12RT flex96C 柴油机说明书 08

Piping Group 8. . . . . . . . . . . . . . . . . . . . . . . . .Servo Oil Piping: Removing, Fitting and Regrinding8447–1/A1. . . .Hydraulic Piping for Exhaust Valve Drive: Removing, Fitting and Regrinding8460–1/A1. . . . .Fuel Pressure Piping: Removing, Fitting and Regrinding of Sealing Faces8733–1/A1 o Intermediate Fuel Accumulator. . . . . . . . . . . . . .–Checking and Setting of Relief Valve with O.M.T. Test Bench8750–1/A1. . . . . . . . . . . . . . .–Checking and Setting of Relief Valve with OBEL Test Bench8750–1/A2. . . .Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling8750–2/A1. . . . . . . . . . . . . . . . . . . . .Fuel Pressure Piping: Removing, Fitting and Regrinding8752–1/A1Tools:Key to Illustrations:1Regrinding device94834a1Servo oil piping 16Lapping body 2Servo oil piping 17Non-return valve 3Leakage oil piping 18Screwed sleeve 4Shut-off valve 19Valve block5Shut-off valve 20Intermediate piece 6,a,bScrew 21Shim 7Flange 22Shim8Screw23Connecting piece 9Clamp piece 24Back-up ring 10Shim25O-ring 11Protective shell 26O-ring 12Claw27O-ring 28O-ring14,a,b Drain screw15BushDFSealing face1.1Preparatory works⇒Remove the casing where necessary.⇒Close shut-off valves 4 and 5 for the relevant servo oil piping.⇒Open drain screw 14.Remark: The spindles of the closed shut-off valves must be tightened with 200 Nm .1.2Removal of servo oil piping 1⇒Open drain screws 14a.⇒Loosen screws 6.⇒Push flanges 7 back till they are no more en-gaged, so that servo oil piping 1 can be re-moved.DThe ends of the servo oil piping must be pro-tected from any damages.Servo Oil PipingRemoving, Fitting and Regrinding1.3Removal of servo oil piping 2⇒Open drain screws 14b.⇒Loosen screws 6a and push flanges 7 back till they are no more engaged.⇒Mark shims 10 together with clamp pieces 9 (Fig. ’A’).⇒Hold servo oil piping (65 kg) by means of a lifting tackle.⇒Loosen and remove screws 8 (Fig. ’A’).⇒Remove clamp pieces with protective shims 11 and shims 10 (Fig. ’A’ viewI-I).⇒Mark shims 21 and 22 together with connecting piece 23.⇒Loosen screws 6b and push flange 7 back.⇒Remove servo oil piping 2.2.1Checking the claw position⇒Before fitting the servo oil piping checkwhether its claws 12 are screwed on properlyas shown in Fig. ’C’, i.e. the servo oil pipingmust protrude by ’x’ = 10 mm compared tothe claw.D Measure ’x’ can be adjusted by turning theclaw using an open-end wrench.Remark: On newer engines claw 12 and thrustring 13 are provided in one piece.2.2Fitting the servo oil pipingsFitting is carried out analogously to the removal but in reverse sequence, wherebythe following points require special attention:D Fitting position of new back-up rings 24 (Fig. ’B’ views IV and V).D All shims must be fitted in the same place as before.D Oil the threads of screws 6, a, b and tighten them crosswise with a torque of170 Nm.D When fitting clamp pieces 9 tighten their screws 8 after all servo oil pipingshave been tightened!D Close all drain screws.D After refitting the servo oil pipings open shut-off valves 4 and 5, and tightentheir spindles with 200 Nm.If a non-return valve 17 has been removed from valve block 19, O-rings 28 must be replaced by new ones.The proper flow direction must be maintained when refitting the non-return valve.⇒Apply LOCTITE 0222 to the screwed sleeve 18 and tighten it with a torque of80 Nm.Device 94834a is to be used for regrinding the seal-ing faces ’DF’.⇒Unscrew corresponding claw 12 (Fig. ’C’).⇒To prevent grinding compound from enteringthe servo oil piping, plug its openings with apiece of cloth.⇒Screw bush 15 onto the relevant thread endof the servo oil piping and regrind sealingface ’DF’ with lapping body 16 as shown inFig. ’E’.⇒First rough-grind the sealing faces with grind-ing compound No. 200, then finish-grindthem with grinding compound No. 500.