Overhaul of 48 class engine lubrication system (pdf 94KB)

Overhaul of 48 class engine lubrication system (pdf 94KB)
ESR 0555
OVERHAUL OF 48 CLASS ENGINE
LUBRICATION SYSTEM
Version 1.0
Issued June 2010
Owner:
Approved
by:
Chief Engineer Rolling Stock
Stephen White,
Technical Specialist Rolling
Stock Performance Standards,
Rolling Stock Access Integrity
Authorised
by:
Michael Uhlig,
Manager,
Rolling Stock Access Integrity
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.
UNCONTROLLED WHEN PRINTED
Page 1 of 7
Engineering Standard
Engineering Standard
Rolling Stock
RailCorp Engineering Standard — Rolling Stock
Overhaul of 48 class engine lubrication system
ESR 0555
Document control
Revision
Date
Summary of change
(RSS 0555) 1.0
August 2007
Based on TRS 1507
(ESR 0555) 1.0
June 2010
Reformatted and renumbered ESR 0555
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..................................................................................................................................................3
2 General ...............................................................................................................................................3
3 Definitions ..........................................................................................................................................3
4 Special Tools .....................................................................................................................................4
5 Disassembly.......................................................................................................................................4
6 Replacement parts ............................................................................................................................4
7 Cleaning .............................................................................................................................................6
8 Inspection and reconditioning procedure ......................................................................................6
9 Assembly............................................................................................................................................6
10 Tolerances..........................................................................................................................................6
11 Performance.......................................................................................................................................7
12 Storage and transportation ..............................................................................................................7
13 Identification ......................................................................................................................................7
14 Referenced standards.......................................................................................................................7
14.1 RailCorp standards ...................................................................................................................7
14.2 Alco standards ..........................................................................................................................7
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 2 of 7
Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of 48 class engine lubrication system
1
ESR 0555
Scope
This standard sets out the minimum requirements, procedures and tests for the overhaul
of the engine lubricating oil system components for 48 class locomotive engines
The lubrication oil system consists of the following components, relief valve, regulating
valve, oil strainer, oil filter, oil cooler, oil pump and associated pipework and flexible
hoses.
Diagram1 – Schematic of the 48 class locomotive lubricating oil system.
2
General
This standard shall be used in conjunction with Alco Maintenance Instructions MI's
11022, 12000, 12002, 12003 and 12005, RailCorp Standards ESR's 250 and 575 and
Alco Spare Parts Manual DRP's 11400, 11419, 13902, 13903, 13904, 14084, 14165 and
14503, to provide clarification, amplification and additional requirements
where
necessary.
Record sheets for component stripdown, rebuild, tolerances and clearances shall be
completed with one copy retained by the Repairer and one copy supplied to the
Purchaser.
3
Definitions
OEM is an abbreviation for Original Equipment Manufacturer
MI is an abbreviation for Maintenance Instruction
DRP is an abbreviation for Renewal Parts List
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 3 of 7
Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of 48 class engine lubrication system
4
ESR 0555
Special Tools
Special tools, gauges and fixtures in accordance with Alco MI 11022 and ESR 0575 shall
be used during overhaul of components.
5
Disassembly
The lubricating oil system components shall be removed and disassembled in
accordance with Alco MI's 11022, 12000, 12002, 12003 and 12005, and ESR 0575.
The lubricating oil system pipe work shall be maintained as a set and shall be reinstalled
on the locomotive from which it was removed. Flanges shall be match marked and oil
lines tagged with the locomotive number to ensure correct assembly.
6
Replacement parts
All replacement parts shall be genuine GE-Alco to the latest revision unless otherwise
specified or approved by the Purchaser.
It is mandatory to renew the following components:
Regulating valve (DRP 13904)
• Gasket, body to spring housing
Alco P/N 2152274
• Gasket, regulating valve to base
Alco P/N 2152267
Lubricating oil pump (DRP 13902)
• Gasket, back plate
Alco P/N 2391363-1
• Gasket, face plate
Alco P/N 2391362-1
• Locknut, 5/8-11
Alco P/N 2153211,
• Lockwire, .054 x 6 in
Alco P/N 65091-0024
• Gasket, pump and plate to base
Alco P/N 2152282,
14 off
2 off
Lubricating oil relief valve (DRP 2716)
• Gasket, copper
Alco P/N 1251143 *
* Note - Genuine Part not required.
Fuel and lubricating oil strainer (DRP 13903)
• Gasket, cover to housing
Alco P/N 1601356
• Element, strainer
Alco P/N 1601492-2
Lubricating oil filter (DRP 14503)
• Gasket, cover to housing
Alco P/N 1601356
• Element, filter (34 inch overall)
Alco P/N 16011911
Associated piping and hoses
All flexible hoses in the lubricating oil system shall be renewed.
