Storage instructions

The engine and all its auxiliaries, including the instruments, spares, tools and various fixtures are furnished being coated with a rust preventer and crated for a protracted storage indoors. The expiration date of the rust-preventing coating is entered in the Engine Logbook.

The engine which is to be put into storage must be kept with all its standard equipment in a dry clean room.

With Manufacturer’s consent the crated engine can be stored outdoors under a shed which gives protection against direct exposure to precipitations and sunshine.

Before putting the engine into storage, inspect the box from the outside for visible defects. If the box appears to be damaged, uncrate and inspect the engine. Renew the coat of rust preventer if this appears to be impaired. All traces of corrosion must he removed and the surface freshly coaled with the rust preventer. Repair the box. Never crank the engine during the storage period and in the course of inspection.… READ THE REST

Cylinder Liner Dismantling and reassembling

Cylinder liners with bores free from visible defects such as fractures, deep scratches, scorings are subject to a check up for the purpose of determining the amount of wear. To that end, the bore is measured at three different levels spaced 20, 75 and 100 mm from the top, respectively, using a hole gauge. Badly worn liners need replacement.

To drive out a cylinder liner, use is made of a special puller applied on taking down the cylinder head and withdrawing the piston with the connecting rod. Preparatory to driving out the liner, apply marks to the liner and block indicating the position of the liner relative to the block.

(adsbygoogle = window.adsbygoogle || []).push({});

Give the liners withdrawn from the block a thoroughly cleaning of carbon and scale, wash the liners. Make sure the outside surface coating is free from laminations.

Preparatory to press-fitting a liner into the block, clean the locating collars and shoulder, slip the packing rings on the liner.… READ THE REST

Dismantling and reassembling Speed Governor

For replacing external spring 26 and internal one 27 of the speed governor, screw out spindle 20 as far as it will go, remove housing 23 and retainer 24.

Speed governor

Fig. Speed governor; 5Д2-1, 5П2, 8П2 and 10П2 diesel engines:1, 20, 33 — splindle; 2 — detent; 3, 5 — spring; 4 — pump cutoff handle; 6 — nut; 7 — bar; 8 — cotter pin; 9 — stopper ring; 10 — pump cut off lever; 11 — upper lever; 12 — bracket; 13 — pin; 14 — lower lever; 15 — fulcrum pin; 16 — spider; 17 — tip; 18 — bracket; 19 — handwheel; 21 — screw; 22 — double-arm lever; 23 — housing; 24 — retainer; 25 — retainer holder; 26 — external spring; 27 — internal spring; 28 — carrier sleeve; 29 — bearing; 30 — sleeve; 31 — weight; 32 — gear

For complete dismantling, lake down bracket 12 integrally with the levers followed by the timing gear cover plate, sleeves 28 and 30, spider 16 with weights 31 and gear 32.… READ THE REST

Fuel Injection Pump Dismantling and reassembling

The procedure of taking apart the fuel injection pump as follows: back off union 12, remove spring 11 and withdraw delivery valve assembly 10, using a special puller. Depress tappet 3, insert a pin into a hole at the bottom of the body, remove retainer ring 23, the pin, lower spring retainer 2, spring 22, upper spring retainer 4, control quadrant 20 and control rack 5. Back off screw 7 and withdraw plunger-and-barrel assembly 21.

Fuel injection pump, 5Д2, 5Д2-1, 5П2, 8П2 and 10П2 diesel engines

Fig. Fuel injection pump, 5Д2, 5Д2-1, 5П2, 8П2 and 10П2 diesel engines: 1 — pump housing; 2 — lower spring retainer; 3 — tappet; 4 — upper spring retainer; 5 — pump control rack; 6, 15, 17 — gaskets; 7 — adjusting screw; 6 — seal; 9 — gasket; 10 — delivery valve assembly; 11, 22 — springs; 12, 16 — unions; 13 — blanking off plug; 14 — bleed screw; 18 — bushing; 19 — union bolt; 20 — control quadrant; 21 — plunger-and-barrel assembly; 23 — retainer ring

Fuel injection pump and diesel engines


Injector Dismantling and reassembling

It is good practice to take apart, repair and adjust injectors at a work place specially equipped for the job.

Preparatory to taking an injector apart, wash it. On disassembling the injector, with all the components in benzine or fuel oil, but never in the same bath with the nozzle body and nozzle valve.


Fig. Injector: 1 — nozzle body; 2 — nozzle valve; 3 — nozzle body nut; 4 — nozzle body holder; 5 — spindle; 6 — spring; 7, 13 — gasket; 8 — nut; 9 — adjusting screw; 10 — lock nut; 11 — cap; 12 — bushing; 14 — bolt

Eliminate all the defects in the form of scratches and pitting from the end face of the nozzle body bolder and from the nozzle body surface mating the nozzle body holder, said defects being dealt with on a lapping plate by using lapping compounds. On finishing with the lapping, both mating faces must present uniformly polished surfaces.… READ THE REST

Dismantling and reassembling Crankshaft

On the 5Д2, 5Д2-1, 5П2, 8П2, 10П2 diesel engines, the crankshaft is driven out of the block integrally with the bearings by a special puller or by a copper drift which is being slightly lapped on after unbolting the block cover plate at the flywheel end of the engine. The bearings are forced off the crankshaft by puller bolts screwed into crankwebs.

On the ДС8, ДС12, П12, П21, П22, 4ч, 6ч diesel engines, spin off the stirrup nuts, remove the stirrups, measure the axial play of the crankshaft and then take down same.

Wash the crankshaft and its constituent parts, clean all the oil passages, blow off with compressed air and then inspect the crankshaft for the purpose of assessing its serviceability.

All defects such as badly scuffed journals with deep circumferential scratches are intolerable. Minor scratches can be eliminated from journals by giving them a rub with oiled emery paper.… READ THE REST

Connecting Rod-Piston Assembly

Carefully remove the carbon from the top of each cylinder liner, using a scraper. Back off the crankpin bearing bolts accessible through the cylinder block manhole, remove the bearing caps and withdraw each of the connecting rods integrally with its piston through the cylinder bore.

Thoroughly clean the components of carbon and inspect them to access their fitness for further service.

As far as the bearing shells are concerned, circumferential scores, deep indentations, molten portions and numerous pitting indicating corrosion make these components unfit for further service. Gritty particles on shells which show no signs of wear call for the replacement of these shells, for these particles may bring about intensive wear of crankpins.

The crankpin bearing bolts are components of vital importance and even a slight defect thereof may result in a major breakdown of the engine. Scrap those holts which have blunt threading, scratches and also those which are bent or elongated.… READ THE REST