
20. Install the cylinder head (01.11.01.nn).............................................................................195
21. Remove the cylinder liner retainer (Fig.4/W4), install the crankcase cover.........................................195
1. Check the cylinder liner.........................................................................................196
1.1 Remove fire ring and pull piston............................................................................196
1.2 Clean the cylinder liner internally (thoroughly cover the crankcase)........................................196
1.3 Measure the cylinder liner with the precision inside micrometer (W2) at the measuring points ...............196
1.4 Reference dimension: Spare cylinder liner...................................................................196
1.5 Enter the measured values in the table (Fig. 2) and thereafter determine the wear (d1 - „refe...............197
1.6 When the wear limit, normally in the area of the top dead center of the piston ring (TDC 1st ...............197
1. Disassemble the cylinder liner...................................................................................198
1.1 Remove the piston and cylinder liner holder (02.06.01.nn)...................................................198
1.2 Remove the sealing ring (fig. 2/21) and O-ring (20) from the cylinder liner collar..........................198
1.3 Measure the wear on the cylinder liner......................................................................198
1.4 Mount the mounting / extraction device (fig. 1/W1). To do so:...............................................199
1.4.1 Place the lever (W1.1) with the extension on the cylinder liner collar................................199
1.4.2 Place the clamping plate (W1.2) under the cylinder liner (3)..........................................199
1.4.3 Fix the clamping plate (W1.2) and lever (W1.1) together by means of the hexagon nuts (W1.4)...........199
1.5 Attach the lifting gear and carefully pull out the cylinder liner (3). Follow up with the lif...............199
1.6 Do not tilt the cylinder liner. Align with the lever (W1.1) if necessary....................................199
1.7 Place the cylinder liner on a suitable base and secure it...................................................199
1.8 Remove the O-ring (fig. 2/22) in the cooling water distributor housing (2)..................................199
1.9 Carefully clean the sealing surface and groove for the O-ring and check for damage..........................199
1.10 Carefully clean the cooling water area on the cylinder liner collar........................................199
1.11 Check all sealing surfaces for damage......................................................................199
1.12 Clean the cylinder liner support, upper and lower fitting in the cylinder crank case.......................199
1. Clean the inside of the cooling water manifold housing (fig. 1/2). If necessary, replace the O...................200
2. Fit a new O-ring (22) in the groove on the cooling water manifold housing........................................200
3. Apply sealing compound to the contact surfaces of the cylinder liner (fig. 1/3) on the cylinde...................201
4. Dismantle the mounting/extraction device (W1) from the drawn cylinder liner......................................201
5. Mount the mounting/extraction device (W1) on the cylinder liner which is to be installed (03.0...................201
6. Attach lifting gear to the mounting/extraction device (W1) and guide the cylinder liner (3) in...................201
6.1 Do not tilt the cylinder liner. If necessary, use the lever (W1.1) to align it..............................201
7. Dismantle the mounting/extraction device (W1) and measure the new cylinder liner.................................202
8. Mount the piston and calibrating ring............................................................................202
1. Check for good mounting and leaks of flanged connections, filters, thermostats and pipe clamps...................203
2. Check leak tightness of the expansion joints, proper suspension of the exhaust gas pipe, (06.0...................203
3. Check the tight fitting of the suspensions and unions in the charge air manifold.................................203
4. Check the monitoring and control equipment for good fitting. Cables and signal pipes must not ...................203
5. Check the foundation bolts and chocks by knocking. Measure the crank web deflection after tigh...................203
6. Check elastic bedding elements for damages.......................................................................203
1. Check the running surface of one camshaft bearing and the corresponding bearing journal from t...................204
1.1 Dismantle the camshaft section of the respective cylinder. Refer to 04.04.01.nn.............................204
1.2 Mount the mounting / extraction device for camshaft sections on the corresponding left hand /...............205
1.3 Remove the hexagon bolts (fig. 1/5) from the bearing journal which is to be checked.........................205
1.4 Pull out the bearing journal (3) without tilting it!........................................................205
1.5 Check the running service of the bearing journal and replace the journal if there is any scor...............205
1.6 Check the camshaft bearing (1) and dismantle it in the event of: - a poor contact pattern - p...............205
1.6.1 Loosen the locating screwing (4) and remove the camshaft bearing. Also check the back of th...........205
2. Reassembly.......................................................................................................205
2.1 Insert the camshaft bearing and align it with the locating screwing (4).....................................205
2.2 Tighten the locating screwing (4) at a torque of............................................................205
2.3 Lubricate the outside of the bearing journal................................................................205
2.4 Fit the bearing journals of cylinder row A and B with straight pins (fig. 1/7) according to t...............205