⇒After grinding thoroughly clean the servo oilpiping.Tools:Key to Illustrations:1Regrinding device948341Hydraulic piping 10Metallic hose 2Stop valve 11Screw 3Drain screw 12Holder 4Pilot valve13Bush5Partition device 14Lapping body 6Screw 15O-ring7Screw 8, 8aHousing 9Sealing ringDFSealing faceWhen working on a hydraulic piping 1 in principle the engine has to be stopped,and it is essential that instructions 0520–1 ’Exchange of a defective hydraulic pip-ing’ in the Operating Manual be strictly followed.Before beginning dismantling works recheck whether stop valve 2 of the oil inlet pipe is closed and drain screw 3 is removed.12Hydraulic Piping for Exhaust Valve Drive Removing, Fitting and RegrindingCHECK⇒Remove holder 12 (Fig. ’A’).⇒Loosen screws 6 and undo screws 7.⇒Turn housing 8a back by 2–3 turns, draw hydraulic piping 1 axially back andmove it to the side.⇒Connect the hydraulic piping to the crane, undo screws 6 and remove the hy-draulic piping.D Pay attention not to damage sealing faces ’DF’ when removing the hydraulic piping.DAll openings must be closed off immediately after removing the connections.B9III86151Check before assembly whether the inside of the hydraulic piping, sealing faces ’DF’ of the piping ends, as well as the seating surfaces of sealing rings 9 are clean and undamaged, and whether O-rings 15 are in good condition.DFitting together should be carried out axially, i.e. the objects to be connected must not be moved closer together laterally , in order to avoid any damaging of sealing faces ’DF’.D Housing 8 or 8a (Fig. ’B’) should be screwed on hydraulic piping 1 in such a manner that after tightening screw 6 or 7 clearance ’x’ is about 3 mm.DAfter assembly open stop valve 2, fit and tighten drain screw 3.CHECKC9483413114DFDevice 94834 is to be used for regrinding the sealing faces ’DF’.⇒Screw off housing 8, 8a concerned (Fig. ’B’).⇒To prevent grinding compound from entering the hydraulic piping, plug its openings with a piece of cloth.⇒Screw bush 13 onto the corresponding thread end of hydraulic piping 1 and grind sealing face ’DF’ with lapping body 14 as shown in Fig. ’C’.⇒First rough-grind the sealing face with grind-ing compound No. 200, then finish-grind it with grinding compound No. 500.⇒After grinding thoroughly clean the hydraulic piping.Tools:Key to Illustrations:Regrinding device94872a1Cylinder cover 10Connection piece 2Injection valve 11Drain screw 3Fuel pressure pipe 12O-ring 4Injection control unit 13O-ring 5Claw14O-ring6Head screw 7Flange8Pipe bracket BD Collar9Thrust ringDFSealing faceWhen working on a fuel pressure pipe 3 in principle the engine has to be stopped,and it is essential that instructions 0510–1 in the Operating Manual be strictly fol-lowed.⇒Remove all pipe brackets 8.⇒Remove head screws 6 from flange 7 on injection valve 2 and injection controlunit 4 (Fig. ’A’ and ’C’).D Pay attention not to damage sealing faces ’DF’ when removing fuel pressure pipes 3.DAll connections must be closed off immediately and sealing faces ’DF’ must be protected after removing fuel pressure pipes.AI - I29513DFFuel Pressure PipingRemoving, Fitting and Regrinding of Sealing FacesCFitting procedure is analogous to the removal but in re-verse sequence.Before fitting fuel pressure pipe 3 check whether its claws 5 are screwed on properly, i.e. the fuel pressure pipe must protrude by ’x’ = 11 mm compared to the claw as shown in Fig. ’B’.Measurement ’x’ can be adjusted by turning the claw us-ing an open end spanner.⇒Fit fuel pressure pipe.⇒Apply Never-Seez NSBT-8 to threads of screws 6and tighten them crosswise with a torque of 40 Nm.CHECKII - II795311139612DF 144⇒Remove claw 5 (Fig. ’B’).⇒Place regrinding device 94872a on sealing face ’DF’as shown in Fig. ’D’.⇒First rough-grind the sealing faces with grinding compound No. 200, then finish-grind them with grinding compound No. 500.⇒After grinding thoroughly clean the fuel pressure piping.D3DF94872aTools:Key to Illustrations:1O.M.T. test bench942721Valve housing10Screw plug1Slide gauge2Valve needle11Ball3Stop ring12Flushing valve4Distance ring12a Spindle5O-ring13Adapter (test head)6Disc spring (11 pieces)7Seating washer8Snap ring AB Drain bore9Spring carrier GW Thread34567981110Before dismantling a relief valve for overhaul (grinding in of the valve needle), dis-tance ’X’ must be measured and recorded as ’X’. For this purpose, distance ring 4must be pressed against stop ring 3 by screw plug 10.