K98MC-C VOLUME II EDITION 1 MAINTENANCEInstructions for Main Engine Type K98MC-C “This book forms part ofa sot of books consisting of tree volumes ented: Vol.| OPERATION Vol. MAINTENANCE Vol lll COMPONENTS AND DESCRIPTIONS. “The purpose ofthese books i to provide general guidance on operation and maintenance and {a desorbe the constuconal features ofa standard version ofthe above engine type. Devons ‘may be found in aepectc plant. In addon, the books can be used for reference purposes, for instance in correspandance and when ordering spare parts Its essontial that te folowing data stated in spare pars ordrsas its used by us to ensure ‘he supply ofthe cortect parts forthe individual engines: 4. Name of vessel 2 Engina No. buitby 3, Plato No, 4, PartNo 5. Quantity required (and description) Examble: MIS Nybo -780 BAW - 90201 - 00-059 10 of (piston ring) Furtharmoro, to ensure optimum flency, relabity and Wotime of tho engine and its ‘components, only esginal sparo parts shouldbe used, ‘The designation’ used in toxts and ilustrations refers to the Information given on the data shoes inserted inthe respective books. ‘As rable and economical operation ofthe desl engines is conditional on corect operation ant ‘maintonance, i essential thatthe engine-room personne is uly acquainted wit the contents of his book. ‘Tis book's subject to copyright protscon. The book must not, ether wholly or pat, be copied, ‘produced, made publ orn anyother way made avaiable toa tid party without the writen consent of his offct rom MAN B&W Digsel AS. MAN B&W Diesel A/S Toginoinsgage $1. Telophv46 998511 00 1DK-2450 Copenhagen Teen 216582 manbw dk Denmark Toltxva5 3805 10 90Plate 90001-62 Cross Section through Engine When refering to tis page, ploase quote Plat 90007 Eon 62 MAN BBW basal NSkgaMc-c No. Edition Title Instructions for Main Engine 900 Introduction 900 ‘90001 900-1 ors 062 215 ‘Table of contents (Cross Section through Engine ‘Checking and Maintenance Schedules 901 Cylinder Cover sor cor 0151 sort 0162 90163 013 21a 169 ove os oot (ylnder Cover, Data ylinder Cover (ylinder Cover Panel Gylinder Cover - Tools ylinder Liner Extra Too! Cylinder Cover ~ Extra Tools 902 Piston with Rod and Stuffing Box. 1024 902.1 1022 902.2 90251 90261 016 air o10 210 208 082 oz Piston, Data Piston Piston Rod Stuffing Box Piston Rod Stufing Box Piston and Piston Fiod Panel Piston and Piston Flod~ Tools Piston and Piston Flod ~ Extra Tools 908 Cylinder Liner and Cylinder Lubrication 1091 903-1 109-2 903-2 90361 ‘Wen refering to is page,please quote Table of Contents Eaton O77 ors 217 ‘008 213 073 ylinder Liner, Data Cylinder Liner Cylinder Lubrleators ylinder Lubrieators Cylinder Liner — Tools MAN BAW Diet A'S PagetTable of Contents KeaMic-c Volume ll~ Maintonanes 90382 90963 1904 Crosshead with Connecting Red 104-1 908-1 1080-2 904.2 1083 9043 j044 908-4 s045 904.5 0451 0461 ‘90402 ‘905 Crankshaft, Thrust Bearing and Turning Gear 105-4 905+ 1052 905.2 1053 905.3 1055 905.5 Pane 2 Eaition Tite (006 Cylinder Liner - Extra Tools (001 Cylinder Linor— Toots 016 Crosshead Beering, Data 218 Crosshead Bearing 016 Crosshead, Data 217 Crosshead 014 Reciprocating Parts, Data 208 Reciprocating Parts 014 Crankpin Bearing, Data 210 Crankpin Bearing 017 Connecting Rod, Data 214 Connecting Rod 113 Connecting Rod and Crosshead Panet 055 Connecting Rod ~ Tools 026 Connecting Rod — Tools 004 Crosshead End Tools 003 Crankshaft Deflection, Data 206 Crankshaft Deflection 016 Main Bearing, Data 222 Main Bearing 014 Thrust Bearing, Data 212 Thrust Bearing G 012 Axial Vibration