2806Perkins柴油發電機組缸套維修安裝測量方法

Cylinder liners

To remove and to fit

Special requirements

Operation 7-2

To remove

  Remove the pistons and connecting rod assemblies, Operation 4-.

2  Fit c overs over the journals of the crankshaft for protection from dirt or water.

  Use the special tool (A), GE5000, to remove the cylinder liners (A2). Make a note of the bore position to

which each liner is fitted.

To fit

  Clean the cylinder liners and the liner bores in the crankcase.

2  Install the cylinder liners in the cylinder block without the ‘O’ ring seals or the filler band. Ensure that the

cylinder liners are fitted to their original pos itions.

  Check the protrusion of the cylinder liners, Operation 7-.

4  Remove the liners and fit new ‘O’ ring seals.

Note: Apply liquid soap and/or clean engine oil immediately before assembly. Do not apply the liquid soap and/

or clean engine oil to the seals  too early as the seals may swell and become pinched by the liners during

installation.

5  When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upper filler band

must be lubricated before installation. If the lower ‘O’ ring seals are black in colour, apply liquid soap to them

and to the cylinder block, and immerse the upper filler band in clean engine oil. If the lower ‘O’ rings are brown

in colour, apply engine oil to them, to the cylinder block and immerse the upper filler band in clean engine oil.

6  After the engine oil or liquid soap has been applied, immerse the filler band in clean engine oil, then

immediately fit the filler band to the groove in the cylinder liner below the liner flange. Immediately install the

cylinder liner in the crankcase before expansion of the band occurs. Use the special tool (B), GE50000, to

install the liners  (B2). Ensure that the liners are fitted to the correct positions.

7  Fit the pistons and connecting rod assemblies, Operation 4-.

7

2800

To check and to adjust the protrusion of the cylinder liners

Special requirements

Operation 7-

Note: Cylinder liner protrusion is measured from the top of the cy linder liner to the top of the spacer plate.

  Ensure that the top face of the cylinder block (A4) is clean. Fit a new spac er plate gasket and fit a clean

spacer plate (A).

2  Fit the cy linder liners to the cylinder block without seals or bands. Ensure that the cylinder liners are fitted

to their original positions.

  Install all of the bolts (A6), GE50005, or the six bolts around the liner (A5) to be checked. A plain washer

(A), GE50006, and a fabric washer (A2), GE50007, must be fitted to each bolt. Tighten the bolts to a torque

of 95 Nm (70 lbf ft).

4 Use the special tool, GE50002, to measure the liner protrusion at the four positions shown (B, B2, B and

B4) and record the measurements for each cylinder.

5  Add the four readings for each cylinder and divide the sum of the readings by four to obtain the average

reading for eac h cylinder.

The correct specifications for cylinder liner protrusion are:

Liner protrusion: 0,025 to 0,52 mm (0.00 to 0.006 in)

Maximum variation in each liner: 0,05 mm (0.0020 in)

Maximum average variation between adjacent liners: 0,05 mm (0.0020 in)

Maximum variation between all liners: 0,02 mm (0.0040 in)

Note: If the liner protrusion changes around the liner, turn the liner to a new position within the bore. If the liner

protrusion is not within the specifications, move the liner to a different bore. Inspect the top face of the cylinder

block.

Continued7

6 If the liner protrusions are all below the specifications or low in the range, 0,025 mm (0.00 in) or 0,05 mm

(0.002 in), try a thinner spacer plate, available from your Perkins dealer. These plates are 0,076 mm (0.00 in)

thinner than the original plate and will increase the liner protrusion. Use these spacer plates to compensate for

low liner protrusions whic h are less than the 0,076 mm (0.00 in). Use these spacer plates if inspec tion of the

top face of the cylinder block reveals no measurable damage directly under the liner flanges but the average

liner protrusion is less than 0,076 mm (0.00 in).

Caution: Do not exceed the maximum liner protrusion of 0,52 mm (0.006 in). Excessive liner protrusion will

cause the liner flange to crack.

7 When the liner protrusion is correct, add a temporary mark to the liner and to the spacer plate to assist with

the assembly procedure. Remove the bolts  and washers, and withdraw the cylinder liners.

8  When the engine is ready for final assembly, the ‘O’ ring seals, the cylinder block and the upper filler band

must be lubricated before installation. If the lower ‘O’ ring seals are black in colour, apply liquid soap to them

and to the cylinder block. Immerse the upper filler band in clean engine oil. If the lower ‘O’ rings are brown in

colour, apply engine oil to them and to the cylinder block. Immerse the upper filler band in clean engine oil.

Note: Apply liquid soap and/or clean engine oil immediately before assembly. Do not apply the liquid soap and/

or clean engine oil to the seals  too early as the seals may swell and become pinched by the liners during

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