⇒After grinding valve needle 2 into the seat of valve housing 1, thoroughly cleanall parts, lightly oil valve needle 2 and apply MOLYKOTE paste G to parts 6, 7,9 and 11.D During assembly, care must be taken that disc springs 6 are correctly posi-tioned (Fig. ’A’).⇒Not yet fit distance ring 4.⇒Tighten screw plug until distance ’X’ is about the same as before dismantling.⇒For testing and setting the relief valve, use test bench 94272 (Fig. ’B’). Intermediate Fuel AccumulatorChecking and Setting of Relief Valve with O.M.T. Test Bench CHECK⇒Place the relief valve (without joint) into adapter 13 of test bench 94272 andtighten it.DPay attention to the manufacturer’s detailed instructions , in particular prior to commissioning and for the operation of the test bench.⇒Open flushing valve 12 a little by spindle 12a at adapter 13. Operate the testbench pump until pressure chambers are filled and diesel oil escapes bubble-free. Close spindle 12a.⇒Increase the pressure on the test bench and observe at what value the reliefvalve opens. Correct opening pressure = 1250 bar.⇒Set required pressure by adjusting screw plug 10. Measure distance ’X’ andnote it as ’X 1’ (Fig. ’A’).⇒Reduce height ’Y’ of the distance ring by the difference between distances ’X 1’and ’X’.⇒Reassemble relief valve with distance ring 4 and tighten screw plug until it isfully down on distance ring.Recheck the opening pressure on the completely assembled relief valve.I1394272B000.931/94⇒Apply Never-Seez NSBT-8 to thread ’GW’ (Fig. ’A’).⇒Screw the relief valve into the intermediate fuel accumulator and tighten it witha torque of 300 Nm .Intermediate Fuel Accumulator: Checking and Setting of Relief Valvewith O.M.T. Test BenchCHECKTools:Key to Illustrations:1OBEL test bench942721Valve housing10Screw plug 1Valve holder94272a2Valve needle11Ball1HP oil pump949313Stop ring12Relief valve 1Pressure gauge949324Distance ring13Receiver1HP hose949355O-ring6Disc spring (11 pieces)7Seating washer AB Drain bore8Snap ring EV Relief valve9Spring carrier GW Thread34567981110Before dismantling a relief valve for overhaul (grinding in of the valve needle), dis-tance ’X’ must be measured and recorded as ’X’. For this purpose, distance ring 4must be pressed against stop ring 3 by screw plug 10.⇒After grinding valve needle 2 into the seat of valve housing 1, thoroughly cleanall parts, lightly oil valve needle 2 and apply MOLYKOTE paste G to parts 6, 7,9 and 11.D During assembly, care must be taken that disc springs 6 are correctly posi-tioned (Fig. ’A’).⇒Not yet fit distance ring 4.⇒Tighten screw plug until distance ’X’ is about the same as before dismantling.⇒For testing and setting the relief valve, use test bench 94272 (Fig. ’B’). Intermediate Fuel AccumulatorChecking and Setting of Relief Valve with OBEL Test Bench CHECK⇒Fit relief valve 12 (without joint) into the valve holder and tighten it.⇒Connect valve holder 94272a to HP oil pump 94931.⇒Close relief valve ’EV’.⇒Increase the pressure by means of HP oil pump and observe at what value therelief valve opens. Correct opening pressure = 1250 bar.⇒Set required pressure by adjusting screw plug 10. Measure distance ’X’ andnote it as ’X 1’ (Fig. ’A’).⇒Reduce height ’Y’ of distance ring 4 by the difference between distances ’X 1’and ’X’.⇒Reassemble relief valve with the distance ring and tighten screw plug until it isfully down on the distance ring.Recheck the opening pressure on the completely assembled relief valve.B942721213⇒Apply Never-Seez NSBT-8 to thread ’GW’ (Fig. ’A’).