Damper, Data 218 Axial Vibration Damper ‘When referring to this page, please quote Table of Coton Edion O17 AN BRW Deal ASKoBMc-c Table of Contents 900, Volume No. Edition Title 90551 191 Panels for Crankshaft, Thrust Shaft, ‘Main Bearing, et, 90561 059 Main Boaring - Tools 90562 105 Crankshaft - Tools 90568 013 Crankshalt— Tools 208 Mechanical Control Gear | 1061016 chain, Data © 061 218 Chain | 1982 O14 Chain Tipton, aia : 906-2 218 Chain Tightener | 1008014 Camshat,Data | oes smo amt | 1064007. Camshat Bearings, ata 06-4 207 Camshat Bearings | 2c. ' 90861 055 Camshaft Tools | 90663 011 Camshaft ~ Tools 207 Starting Air System 107-1 009 Starting Air Distributor, Data 807-1 210 Starting Air Distributor 107-2 009 Starting Air Valve, Data 907-2 207 Starting Air Valve i 908 Exhaust Valve : 108-1 009 High-Pressure Pipe, Data 908-1 211 High-Pressure Pipe 108-2 015 Exhaust Valve, Data 9082 215 Exhaust Valve 1083 O11 Exhaust Valve Actuator, Data ‘Wan refering fo his page, please quote Tabe of Contents Elion O77, Page MAN Ba Diseal AIS| 900 Table of Contents koamo-c Volume I No. Edition Title 9083 216 Exhaust Valve Actuator 408-4 010 Exhaust Valve Roller Guide, Data 908-4 211 Exhaust Valve Roller Guide 108-5 007 Exhaust Valve Cam, Data 9085 211 Exhaust Vave Cam 108-7 010 Exhaust Valve Special Running, Deta 908-7 209. Exhaust Valve Special Running | 90851 160. Exhaust Valve Pane! 90861 037 Exhaust Valve — Tools ‘90862 029 Exhaust Valve ~ Tools 909 Fuel Oi! System | 1084 019. Fuel Pump Lead, Data 9091 221 Fuel Pump Lead 109-2 003 VIT System, Data 908.2 205 VIT System 4093 013. Fuel Pump Cam, Data | 9099212 Fuel Pump Cam 409-4 019. Fuel Pump, Data 908-4213 Fuel Pump 1085 018 Fuel Pump Top Cover, Data | 9095-214 Fuel Pump Top Cover 108-6 012 Fuel Pump Barrel Assembly, Data 908.6 211 Fuel Pump Barrol Assembly 108-7 010 Fuel Pump Suction Valve, Data 908.7 209 Fuel Purp Suction Valve 1098 012 Fuel Pump Puncture Valve, Data | 908.8 210 Fuel Pump Puncture Valve 109.9 009. Fuel Pump Shock Absorber, Data 908.8 210 Fuel Pump Shock Absorber | 108-10 007 Lifting Gear for Roller Guide, Data Pane) When veering otis page, please quote Table of Gontons Elion 77, NAN SAW Die NSKosMo-c Table of Contents 900 { Volume ll Maintenance No. Edition Title Workcards in Procedures | 909-10 206 Liting Gear for Roller Guide 100-11 015 FuelVatve, Data 908-11 215 Fuel Valve 109-12 018 Spindle Guide, Data 909-12 212 Spindle Guide 10913 O11 Nonetum Valve, Data i 909-13 206 Non-etumn Valve | 108-14 024 Fuel Oil High Presseure Pipe, Data i 908-14 220 Fuel Ol High-Prossoure Pipe | 108-15 018 Fuel Pump Roller Guide, Data | 908-15 216 Fuel Pump Roller Guide 90951 $78 Fuel Valve and Fuel Pump Pane! } 90961 052 Fucl Valve Systom~ Tools 90962 065. Mouting Tools for Fuel Pump Seals | 10 Tuocharge Sytem | 104019. AirCooter Element, Data 9104 214 ArCooler tment 1102 009 Nom Return Vo, Data 9102 210 Nom etum Vave | $908 008 Anti Blower, Data 8103 210. Audiay Biower 110-4 008 Butorty Vaves, Data 9104 204 Buttery Vales 005 208 1105 Turbocharger Turbine, Data 9108 Turbocharger Turbine * 1106 010 Wator Mist Catcher, Data 9106 210 Water Mist Catcher 91051 040 Cooler and TurbochargerPanel 81061 059 Ar Cooler — Tools ‘iin refering to this page, please quote Table of Contents Elon 77 ———~=~S~*~*~*~*~*« OTT | NAN BW Dial NSNo. Edition Title on a4 ona m2 one 912 net ora 82025 782228 22 o122 7a2205 72226 nes 9123 e261 91263 913 General Tools 913-4 9135 9136 9137 o1stt Safety Equipment 008 207 008 an ‘Assembly of Large Parts oo7 208 00 oe oor zor 000 ‘002 ‘008 207 058 054 208 208 208 206 