Inspect and qualify, in-place, the turbocharger and clutch utilizing the EMD roller clutch and run-down time tests. Clean and inspect the parts catcher. Upgrade the after-coolers to 4-pass for cylinder engines; rebuild or install UTEX after-cooler cores for cylinder engines; inspect after-cooler ducts for cracks and repair as required. Remove all engine power assemblies. Clean and inspect oil separator screen, ejector assembly, and eductor tube assembly. Remove exhaust stack manifolds and replace exhaust manifold gaskets.
Inspect manifolds and advise VRE of cracks, etc to determine disposition of the manifolds; inspect top deck exhaust manifold bolt holes to allow for proper torquing of stack manifolds - repair holes as required with Keylocking thread repair inserts. Thoroughly clean the airboxes, oil pan, crankcase, and Michiana tank and remove dirt, debris, and chips. Inspect the engine for structural cracks and advise VRE of inspection results to determine disposition of material.
Replace all Michiana lube oil filters. Remove clean and re-install inertial air filters. Replace engine air filters. Replace all fuel filters. Install new lower main bearings and main bearing thrust collars. Inspect and qualify the piston cooling tubes P-pipes ; replace as required. Rebuild power assemblies as follows: 1. Completely disassemble, clean, and inspect each power assembly. Clean and inspect connecting rods for length, twist, piston pin surface and bore parallel. Pistons shall have tin plated skirts and ring sets with chrome faced no.
Carriers shall be checked visually and dimensionally, inspected, and reassembled with new thrust washer and snap ring. Cast iron cylinder liners with hardened upper bore shall be used. Rebuild cylinder heads with new Inconel valves, valve guides, valve springs, and valve retainers installed in rebuilt cylinder head.
Heads shall be Diamond 5 or newer. Install new liner seals and head gaskets. Install new lower liner inserts. The completed assembly shall be hydrostatic pressure tested. Record the old and the new head, liner, and rod serial numbers by location. Plate-type crabs and new head seat rings shall be used when installing the Power Assembly in the engine.
Inspect cams and replace as required, inspect cam followers, valve bridges, rocker arms, rocker arm bushings, and rocker pins. Replace camshaft bearings with new. Install remanufactured fuel injectors Green Label, Eco-Tips and record serial numbers by location. Replace primary canister fuel filter and pipe as required. Replace water pumps with UTEX units; record serial numbers. Remove top deck cover supports, regasket, and reinstall covers.
Replace worn latches as required. Replace engine governor unit with qualified UTEX unit; repair the governor linkage as required. Replace crank case pressure and low water pressure detector engine protector with OEM qualified unit. Check turbo lube pump operation by observing lube oil flow at camshaft gear train. Debur, inspect, and install the injector control linkage. Assemble engine using all new gaskets, seals, o-rings, bushings and miscellaneous hardware.
Silicone sealant e. RTV shall not be used to substitute for properly fitting seals and gaskets. Assemble using OEM recommended torque specifications, clearances and gear lash. Provide assembly record sheets. Make and record lead readings for each cylinder. Inspect and qualify all electrical and electronic components and wiring on the engine that have been handled or moved during the overhaul; and B. Replace with new as necessary. No butt splices shall be acceptable without written permission from VRE.
Identify work needed to bring the locomotive into compliance with Federal Railroad Administration FRA regulations; provide a proposal to VRE for corrective action needed to achieve compliance; provide current FRA form 49A cab card for each locomotive to be signed by a certified inspector on delivery of the locomotive to VRE. Wash and clean the battery cells, connections, and battery box.
The battery shall be filled, qualified, and charged, and the specific gravity of the electrolyte in each cell checked and recorded. Damage to the battery box shall be evaluated and corrective action proposed to VRE. For this purpose, the company has about dynamometer stands in Europe and the USA. Priority of the brand has not changed since — these are engines for heavy trucks.
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