⇒Screw the relief valve into the intermediate fuel accumulator and tighten it witha torque of 300 Nm .Intermediate Fuel Accumulator: Checking and Setting of Relief Valvewith OBEL Test BenchCHECKKey to Illustrations:1Intermediate fuel accumulator 29Valve tip 2Flange30Ball3Fuel pressure control valve 31Hose section 4Screw32Screw 5Locating pin33Cover 6Intermediate ring 34Valve seat 7Connection piece 35Filter8Knurled screw 36Solenoid valve 9Adjusting disc 37Cable socket 10Spring carrier 38Prop 11Valve body 39Screw 12Spring housing40Union13Compression spring 41Screw plug 14Compression spring 42O-ring 15Spring carrier 43O-ring 16Slide valve44O-ring (oil pressure regulating valve)45O-ring 17Measuring cylinder 46O-ring 18Bush47O-ring 19Cup spring 48O-ring 20Screw plug 49O-ring 21Screw 50O-ring 22Cylinder51O-ring 23Compression spring 52O-ring 24Piston 53O-ring 25Screw54O-ring 26Locating pin 55O-ring27Cover 28PistonOE Oil inlet pipeOverview1.General 1/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.Removal of fuel pressure control valve 2/6. . . . . . . . . . . . . . . . .3.Fitting the fuel pressure control valve 2/6. . . . . . . . . . . . . . . . . .4.Cleaning the filter 3/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.Dismantling the regulating part 4/6. . . . . . . . . . . . . . . . . . . . . . . . . 6.Assembling the regulating part 4/6. . . . . . . . . . . . . . . . . . . . . . . . .7.Dismantling the HP part 6/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .pping the valve seat 6/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.Assembling the HP part 6/6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .When working on a fuel pressure control valve in principle the engine has to be stopped, and it is essential that instructions 0510–1 in the Operating Manual be strictly followed.Remark: The work station must be clean; welding and grinding should not be done nearby!Fuel Pressure Control ValveRemoval, Fitting, Dismantling and Assembling⇒Remove all pipings from fuel pressure control valve 3.⇒Withdraw cable socket 37 from solenoid valve 36.⇒Connect the fuel pressure control valve (45 kg) to the crane by means of alifting tackle and tauten the latter.⇒Loosen screws 4 and move the fuel pressure control valve in arrow direction,taking care that intermediate ring 6 and connection piece 7 do not fall down.AI⇒Bring the fuel pressure control valve in fitting position at the intermediate fuelaccumulator by means of the crane.⇒Apply Never-Seez NSBT-8 to the screw threads 4.⇒Place new O-rings 53 and 54 into the grooves of intermediate ring 6.⇒Fit the intermediate ring over locating pin 5 and insert connection piece 7.⇒Fasten the fuel pressure control valve to intermediate piece 2 with screws 4and tighten them with a torque of 190 Nm .⇒Refit pipings and cable socket 37.Fuel Pressure Control Valve: Removal, Fitting, Dismantling and Assembling⇒Remove oil inlet pipe ’OE’ and union 40.⇒Loosen filter 35 and clean it.DFitting the filter (secured with LOCTITE No. 542) is carried out analogously to the removal but in the reverse sequence.B5336⇒Loosen and remove spring housing 12.⇒Remove spring carrier 10, compression springs 13 and 14.⇒Loosen screw plug 20 and remove it together with cup springs 19, measuringcylinder 17 and bush 18.Attention! T ake care not to lose the measuring cylinder.⇒Push slide valve 16 upwards and remove it.⇒Remove O-ring 42.⇒Clean all part and check them visually for wear.⇒Prior to fitting apply oil to the cleaned parts.⇒Replace all O-rings by new ones.⇒Fit the slide valve.Check the slide valve for ease of movement.⇒Fit O-ring 42 and pay attention that it lies behind the collar of the slide valve asshown in detail Fig. ’C’.⇒Fit bush 18 with measuring cylinder 17.Check the measuring cylinder for ease of movement.⇒Fit cup springs 19 and pay attention to their arrangement as shown in detailFig. ’C’.⇒Fit and tighten screw plug 20.⇒Fit spring carrier 15, compression springs 13 and 14.⇒Fit spring carrier 10 with O-ring 43 into spring housing 12.⇒Tighten spring housing.⇒Turn knurled screw 8 inwards till the stop.CHECKCHECKC⇒Loosen screws 21 and remove cylinder 22 together with compression spring23 and piston 24.⇒Loosen screws 25 and remove cover 27.⇒Draw piston 28 from valve body 11.Attention! T ake care that the valve tip 29 and ball 30 do not fall down.⇒Remove valve tip 29, ball 30 and hose section 31.