208 Table of Contents Koanc-c. Volume II— Maintenance Safety Valve, Data Safety Valve Rollet Valve, Data Relet Valve Holding Down and End Chock Bolts, Data Holding Down and End Chock Bolts (Cast ron) checking Hydraulcaly Tightened Holding own Bolts, MC Engines Checking Side Chocks and End Chocks with Bolts, MC Engines Holding Down and End Chock Bolts, Data Holding Down an End Chock Bolts (Epoxy) Checking Hydraulcaly Tightened Holding Down Bolts, MC Engines. Checking Side Chocks and End Chocks with Bolts, MC Engines Stay Bolts, Data Stay Bots Large Parts - Toole Hydraulic Tools Hydraulic Toots “Torque Spanner ‘Tightening Gauge Scrows and Nuts Lubricating Procedures Paces ___—~—=~=«he ering Yo is page, lease qute Table of Contes Ealion 077 Page 6 7 NON Baw Beos ASKoBMc-c Table of Contents 900, Volume I~ Maintenance No. Edition Title Workcards in Procedures 91351 024 Accessories for Hydraulle Tools 91356 045 Liting Toots 91961 046 Spanners 91962 050 Spanners 81363 031 Spanners 91364 056 Spanners, etc 91366 060 Instruments i ‘efering fo his page, ploase quote Table of Cantos Eton 017, Pane 7 SEW Diesel A'S =: 2Checking and M ‘and Maintenance Schedules Ina. als et which itis deemed appropt ate to inspect the indvidual components of tne tengine and to cary out overhauls, necessary, based on the engine conaition or on time eit ‘The stated Normal hours of service should only be used as 2 guide, as differences inthe actual service condions, the quay ofthe fuel oi oF I= bricating ol, the treatment of cooling water, ete wil decisively inluence the actual sorviee re- sults, and thus the intervals between necessary 900-4 Design moditcations may necossitate a revision of th instructions, in which case the revised in structions and changed overhauling interval, if any, will apply and supersode those originally is ‘sued (soe 2.9 our Service Letters) In addition tothe checking and overhauling inter- vals stated in this schedule, please note thatthe periodical survey requirements ofthe classifica. tion society may require additional checks and ‘overhauls to be caried out. For turther informa: tion please refer tothe casaiication society. overhauling. ‘The procedures are divided Into three categories: Condition checking procedures marked under the heading Normal hours of service with a C, deal withthe service condition of a number of engine compo: rents, and form the basis for estimating whether further over hauling is necessary. In a number of cases the condition checking procaduret refer to Volume lof the instruction Book, in | ‘which more detailed descriptions and working procedures can be foun. Condlition-based overhauling procedure ‘are those procedures which under the heading Normal hours of service aro markod with an O, and eppesite which, under the heading Overhaul to be based on procedure No. (column P) 8 procedure number Is stated, ‘This procedure number normally refers fo one of the above con: ‘ition checking procedures which form tne basis o the overnaut. For thls reason, the intervals stated are for guidance only ‘Time-based overhauling proce- dures also marked with an O under the hasdings Normal hours of ‘service of Based on observations, ae the procedures where ‘an actual basis for estimation is lacking. Its recommended, therelore to carry out these procedures atthe overhauling inte- : vals lated as a basis, \where @ symbol O or € is Indicated In Based on observations (column 8}, this i due to the fact that special service condltions may make checking or overhauling necessary beyond the actual standard schedules indicated, \Whan refering to is page,please quote Maintenance Schedules 800-1 Ealion 215 MANGRW Diesel AS PagetChecking and Maintenance Schedules. 