Engine base with screens and covers (DRP 11400)
• nil
© Rail Corporation
Issued June 2010
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Page 4 of 7
Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of 48 class engine lubrication system
ESR 0555
Lubricating oil to valve levers and fuel pump supports (DRP 14165)
• nil
Lubricating oil to camshaft gear (DRP 14165)
• nil
Lubricating oil drain from governor
• nil
Lubricating oil drain from turbo (DRP 14165)
• Hose flexible, from turbo to base
Alco P/N 24023516
Lubricating oil to camshaft to valve gear header (DRP 14165)
• nil
Lubricating oil to governor (DRP 14165)
• nil
Lubricating oil to vibration damper
• nil
Lubricating oil filler pipe (DRP 14165)
• Gasket, pipe to base
Alco P/N 2152267
Lubricating oil to turbo (DRP 14165)
• Hose, flexible, valve gear header to turbo
Alco P/N 2402359
Lubricating oil regulating valve (DRP 13904)
• Gasket, regulating valve to base
Alco P/N 2152267
Lubricating oil strainer to base (DRP 13903)
• Gasket, element to cover and base
Alco P/N 1671686
Lubricating oil drain from crankcase exhauster (DRP 14084)
• Hose, flexible, blower to gear cover
Alco P/N 24030748
Oil cooler
• The replacement of parts shall be in accordance with ESR 0575.
The following components are to be replaced on condition:
Regulating valve (DRP 13904)
• Bushing, seat
Alco P/N 2491117
• Disc, cup
Alco P/N 2491128
Lubricating oil relief valve (DRP 2716)
• Body
Alco P/N 1251087
• Piston
Alco P/N 1251174
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 5 of 7
Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of 48 class engine lubrication system
ESR 0555
The lubricating oil pressure gauge shall be replaced with a new gauge.
All gate valves (drain valves) in the lubricating oil system pipe work shall be replaced with
new gate valves.
Genuine GE-Alco lockwire is not required. A suitable alternative supplier is acceptable.
7
Cleaning
The disassembled lubricating oil system components shall be cleaned with a non toxic
organic cleaner such as Quaker Solv cleaner 76 or equivalent. This is best achieved
using a cleaning tank with temperature regulation and agitator action This will reduce the
cleaning time period. Internal passageways in pipework are to be thoroughly cleaned.
Continue cleaning process until all impurities have been removed.
Gasket faces shall be thoroughly cleaned and care must be taken so as not to scratch
these faces.
Rinse components with steam/water spray immediately after removal from the tank to
remove any residue.
8
Inspection and reconditioning procedure
All reusable parts shall be inspected and requalified in accordance with Alco MI's 11022,
12000, 12002, 12003 and 12005, and ESR 0575.
Gear teeth condition shall be assessed in accordance with Alco MI 11030.
The regulating and relief valves shall be set in accordance with ESR 0250.
The repairer shall develop appropriate inspection report sheets and procedures for use
with this Specification. The report shall include a visual inspection of teeth for wear,
thermal cracks or scoring. Component dimensions and tolerances shall be provided.
Evidence of a check of oil passages for cleanliness shall be provided.
Report sheets showing condition, dimensions, clearances and tolerance of components
shall be submitted to the Purchaser. These details will be used for component tracking
and maintenance planning. The sheets shall also indicate those components that exceed
manufacturer’s tolerances or cannot be re-used.
9
Assembly
The lubricating oil system shall be reassembled in accordance with Alco MI's 11022,
12000, 12002, 12003 and 12005, and ESR 0575.
The lubrication system pipe work shall be reinstalled on the engine/locomotive after requalification. Match marks shall be aligned.
10
Tolerances
During inspection and assembly all required dimensions, clearances, tolerances and
torques are to be as specified in Alco MI's 11022, 12000, 12002, 12003 and 12005, and
ESR 0575.
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 6 of 7
Version 1.0
RailCorp Engineering Standard — Rolling Stock
Overhaul of 48 class engine lubrication system
11
ESR 0555
Performance
The standards set for the overhaul of Alco 251B-6LS engine lubricating oil systems in this
Standard/Instruction shall provide a satisfactory level of performance for a nominal six (6)
year operating period.
12
Storage and transportation
If any components of the lubricating oil system are not to be immediately installed on an
engine, then all wearing surfaces are to be lubricated with a suitable corrosion inhibitor
such as Tectyl 506 or equivalent.
For storage and transportation purposes cover plates shall be applied to the oil cooler
flange faces and the oil pump shall be protected in a suitable container.
13
Identification
Reused oil coolers are to retain any existing serial number. If it is replaced with a new oil
cooler then a new serial number is to be stamped on the identification plate.
14
Referenced standards
14.1
RailCorp standards
ESR 0250 Alco oil regulating and relief valves.
ESR 0575 Overhaul specification oil coolers.
14.2
Alco standards
MI 11022 Alco Maintenance Manual - 48 & 80 class lubricating oil pump.
MI 12000 Alco Maintenance Manual - 48 class lubricating oil filter.
MI 12002 Alco Maintenance Manual - 48 class pressure regulating valve.
MI 12003 Alco Maintenance Manual - 48 class lubricating oil strainer.
MI 12005 Alco Maintenance Manual - 48 class by-pass & relief valves.
DRP 2716 Alco Part List - 48 class lubricating oil relief valve
DRP 11400
Alco Part List - 48 class engine base with screens & covers.
DRP 11419
Alco Part List - 48 & 80 class engine base with screens & covers.
DRP 13902
Alco Part List - 48 class lubricating oil pump & drive.
DRP 13903
Alco Part List - 48 class lubricating oil strainer.
DRP 13904
Alco Part List - 48 & 80 class lubricating oil regulating valve.
DRP 14084
Alco Part List - 48 class crankcase exhauster.
DRP 14165
Alco Part List - 48 class lubricating oil piping.
DRP 14503
Alco Part List - 48 class fuel & lubricating oil filter.
© Rail Corporation
Issued June 2010
UNCONTROLLED WHEN PRINTED
Page 7 of 7
Version 1.0
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