⇒Remove screws 32 and remove cover 33.A worn (scratched) valve seat surface must be lapped in a lathe by means of a lapping mandrel, therefore valve seat 34 must be removed from valve body 11. The valve seat has an angle of 90_, however, the valve tip angle amounts to 89_. Remark: Due to lapping, the opening pressure of the fuel pressure control valve isnot affected.⇒Prior to fitting apply oil to the cleaned parts.⇒Replace all O-rings by new ones.⇒Fit and tighten valve seat 34.⇒Fit cover 33 with O-rings 44 and 45.⇒Equally tighten screws 32.⇒Fit hose section 31, ball 30 and valve tip 29 together with its O-rings 46 into piston 28.Remark: Prior to fitting O-rings 46 must be cut up into two equal halves, as theyserve as positioning of the valve tip.⇒Fit piston 28 with O-rings 47 and 48.⇒Fit O-rings 49.⇒Fit cover 27 together with O-ring 50 and tighten screws 25.⇒Fit O-rings 51 and 52.⇒Insert compression spring 23 and piston 24 into cylinder 22, place them on cover 27 and tighten screws 21.Tools:Key to Illustrations:1Regrinding device 948721Intermediate fuel accumulator 13Claw1Turnbuckle948732Stop valve 14Thrust ring 3Stop valve 15Drain screw 4Heating pipe16Valve block5Fuel pressure piping 17Screwed sleeve 6Fuel pressure piping 18Non-return valve 7Fuel pressure piping 19O-ring 8Pipe bracket 20O-ring 9,a,b Screw 21O-ring10,a Flange 11Screw12Intermediate pieceDFSealing face1.1Preparation to removal⇒Close steam supply to heating pipes 4 on plant side.⇒Remove casings where necessary.⇒Close respective stop valves 2 and 3.Remark: The spindles of closed stop valves 2 and 3 must be tightened with 100 Nm.⇒Open corresponding drain screws 15 (Fig. ’B’view III).Fuel Pressure PipingRemoving, Fitting and Regrinding1.2Removal of fuel pressure pipings 6 and 7D If a fuel pressure piping 6 must be removed, first dismantle the corresponding fuel pressure piping 7.DThe sealing faces ’DF’ at the pipe ends must be protected from any possible damages.1.2.1Removal of fuel pressure piping 7⇒Loosen corresponding heating pipe 4.⇒Undo screws 9 and push flanges 10a back till they do not mesh any more.⇒Pull fuel pressure piping 7 away and remove it from intermediate fuel accumu-lator 1.1.2.2Removal of fuel pressure piping 6⇒Undo screws 9a and push flange 10 back.⇒Undo screws 11 and remove them together with intermediate piece 12.⇒Undo screws 9b and remove fuel pressure piping 6.B456011.801/0449b 61041.3Removal of fuel pressure piping 5⇒Place turnbuckle 94873 between fuel pres-sure piping 5 as shown in Fig. ’C’.Remark: T ension turnbuckle 94873, so that it does not fall down.⇒Undo screws 9b and push flange 10 back till it does not mesh any more.⇒Remove fuel pressure piping 5.DThe sealing faces ’DF’ at the pipe ends must be protected from any possible damages.CDFitting procedure is analogous to the removal but in reverse sequence.Before fitting fuel pressure pipings 5, 6 or 7, check whether their claws 13 are screwed on properly,i.e. fuel pressure pipe must protrude by ’x’ = 16.5mm compared to the claw, as shown in Fig. ’D’.Measurement ’x’ can be adjusted by turning the claw using an open end spanner.Remark:For fitting fuel pressure piping 5 must be expanded to approx. 383 mm with turnbuckle 94873 as shown in Fig. ’C’.⇒Apply Never-Seez NSBT-8 to threads of screws 9, a, b and tighten them crosswise with a torque of 45 Nm.⇒Close all drain screws.⇒After refitting the fuel pressure piping open stop valves 2 and 3 and tighten their spindles with 100 Nm .CHECK5, 6, 7101413If a non-return valve 18 has been removed from valve block 16, O-rings 21 must be replaced by new ones.The proper flow direction (see arrow engraved in valve block) must be maintained when refitting the non-return valve (Fig. ’E’).⇒Apply LOCTITE 0222 to the screwed sleeve 17 and tighten it with a torque of80 Nm .EI - I⇒Remove claw 13 (Fig. ’D’).⇒Place regrinding device 94872 on sealing face ’DF’as shown in Fig. ’F’.⇒First rough-grind the sealing faces with grinding compound No. 200, then finish-grind them with grinding compound No. 500.⇒After grinding thoroughly clean the fuel pressure piping.F5, 6, 7DF94872。