900-1 i | (2) \ 1 Sa OS Ck i OTE X: Ai atc © ew oranenaee 2: ott amc P: Sree brd on pone tee wt Sommer mon 0: Owner tart Tieal hors of service BH) 2[s[el[sl[wlalel]e i . is \inen refering to tis page, please quote Maintenance Schedules 600-1 Eaton 275 MAN BaW Dito! ASfs ‘Checking and Maintenance Schedules 900-1 7 Sa Op Sa RST pn BET X. Ramtec 3: mecca ea outa amma P: Ort bobredon ceive o.oo Hi oceans °! cuanfuwariaat Tao BG as recta wlelefelelwla[epe 08 ecnanical Corr! Gow = por ecuua ‘heck new valves aor 6000 noure Subsequenty overhaul at intervals of 16000 io okie ai Pepe)Checking and Maintenance Schedules ‘90041 | | | | Ve Ses Vana Operate? Tr heck nonbvethauod pars aa 600-1600 Fours 1: Rajan to be said ut 1: Based on aserations (C= chook the conn : Overhaul ob based on procodure Noor forte 1M: See stars nabuetons (0: Ovemautto be cate out Teral Rouse sence P05) wlala[s|e [wl] 5] e Pee ee -8 Fue! Pump Sarl Assonby +8 Water Mist Catcher Fi c i z #: # &ay Checking and Maintenance Schedules 900-1 <2 "Wr See Vou T-Operaion™ Wr Chek nwovetied prs a 0 100 fw A! Aajstnent be aro ot ‘Based on oosretons (C: Check he contin Overhaul obo Dasod on prosdire No off o Mt: Seo mater stone (©: Overhaul tbe eared out ‘ema Roe of anos (1005) No. _Provedure wl2]4|e[e| wl] a o11_safety Eaupmen Donan Sct ote Eon] © | ‘When refering to is page, please quote Maintenance Schedules 800-1 Elton 215 MAN BAW Diesel A'S Panes 0Cylinder Cover 101-1 Baw Data SAFETY PRECAUTIONS ‘Stopped engine =) x] Block the tating mechanism ‘Shutof staring ir supply Engage turning gear ‘Shutoff coating water ‘Shutoff fuel of >> ‘Shutoff beating ot Lock turbocharger rotors Data et ossrtin vee ut DA Woightofexnoust vavestus 200g 2 Weight of. cover compete with valves 11800 D9 Weight of cooling jacket 335kg D4 Scrowingn torque 00 Nm “exhaust valve studs DS Sovowingin toque 110N starting vale studs D6 Scrowingin toque 140.Nen “ool valve stds D7 Hydraule pressure ~gamanting 1500-1650 bar D8 Hydrauie pressure lightening 1600 bar When refering to this page,please quote Data Shoot 107-1 Edin 1S MAN BAW Dito! AS Standard Tools: See Section 913 50-900 Nm = H700Nmn tat 13m Paget101-4 Spare Parts, 2010108 128 901018 151 020200 178 Cylinder Cover ssrton Oinge Gasket Seating ngs bang ‘When refering fo Bis page,please quote Data Shee! 101-1 Eaton 18 MAN 88 Dose NSCylinder Cover, so14.2 Dismanting Ss. 1. Sot blocking device A on the main starting valve in the BLOCKED poston, Engage turing gear B. Close fut oll init valve ©. Close cooling water init valve D. Close cooling water outlet valves E and F. pen cooling water dain cocks G and # Shut oft the contro air and safety ar supply. ‘ont the manoeuvring system through the bal valve. Also shutoff the air supply on the reduction unit for the hydraule/pneumaic exhaust valve, and vent the sysiom, When referring to this page, please quote Procedure 801-12 Eatin 218 Page # (14) i MANBBW Owto! NSD902 Cylinder Cover (oa) Dismanting 2. Remove the cooling water inlet and outlet pipes from the exhaust valve. Romove the screws which fasten the cool Ing water oust pipe fo the cylinder cover. Dismount the fue! ol high pressure pipes. ‘S2e Procodure 909-14.2. Diemount the controlar pipe from the start- ing valve. Remove the starting alr pipe 3. Diemount the hydraulic high-pressure pipe, 880 Procedure 908-1.2 Dismount the drain ol pipe between the ex: haust valve and the hydraulic activator, the air pipe for the