"Sheer, Maintenance 2105-2/A1 Cylinder Liner ZA40S | Removing and Fitting a Cylinder Liner Tools Key to Mlustratons: 1 Hydr- hand pump 940302 Oftinderliner 9 screws 1 Branch piece 9408.03 2 Onings 10 Connecting rod head 1 rear pope swoe0s +3 Screw 20 11 Screws 2 HPhoses 9408.09 4. Centing piece 1 Torque wrench 98175: Screws 1 Devic fr lapping 962101 6 Engine housing 1 Breese yoke Santo 774 Orringe 1. Suspension device 54708 "8 Cylinderlubrcaing pipe +” Tightening according 1 Fixing plate 943308 tolnstructions 1 Shackle 1 Rope (capacity 11) ‘Remark regarding running-in of new cylinder liners ‘When one or more cylinder liners are replaced, these have first to be run-in, whereby the indications of the Operating Instructions on section 0360 'Running-in the Engine after an Overhaul’ have to be followed. Preparatory workfor the removal ofa cylinder liner — Drain al the cooling water from the engine. Remove the eylinder head and withdraw the piston ofthe eylaes liset concerned (see group 2701~1 and 3401—1). ~ Bar the crankshaft until the crank ofthe liner concerned stands in L.C, ~ Cover the space below the cvlinder liner concerned with clean cardboard or similar to ensure that no foreign particles can enter the crankcase. Removal On engines equipped with pistons without inner lubrication, loosen pipe connections 8 and remove the banjo bolts (Fig.’) — Loosen screw 3 of the centring piece 4 and remove it (Fig. — Tumn the connecting rod head 10 o the position shown in Fig — Connect the jacking yoke 9421.04 by two HP-hoses 9408.09 tothe hydraulic hand pump 9408.02 and fasten it withthe serews 11 to the connecting rod head 10 as shown in Fig. ’B' — Timm the connecting rod head with fastened jacking yoke into the position as shown in Fig, ’C’. — Atthe same time fit two stud 12 and screw fasten the fixing plate 9433.09, as shown in Fig.’Ay'toconnecting rod head 10. The fixing plate must come tole on counterweight 13. The ixing of te connecting rod head isnecessary tor safety reasons in order to prevent an inadvertent turning of the connecting rod head with the pressure yoke fitted — Actuate the hand pump 9408.02 carefully paying attention that the yoke correctly mates the bottom of the cylinder liner, ~ Check again whether the screw 3 has actually been removed (Fig. ~ Continue pumping and jack the cylinder hiner out o its guide. ). “Attention | The stroke of the jack inthe yoke is only 54 mm, — Mount the suspension device 9421.08 on the cylinder liner top and fasten itwith the screws9 (Fig. and’E’), Watch. that the screws 9 mate with the holes in the cylinder liner collar, ~ Fasten one shackle with the rope at AH’ on the suspension device and pull the cylinder liner (about 450 kg) out (Fig, C) V-Mot. 1 10952105-2/A1 Maintenance Sheer ZA0S. — Remove the jacking yoke, the hydr. hand pump as well as the fixing plate 9433.09 and both studs 12 from the engine. — Place the rennuved lines lines wn a even surface aun seamove the suspension device- ~ Clean the landing surface on the engine housing and check whether it is damaged. ~ Clean the guiding bores inthe engine housing and if necessary smooth out with emery cloth. Fitting ~ Check whether the landing surface for the cylinder liner and the guiding bores in the engine housing are clean and smooth. ~ Smear the landing surface on cylinder liner/engine housing with sealing compound Hylomar SQ32/M or Golden Her- ‘metite. — Equip the oylinder liner with new heat resisting O-rings (see group 0328—1) and smear these as well as the guiding surfaces F” in the engine frame with fresh engine lubricating oi. — Mount the suspension device 9421.08, fasten it with the screws 9 in the liner collar and lift the cylinder liner with the ‘crane on shackle and rope at the suspension point “AH (weight about 450 kg). — With the cylinder liner suspended, blow compressed air through the lubricating oil bores at the bottom (only for en- ‘gine equipped with pistons without inner lubrication). ~ Lower the cylinder liner slowly and carefully into the engine housing. — Before the cylinder liner mates the guide bores, tum it so that the centring piece 4 when further lowered will Gtinto the bore provided on the camshaft side. With smooth and well lubricated guide bores ’F” and O-rings, the cylinder ier will slide down under its own weight into the engine housing. If necessary tap the liner collar lightly witha lead hammer. ~ Finally locate the liner with the screw 3 dipped in oil and attach cylinder lubricating pipes to the bottom end of the liner (only for engine equipped with pistons without inner lubrication). Tighten the sorew 3 with 150 Nm. ~ If necessary lap the sealing surface on the liner collar with lapping ring 9421.01 and lapping paste. Actuate the hand crank ofthe cylinder lubricator and check thatthe oll issues from both lubricating holes inthe rele- ‘vant cylinder liner (only for engine equipped with pistons without inner lubrication). 1995, 2 VeMotZA40S Maintenance 2105-2/A12105-2/A1 (~~ ro ei \ 1995