ESR 0559 - Overhaul of 48 class locomotive engine block ...

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Engineering Standard Rolling Stock

ESR 0559

OVERHAUL OF 48 CLASS LOCOMOTIVE ENGINE BLOCK &

PAN

Version 1.0

Issued June 2010

Disclaimer This document was prepared for use on the RailCorp Network only. RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the copy of the document it is viewing is the current version of the document as in use by RailCorp. RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes any liability which arises in any manner by the use of this document. Copyright The information in this document is protected by Copyright and no part of this document may be reproduced, altered, stored or transmitted by any person without the prior consent of RailCorp.

Owner: Chief Engineer Rolling Stock Approved by:

Stephen White, Technical Specialist Rolling Stock Performance Standards, Rolling Stock Access Integrity

Authorised by:

Michael Uhlig, Manager, Rolling Stock Access Integrity

UNCONTROLLED WHEN PRINTED of 10

RailCorp Engineering Standard — Rolling Stock Overhaul of 48 class locomotive engine block & pan ESR 0559

© Rail Corporation of 10 Issued June 2010 UNCONTROLLED WHEN PRINTED Version 1.0

Document control

Revision Date Summary of change (RSS 0558) 1.0 August 2007 Based on TRS 1535 (ESR 0558) 1.0 June 2010 Reformatted and renumbered ESR 0558

Summary of changes from previous version

Summary of change Section NOTE – If the final document is small enough for the ‘Contents’ and ‘Document control’ to fit on one page remove the page break between the existing pages 2 and 3. HOWEVER if the ‘Document control’ page carries over to a second page separate pages must be used for ‘Contents’ and ‘Document control’



Contents

1 Scope..................................................................................................................................................4 2 General ...............................................................................................................................................4 3 Replacement parts ............................................................................................................................4 4 Disassembly.......................................................................................................................................4 5 Inspection and overhaul ...................................................................................................................5

5.1 Block and pan ...........................................................................................................................5 5.2 Lower cylinder liner sleeve........................................................................................................5 5.3 Upper cylinder bore...................................................................................................................5 5.4 Main bearing bores ...................................................................................................................5 5.5 Camshaft bore...........................................................................................................................6 5.6 Cylinder head studs ..................................................................................................................6 5.7 Lifting lugs .................................................................................................................................7 5.8 Oil rails ......................................................................................................................................7 5.9 Pump intake pipe strainer .........................................................................................................7 5.10 Water and oil pump adaptor plates ...........................................................................................7 5.11 Crankshaft explosion door ........................................................................................................7 5.12 Inspection covers ......................................................................................................................7

6 Assembly............................................................................................................................................7 7 Storage and transportation ..............................................................................................................7 8 Reference standards.........................................................................................................................8

8.1 RailCorp standards ...................................................................................................................8 8.2 Alco standards ..........................................................................................................................8

Appendix A Photographs ......................................................................................................................9



1 Scope This standard sets out the minimum requirements, procedures and tests for the overhaul of the engine block and pan for 48 class locomotives.

2 General This standard is to be used in conjunction with the Manufacturer's Maintenance Instruction MI-11062 and MI-11079 and Alco Parts List DRP-11419 and DRP-13100 unless otherwise stated.

The Repairer shall develop appropriate inspection report sheets and procedures for use with this specification. The inspection sheets shall include the list of components that, because of condition, cannot be re-used.

The Repairer shall complete all documentation regarding the overhaul of the Engine Block and Pan. This shall include a comprehensive re-build record and component serial number listing to facilitate component tracking, wear rate determination etc. One copy shall be retained by the Repairer and one copy sent to the Purchaser.

3 Replacement parts It is mandatory to replace the following items:

• Hold down bolt tab plates

• Lower cylinder liner sleeves

• All gaskets

• "O" rings

• Main bearings (identified and dated)

• Upper cylinder liner sleeve - 48 class locomotive (251B-6LS engine block) only.

All new parts shall be sourced from the O.E.M unless alternative suppliers have been approved by the Purchaser.

Other items shall be re-used if their condition is satisfactory for the specified operational requirements.

All new and re-used parts shall be stored in an area free from the effects of climate and dust.

4 Disassembly The engine block and pan shall be disassembled in accordance with Manufacturer's Maintenance Instruction MI-11079.

Components to be reused from each engine block shall be kept together for cleaning and re-assembly.