pneumatic exhaust valve, land the pipes for the sealing ai arcang mont 4. Remove the protective jacket intermediate pipe between ceiver and the exhaust valve, Dismount the screws inthe flange between the intermediate pipe and the exhaust re- ceiver, The four lowermost serewe need not be dismantied, just loosened. Femove the protective caps from the oylin- der cover nuts Page) When leigh page ase uci Procede y-5.7 Fon 773ey Cylinder Cover 9014.2 Baw) Dismanting ‘5. Position the cylinder cover tightening tool | 5: — D7 cover the cylinder cover. _—— Pull down the spacer rings and the rydrau- lc Jacks over the nuts For operation of the hydrauile tools, see Ghapter 913, tthe eytinder cover isnot to be overhauled, the cylinder cover tightening tool may main placed on the cylinder cover while the bylinder cover ls removed from the engine If he eytinder cover isto be overhauled, re ‘move the cylindar caver tightening to! from the eylinder cover. 6. Hook the engine room erane on t the iting attachment on top of the exhaust valve Lit away the cylinder caver compete 7. Mount the cylinder cover support teol on the cover above the chain wheel Page S (77) Vien refering to is page,please MAN BAW Dlsel AS901-42 Cylinder Cover Dismanting 8. Land the cylinder cover on the suppor tol ‘The cylinder cover support tool should conly be used when the ship isin por. 8. Ifthe cylinder cover is t0 be overhauled it Is recommended instead to land the cylin der cover on a couple of wooden planks. 40, Remove and discard the seating ring be- ‘ween cylinder cover and cylinder liner Poe When reforing fo thie pag, ploave quote Procedure 0071.3 Eon 279 'WAN BAW Diese ASOverhaul Dismount al valves and plpes on the cyin- der cover. See Procedure 907-2.2, 908:2.2 and 909-172, Dismount all studs on the top of the cylinder Unscrew the four seraws which secure the ‘cooling jacket to the eyinder cover. Lit the oytinder cover tree of the cooling Jackot and land it on @ couple of planks. It the cooling jacket sticks, use dismanting serewe ta Tore the jackelicaver apart. Remove and siscard the O-ings from the cover, and carefully lean the cooling jacket and the cylinder cover Provide the cylinder cover with new 0: rings, wall lubricated with ol uf the cylinder cover and quide the jacket cover inio postion, using the guide pin as Cylinder Cover reference (camshait sid). Mount and tighten the screws forthe coot ng jacket, i i iy 2B ‘When referring to this page, please quote Procedure 801-1.9 Edition 273, MAN BW Dito! NS Page 5017)901-13 Cylinder Cover ovr (a\ 5. 5. Reconsition the valve bores as follows: seating face cutter, and a gtinging mandrel Clean the fuol valve bores, using the car- bon cutter. f required, recanition the fuel valve seating withthe appropriate cuter. T Fuel valve bore 6. The too! consists of @ common spindle with handle, and of a guide, @ carbon cutter, a 'N Grind the seating withthe grinding mandrel ‘and a grinding compound (e.g. Carborun- ‘eum No. 200). ‘Atter the milinglrinding, clean the bore ‘and seating carefully, and check that the ‘seating is not damaged. Exhaust valve bore 7. The tool consists of a spindle with handle and a grinding dis. ‘Altr cleaning the valve bore and seating, ‘tind the seating withthe grinding dise and 4 grinding compound (e.g. Carborundum No. 200). ‘After the grinding, clean the bore and seat- Ing carefuly, and check that the seating is "MAN BW Oise AS not damaged i 7 | o | Paes When retain ois page,please ate Prostate S07 13 Faton 73ed Cylinder Cover 901-13 Baw Overhaul ‘Starting valve bore 6 i 4, Tho tool consists of a guide, a cuter, and a grinding csc Recondition the starting valve bore and seating in the same way as described for the fuel valve bore. When replacing valves on a cylinder cover thal is mounted on the engine, recondition the valve bores/seating inthe samo way as escrivad here, but without lsmounting the studs. 