2.5 Further assembly: refer 04.04.01.nn.........................................................................205
1. Inspection of tooth faces and oil nozzles........................................................................208
1.1 Dismantle the gear casing covers on both sides of the engine................................................208
1.2 Check the tooth faces of both camshaft gear gear wheels (Fig.1/1, 4),the intermediate wheel ...............208
1.3 Measure the tooth clearance between intermediate wheel and camshaft gear wheels (x) and betwe...............208
1.4 1.4 Check function and tight fit of oil nozzles (2).........................................................208
1.5 1.5 Check the gaskets and mount the gear casing cover.......................................................208
2. 6. Check the axial clearance „s“ of the intermediate wheel (Fig. 2/3)............................................209
2.1 Dismantle the protective hood for the flywheel and the cover (10) with the gasket...........................209
2.2 If necessary, loosen the drainage pipe (15).................................................................209
2.3 Pull the intermediate wheel (3) against the cylinder crankcase towards the coupling side....................209
2.4 Mount the dial gauge together with the holder. Place the dial gauge on the intermediate wheel...............209
2.5 Push the intermediate wheel toward the opposite side of the coupling and determine the axial ...............209
2.6 2.6 Check the gasket on the cover (10) and replace it, if necessary. Mount the cover together...............209
2.7 2.7 Mount the protective hood on the flywheel and - if removed at all - mount the drainage pi...............209
1. Remove the exhaust line shroud.......................................................................................210
2. Check all bolted connections to make sure that they are tight........................................................211
3. Carbon, which can especially be found at flanges and compensators, is a sign of leaks................................211
4. Replace any defective exhaust lines (Fig. 1/ 1) or exhaust pipes (2).................................................211
4.1 Loosen and remove adjacent compensators (6). When removing an exhaust line (1), the correspon...................211
4.2 Loosen the hex head bolts/nuts (Fig. 2/ 10) so that both upper clamp sections are still conne...................212
4.3 Slide the upper sections of the clamps (9) aside, remove the chain links (11) from the lower ...................212
4.4 Remove both upper clamp sections (9) together, replace the defective exhaust line (1) or the ...................212
4.5 Prepare the fitted pieces (Fig. 1/ x / y) for the installation of the new exhaust pipe. Fitte...................212
4.6 Bolt the fitted pieces to the new exhaust line (1) or the new exhaust pipe (2)..................................212
4.7 Install the new exhaust line (1), exhaust pipe (2) and upper clamp sections (Fig. 2/ 9).........................212
4.8 Remove the fitted pieces. Install the compensator(s) (5 and 6) and bolt into place..............................212
5. Replace any compensators with cracked bellows........................................................................212
6. Install the exhaust line shrouding...................................................................................212
1. Switch off the lubricating oil prelubricating pump...............................................................214
2. Drain the lubricating oil circulation tank.......................................................................214
3. Clean the lubricating oil circulation tank and crank case compartment if necessary...............................214
4. Check the lubricating oil safety filter (1) (08.04.03.nn)........................................................214
5. Check the filter in the suction lines of the lubricating oil pumps and the separator pump and ...................214
6. Clean the lubricating oil duplex filter (08.04.01.nn)............................................................215
7. Clean the lubricating oil automatic filter.......................................................................215
8. Dismantle the lubricating oil cooler and clean it (see manufacturer's documents, manual C, sec...................215
9. Fill up the circulation tank with new lubricating oil (lubricating oil quality, A4.05.08.nn) u...................215
10. Fill up the lubricating oil system and take the lubricating oil prelubricating pump into oper...................215
1. Remove the control oil drain connection (Fig. 1/1) and the control oil connection (2)................................216
2. Loosen the line clamp (3)............................................................................................216
3. Loosen the cylinder bolts (Fig. 2/12) and remove with the valve cover (13) and O- ring (14)..........................216
4. Remove the pressure spring (15) and piston (16) from the safety valve (17)...........................................216
5. Check the sealing and guide surfaces of the piston (16) and grind the valve seat (17) if neces.......................216
6. Check the O-ring (14), replace if necessary..........................................................................216
7. Install the safety valve in the reverse procedure as removal.........................................................216
8. Start the engine oil pump and vent the oil system. Check the oil system for leaks....................................216
1. Sequence of operations...........................................................................................221
1.1 Unscrew the plug thermometer or probe insert at the highest point of the pipe section to be d...............221
1.2 Dismantle the bracket (5) and pull out the filter insert (3)................................................221
1.3 Check the filter insert and wash it out. Replace the O-rings (6 /7).........................................221
1.4 Push in the filter insert and mount the bracket (5) with a new gasket (4)...................................221
1.5 Screw in the plug thermometer or probe insert with new gaskets..............................................221
