Cylinder Block, Liners and Cylinder Heads
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| Illustration 1 | g00816330 |
(1) Cylinder block (2) Cylinder liner (3) Filler band (4) O-ring seals (5) Main bearing cap (6) Stud (7) Nut (8) Saddle bolt (9) Stud | |
Cylinder block (1) is a one-piece casting. The air inlet plenum extends for the full length of the cylinder block in order to provide even distribution of air to the cylinders.
Cylinder liners (2) can be removed for replacement. The top surface of the cylinder block is the seat for the cylinder liner flange. Engine coolant flows around the cylinder liners in order to keep the cylinder liners cool. Filler band (3) and three O-ring seals (4) seal the coolant in the cylinder block.
Main bearing caps (5) are fastened to the cylinder block with two studs (6) per cap. Nuts (7) for the studs are hydraulically tensioned. Each main bearing cap has one saddle bolt (8) on each side of the cylinder block. The saddle bolts help prevent the movement of the main bearing cap. The saddle bolts also add strength to the lower area of the cylinder block.
The engine has a separate cylinder head for each cylinder. Each cylinder head is fastened to the cylinder block by four studs (9) and four nuts (10). The studs are hydraulically tensioned. The nuts are tightened by hand and the hydraulic tension is released.
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| Illustration 2 | g00816362 |
(10) Nut (11) O-ring seal (12) Opening (13) O-ring seal (14) Combustion gasket | |
Each cylinder head contains the valve mechanism for inlet air, fuel, and exhaust gas. For information on the valve mechanism, refer to Systems Operation, "Air Inlet and Exhaust System". The inlet and exhaust valves move in replaceable valve guides which are pressed into the cylinder head.
O-ring seals (11) seal coolant that flows to the cylinder head through four adapters. Engine oil that returns to the engine oil pan through opening (12) is sealed with O-ring seals (13). The seals are installed in two plates for each cylinder head.
Combustion gas is sealed by combustion gasket (14) that is installed between the cylinder liner flange and the cylinder head.
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| Illustration 3 | g00816437 |
(15) Cover for the camshaft (16) Cover for the crankcase (17) Crankcase explosion relief valve | |
Covers (15) allow access to the camshafts, the valve lifters, and the valve lifter guides.
Covers (16) allow access to the crankshaft, the connecting rods, the piston cooling jets, and the main bearings.
Crankcase explosion relief valves (17) open in order to relieve the pressure in case of an explosion in the crankcase. The valves close immediately in order to keep fresh air from entering the crankcase. A pressure of 7 kPa (1 psi) is required to open the valve. An oil screen quenches any flames from an explosion. Do not change the total number of crankcase explosion relief valves that are installed on the engine.
Pistons, Rings and Connecting Rods
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| Illustration 4 | g00816458 |
(1) Piston (2) Compression rings (3) Oil ring (4) Connecting rod (5) Piston pin (6) Pin retainer (7) Bolt (8) Connecting rod cap (9) Connecting rod bearing | |
Aluminum pistons (1) have a steel crown and three rings. The rings include two compression rings (2) and one oil ring (3). All the rings are located above the piston pin bore. The oil ring is a three-piece ring. Engine oil returns to the crankcase through holes in the oil ring groove.
The piston is attached to connecting rod (4) with piston pin (5) and two pin retainers (6). The connecting rod has a taper on the pin bore end. This taper gives the connecting rod and the piston more strength in the areas with the most load. Four bolts (7) hold connecting rod cap (8) to the connecting rod. This design keeps the connecting rod width to a minimum, so that a larger connecting rod bearing (9) can be used and the connecting rod can still be removed through the cylinder liner.
The piston has two 1/2 -13 NC threaded holes in the crown for lifting the piston and connecting rod assembly.
Crankshaft
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| Illustration 5 | g00816471 |
(1) Journal (2) Main bearing (3) Thrust plates (4) Flange | |
The crankshaft changes the combustion forces in the cylinders into usable rotating torque which powers the driven equipment. The connecting rods for the pistons are connected to journals (1). A counterweight for each cylinder is welded to the crankshaft.
Pressure oil is supplied to main bearings (2) through drilled passages in the webs of the cylinder block. The engine oil flows through passages that are drilled in the crankshaft in order to provide lubrication for the connecting rod bearings.
The G3612 Engine has seven main bearings. The G3616 Engine has nine main bearings. Two thrust plates (3) control the end play of the crankshaft.
Flanges (4) are machined at both ends of the crankshaft for mounting of the flywheel and vibration damper.
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| Illustration 6 | g00816530 |
Vibration damper | |
The vibration damper is bolted to the front of the crankshaft in order to reduce torsional vibrations (twist) that can cause damage to the engine.
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| Illustration 7 | g00807826 |
Cross sections of the crankshaft seals and wear sleeves | |
Seals and wear sleeves are used at both ends of the crankshaft. Oil is sealed by the lip seals and the wear sleeves help prevent wear on the crankshaft.
The crankshaft drives a group of gears on the front and rear of the engine.
Camshafts
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| Illustration 8 | g00816510 |
Camshaft assembly | |
The engine has a camshaft assembly for each bank.
The camshafts are assembled with identical segments, journals, spacers and a drive end. Each segment has three lobes. Individual segments can be replaced for each cylinder through access holes in the cylinder block. Each camshaft assembly is supported by seven bearings. A thrust plate at the rear of each camshaft controls end play.
As the camshaft turns, each lobe moves a lifter assembly. There are three lifter assemblies for each cylinder. Each outer lifter assembly moves a pushrod for two inlet valves or exhaust valves. The center lifter assembly moves a pushrod that operates the gas admission valve.
The relation of the camshafts to the crankshaft position cause the valves to operate at the correct time. The camshafts must be in time with the crankshaft.
Front Gear Group
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| Illustration 9 | g00816519 |
The gear group in the front housing of the engine drives the jacket water pump, the aftercooler/oil cooler pump, the engine oil pump, and the pump for the hydraulic oil.
Rear Gear Group
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| Illustration 10 | g00816521 |
The rear gear group drives the driven equipment and the camshafts.