9. Clean the bores for safely valveinicator cock. |The rearine otis page ioe avo Procedure 907 13 Eaion 21S ———SCSCS~S~S~S~*«S TTY MARTSEW Deal AS901-1.3 Cylinder Cover Oval (Gam) | 10. Lubricate the threads with ‘Never Seize’ or Molybdenum Disulphide (MoS;) and mount the valve studs. TTighien up the studs in accordance with the | serewing-in torque stated on the data | sheet Fill up the grooves between tho valve studs ‘and the bores for tha vaive studs with per- matex to prevent water of cl ftom entering the bores during operation of the engine Provide the water connection flanges with fnew gaskets, and keep the cylinder cover ready for replacement ‘Aways fit new or overhauled valves before ‘cylinder cover is mounted on the engine, 11. For examinaton/oleaning of the underside forthe inside ofthe cylinder cover the ctin- dr cover support toal must be used hen rearing otis page,please quote Procedure 801-1.3 Edion 279 TaN BAW Oloea AVSCylinder Cover ___ Mounting 1. Place a new sealing ring on top of the oy Inder tne. 2. With the cyfinder cover sill placed on the cylinder cover support too, carefully wipe ‘contact eurace which faces the cyinder 8. Provide the cooling water connecting pines with new O-rings ‘and lubricate them with (grease oF soft soap, Mount @ new ‘Klinger’ seating ring in the groove of the flange of the intermediate Pipe. Lower the cover carefully into postion During the landing, carefully check that the cooling water connecting pipes engage cor- recily wih the holes in the cooling Jacket. ‘When refering to his page, ploase quote Procoaire GOT Eaton 273 — Page 817)01-14 Cylinder Cover Mourig (ad) 4. Mount al eight nuts onthe studs and serew them down to the cylinder cover Position the cylinder cover tightening tool over the cylinder cover. Pull down the spacer ringe and hydraulic Jacks of the tightening tool and screw the Jacks on tothe studs. For operation of hydraull jacks, see Proce- ure 913-4 Connect the hydraulic hoses to the jacks ‘and raise the pressure to the level stated in Data. Tighten the nuts with a tommy bar. Release the pressure, Remove the hysrau- fc jacks. 5, Mount the protective caps on the cylinder cover studs, ‘Align the intermediate pipe so that the holes in the flange of the intermediate pipe Aare in lino with the threaded hols in the ex 5. Page 10000) aust vave Mount the screws ofthe flange between the Intormadiat pipe and the exhauet receive. ‘Note! ‘or Molybdenum Disuphide (MoS,) before mounting | Mount the insulating jacket around the in- termadiate pin. ote Procedure 907-14 Editon 213 WAN B&W Diesel AIS(a Cylinder Cover ) Mounting 6 6. Mount the return oll pipe, the sealing air pipe and the air pipe for pneumatic closing ff the exhaust valve. Mount the high-pressure pipe for the hy- ‘raule valve gear ‘See Procedure 908-1.4 7. Mount the stating air pipe and control aie Pipe for the starting valve Mount the cooting water inlet and outlet Pipes on the exhaust valve, Mount the drain pipe on the intermediate pipe between the exhaust valve and the cyl Inder cover. Using @ crowioot wrench and torque span ner, Mount the fue of high-pressure pipes. ‘Sao Procedure 909-14.4. Connect the outlet pipe from the return oi pipe on the uel valves. ‘Shut the drain valves and open