Block and pan shall remain matched. Pan shall be stamped with the block's serial number.

The lube oil tube between the block and pan shall be removed before splitting.

The block and pan shall be split as outlined in MI-11079.


5 Inspection and overhaul

5.1 Block and pan Clean and inspect the engine block and pan for cracks, signs of leaks and other damage, paying particular attention to the crankshaft, camshaft and engine block liner bores.

If cracks or any other serious damage is detected the Purchaser shall be contacted regarding a decision on whether or not the block can be salvaged.

5.2 Lower cylinder liner sleeve Renew all lower cylinder liner sleeves.

5.3 Upper cylinder bore Inspect upper cylinder liner bores and ensure that they are not fretted and that the dimensions are within the limits shown in Figure 1. If upper bores fail to satisfy the limits in Figure 1 then notify the Purchaser for reclamation policy.

Figure 1. Cylinder liner bore fit (dimensions shown in inches)

5.4 Main bearing bores With the original main bearing caps installed and tightened to correct elongation, check the bores for wear and misalignment against the limits shown in MI-11079. Advise Purchaser if not within limits.

Check out-of-roundness at planes A, B and C, and D, E and F as shown in Fig. 2. Bore diameter must not exceed limit. Advise Purchaser if not within limits.

Check vertical taper between planes A and D (on Fig. 2) and taper at 45° from vertical between planes B and F, and C and E. Advise Purchaser if not within limits.



Figure 2. Checking main bearing bores out-of-round

Check horizontal misalignment of any adjacent bores and that of any two non-adjacent bores as shown in Fig. 3. Alignment qualification is to be carried out with optical measurement equipment or an approved equivalent process.

Check vertical misalignment of any three adjacent bores and any two non-adjacent bores with optical method as shown in Fig. 3. Limit is measured between highest and lowest bores. No compensation is allowed for bore out-of-roundness, taper or variation in diameter.

Figure 3 Checking vertical and horizontal misalignment of main bearing bores

5.5 Camshaft bore The camshaft bearing support webs shall be checked for cracks. Advise Purchaser if cracks are detected.

The bore diameters should be checked against the limit shown in the Specification. On installation, the split in the bushing shall be at a 90° angle to the engine block liner bore and shall be facing outward.

5.6 Cylinder head studs Ensure all cylinder head studs are completely screwed into the engine block. Oversize studs are available on reference to the Purchaser.




5.7 Lifting lugs Crack test and certify all lifting lugs.

5.8 Oil rails Remove oil rails and renew gaskets.

5.9 Pump intake pipe strainer Remove pump intake pipe strainer and clean.

5.10 Water and oil pump adaptor plates Remove water and oil pump adaptor plates and renew gaskets.

5.11 Crankshaft explosion door Disassemble and clean door assembly.

Inspect clamp bar and valve springs for wear and physical damage. Replace if necessary.

Inspect locking knob and de-burr if necessary.

Assemble with new valve and spindle "O" rings and base door gasket.

5.12 Inspection covers Disassemble and clean covers.

Inspect clamp bar for wear and physical damage. Replace if necessary.

Inspect locking knob and de-burr if necessary.

Assemble with new gasket.

6 Assembly Assemble as described in Manufacturer's Maintenance Instruction, MI-11079.

New hold down bolt tab plates shall be fitted to hold down feet on pan.

7 Storage and transportation Prior to storing the overhauled block and base, it shall be pre lubricated with an acceptable preservative oil such as Shell ENSIS engine oil 30 or Tectyl 823 EM.

The overhauled block and pan shall have all openings and orifices blanked off to prevent the entry of dirt or foreign materials during storage and transportation.

The block and pan shall be mounted in a suitable stand for transportation. The stand shall provide adequate protection for the block and pan and shall prevent it from tipping over during transportation.



8 Reference standards

8.1 RailCorp standards ESR 0550 Overhaul of 48 class locomotive engine assembly

8.2 Alco standards MI-11062 Alco Instruction Manual, engine base

MI-11079 Alco Instruction Manual, cylinder block

DRP-11419 Alco Parts List, Base (engine) with screens and covers

DRP-13100 Alco Parts List, 48 class cylinder block

DRP-14638 Alco Parts List, 80 class cylinder block


Appendix A Photographs

Alco 251ce Engine block showing strengthened camshaft bearing support webbing



Pre Alco 251ce Engine block camshaft bearing support webbing.


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