1.6 Take the standby lubricating oil pump into operation and fill the lubricating oil system....................221
1. Disassembly......................................................................................................222
1.1 Loosen the cheese head screws (8) evenly to relieve the pressure spring (3).................................222
1.2 Remove and dismantle the control valve (1)..................................................................222
1.2.1 Loosen the hexagon nut (18) and completely unscrew the spindle (19) by turning it counter- ...........222
1.2.2 Loosen the screw connection (17) and remove it together with the sealing ring (14) and bush...........222
1.2.3 Remove the locking ring (9) and take out the piston (11) with washer (15) and pressure spri...........222
1.2.4 Remove the screw plug (26) of the pilot control unit (A-A) with the sealing ring (25), wash...........222
1.3 Clean all parts with gas oil and check them.................................................................223
1.4 Check the free passage of the control oil bore (12) in the pressure control valve and in the ...............223
1.5 Check the valve seats, balls, piston seating as well as the slide faces and grind them if nec...............223
2. Reassembly.......................................................................................................224
2.1 Check the O-ring (7) and sealing ring (14) and replace them if necessary....................................224
2.2 Assembly is effected in the reverse sequence of disassembly. Pay attention to the free moveme...............224
2.3 Check the lubricating oil pressure at the pressure gauge on the control panel and adjust it i...............224
3. Adjustment.......................................................................................................224
3.1 Pressure to be set (see engine data A1.05)..................................................................224
3.2 Loosen the hexagon nut (18).................................................................................224
3.3 Secure the setting with the hexagon nut (18)................................................................224
1. Carry out steps 1.1 and 1.2 simultaneously for approx. 5 min.............................................225
1.1 Start the stand-by pump.............................................................................225
1.2 Turn the engine by means of the barring gear........................................................225
- NOCKENWELLE, VOLLST. 1 343122 AA CAMSHAFT ASSEMBLY........................................................................301
1 NOCKENWELLENTEILSTÜCK 8 343122-001 CAMSHAFT SECTION.......................................................................301
2 LAGERZAPFEN 1 9.3122-002 BEARING JOURNAL..................................................................................301
4 LAGERZAPFEN 8 9.3120-004 BEARING JOURNAL..................................................................................301
5 ZAHNRAD 1 9.3120-105 GEARWHEEL............................................................................................301
6 DICHTUNG # 1 9.4111-109 GASKET............................................................................................301
7 ANLAUFSCHEIBE 1 9.3120-206 BUTTING DISK...................................................................................301
8 DECKEL 1 9.3120-007 COVER.................................................................................................301
9 DECKEL 1 9.4111-107 COVER.................................................................................................301
10 SECHSKANTSCHRAUBE 3 1.1367-466 HEXAGON BOLT..............................................................................301
11 SECHSKANTSCHRAUBE 4 1.1387-307 HEXAGON SCREW.............................................................................301
12 SPANNSCHEIBE 11 1.0068-240 CONICAL SPRING WASHER.........................................................................301
13 ZYLINDERSTIFT 16 1.0026-299 PARALLEL PIN.................................................................................301
15 SECHSKANTSCHRAUBE 11 1.1387-446 HEXAGON SCREW............................................................................301
16 VERSCHLUSSSCHRAUBE 1 1.1041-821 HEXAGON HEAD SCREW PLUG..................................................................301
17 DICHTRING # 1 1.7010-332 JOINT RING......................................................................................301
21 SECHSKANTSCHRAUBE 272 1.1374-375 HEXAGON BOLT............................................................................301
23 DECKEL 1 343123-004 COVER................................................................................................301
25 DICHTUNG # 1 343123-005 GASKET...........................................................................................302
26 SECHSKANTSCHRAUBE 8 1.1372-373 HEXAGON BOLT..............................................................................302
28 SCHEIBE 8 1.0040-227 WASHER..............................................................................................302
Turbocharger................................................................................................................ 0
TPL 61-A.. - 65-A........................................................................................................... 0
Charge Air Cooler........................................................................................................... 0
-........................................................................................................................... 0
Please select target document for B1.05.08.9.641n ??:.......................................................................418
• B1.05.08.9.6410 FF....................................................................................................418
• B1.05.08.9.6417 TT....................................................................................................418
CAT ENGINE TYPE GCM34 OPERATING INSTRUCTIONS MANUAL – PDF DOWNLOAD:
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