the cooling Water inlet. Altar venting the cyinder seo: ‘Non, shut the vent cocks and open the coat Ing water out valve (Open the fuel of, ubricating oll and alr sup- plies tothe alarm system, Caution ‘The air supply tothe exhaust valve must always be connected before turning on | the of supply tothe exhaust valve actua- tor ‘This is very important, because oth wise the valve wil open more than intended. ‘hon refering to i page MAN B&W Dist! NS gusta Procedure 807-14 Eaton 15 sorta| Plate 90151-168. Cylinder Cover Panel Tem tom Ma Part Description aa Part Dascrption 010 |") Toot panel 022 | Nameplate 046. |Grincing tool (058. | Ning and grinding tool for ful valve soat (060. | Ming and grinding tot for starting | valve seat (071. | Diemanting too! or fol valve 083 [Handle (095. Grinding rng for starting vane 108. | Grinding hancle for staring valve 117 | Pressure taster 129 | Extension studs for it of eylndor 010- |*) Tool pana, compete 329 | with fools *) Optional extrasCylinder Cover - Tools Plate 90161-92 159 Wer elgioa cs pane, pave ate Pas S761 Een MAN B&W Diesel A'S Please asPlate 00181-92 Cylinder Cover - Tools item No, Part Description “Item No, Part Description os cor 039 040 052 064 076 088 m 135 “7 159 160, 172 184 196 218 Bat 243 Tightonng tal fr eyinder cover, complete Lifting davico Hose with unions Balancing ring, upor Spring balance Balancing ring, lower Hoar-shaped thimble Wire tock Hydraulic jack, complete wth spacer ing [Screw Sel-ocking nut O-ing with back-up ring, 230/240 en [O-rng with back-up sing, 160/170 mm Ling chains for cylinder cover ‘Quick coupling, complete Gasket Hysraulc jack Spring pin Spacer ringCylinder Liner - Extra Tool Plate 90162-16 “When rtaring to is page, pease quate Plat 60762 Eaion 1S MAN'BAW Olea! AS 022Plate 90162-16 Cylinder Cover - Extra Tool en ten ten a eeipon ten an Desreton 10 | rnng mace x yin emer ova | eng eaCylinder Cover - Support Tool Plate 90163-01Plate 90163-01 Cylinder Cover - Support Too! Part Descxpton ig Part Deseiation 016 | Cynder cover rackPiston 1024 Data | SAFETY PRECAUTIONS Standard Toots: Se Section 918 [X_] stopped engine XC] Blok ne trig mchanim ZX, [st often eupiy X | Engge turing gear —_ XC] Shut cooing eter XC] shutotetot ix] esate en's in XX | Shut off hubrication oi! aed ana Lock tutocarer rs oO @ axe Data pt en van 0 O41 Ninian aia wi 285 mm D2 Moanin vrzal hgh poms Noo tana? 21.87 mm feo Ne. Sand {a7 mm 9 Max pemisiebuaway: Sana pion sam O-ring gop peton ing Nt 120mm 5 Miran te ing sop | atoning Now 2Sand4 120mm D6 Voreaslerence ovease nm D7 Petoncampite 350019) Da Paton ‘erg De Paton sat srg Dio Tei ave “pao cat sonm bot Poamenmypie cong Biz Toning ore boing ne 120 im D419 Patnied soso ig Dus Tesrprasue "rer 16 Tgtterng rave lesape te sonm 47 Toning erue “fg tol son 18 Tghenngtave tpkion BON D9 Minit ya vpn get comm | 20 hima se 9 ton ringhon 2,and4 49mm 0.21 Hyrai presne "tomarting 1500-1680 bar 0-2 yt presse | onteing 1500 tar ‘ihn tog sae, ose auto Daa Soo 087 Eon TB ———SSSCSC MAN BW Dist A'S1024 Spare Parts 9020100 096 90201300 106 90001300118 0001-70181 90201300035 9020105 047 0101302151 neret Piston rng No. 1 Piston rng No.2 Fiston rng No. 3 Piston ring No.4 Gasket 1 1 1 1 1 1 ‘hon refering to is page,please quote Dats Sheet 102-1 Editon 18 Page 2 @) MAN BAW Diesel NSSeavenge port inspection ‘To detect possibie leakages from the piston or cylinder cover, keep the cooling water and coo! ing oll ceculating during the scavenge port in- spection, 1. Remove the inspection covers on the cam- shaft side ofthe oyinder tame. “The scavenge port ingpection can also be carrie out rom within the scavenge Clean the openings. Bogin the inspection at the eylinder whose piston is nearest BDC. 2, With the piston in BDC, inspect the piston crown and the cylinder wall Note down the resuts. ‘See Volume I, Operation, Chapter 707. 8. Tum the engine. While the piston is passing the scavenge air ports, inspect the pision rings, he ringlands and the piston skirt. Check tne movabilty and the tension ofthe piston ringe, by progeing againet thorn with 5 woaden sick Note down the resus. (oa Piston aw Checking When refering to is page, please quclo Provedire O21 Edlionzi7 ~*~ MAN BAW Diese A'S902-1.1 Piston | Checking feos) 4, iter turning the piston upwards, past the ‘scavenge alt ports, inspect the piston rod ‘and the lower part of the eylinder wall. Note down the results. ‘5. Re-mount the inspection covers onthe cyl Inder trame. I necessary, replace the gas- kets, Piston rings and piston crown 6. Remove the piston trom the eylinder and piace It on the piston support. See Procedure 902-12. Note! Itis recommended to replace all the pis- ton rings whenever a piston is removed ‘tom the engine. | Page2 (a Wien refering to his page,please quote Procedure G02°1.1 Eaton 277 WAN B&W Dlaea AS902-141 @ = 7. Before dsmanting the plston rings, meas- ture the free ring gap ofall the piston rings. IF the piston rng gap of one of the piston ‘ings is less than stated in Data, the piston ting must be replaced. 18, Take off the piston singe by meane of the ‘ing expander. (Clean and inspect the rings. 9. Measure and record the radial wicth ofthe tings. See Volume Operation, Chapter 707. Worn rings must be replaced it ‘with is less than stated in Data radial902-41 Piston Checking 10. Piston rings with milled a Co | grooves must be replaced ifthe radial depth Le Of the grooves has worn down to less than | mm, 11. Glean the ring grooves and check them tor ‘burn marks or other deformation. Measure the ring grooves with a dlal gauge oF a caliper gauge. | Crearance in piston ring grooves: ‘The maximum vertical helght in a worn ring groove must not exceed the vale stated in Data. “The groove is also worn out there is no chromium layer 12, Clean the piston crown and check the burn- ‘away by means of the template. For maxi- ‘mum permissible burn-away value, see Da- & (Check the burn-away on the whole circum- ference ofthe piston crown, 12. Wen refering to is page,please que Procedure 902-11 Fallon 217 "WAN 28W Deel IS Page a 0)(N ces 9024.1 18, Botore mounting a new piston ring, meas- | 13 ute the piston ring gap. When measuring, Insert the piston sing in either a new cylinder liner or in the bottom of @ used cylinder (below the ring travel is zone}. le rorntinin nga see oa, D-19 For piston ring No. 1, cary out @ horizontal | 1 measurement. iB 14, For piston ring Nos. 2, 9 and 4, carry out a |B ‘ited measurement, see the sketch, i 15, Fit the piston rings (atternately righthand and lochand cuts withthe ring gape stag- gered 180° and wih the Top mark up- Wards), using the ring expander. When mounting the piston rings, use the Fing expander 1o prevent unintended detor- ration of the ring 16. Check the vertical clearance between the new piston ring and the new oF recondi- tioned ring groove with a feeler gauge. Se Data, When refering to is page,please quota Procedure 021.1 Eaion 217 MAN BAW Disel AS Pages 09)Piston Dismantling waw 1. Turn the crosshead down far enough to give access to the piston rod stung box and the hydraulic nts forthe pict rod 2. Release the stuffing box by removing the Innermast screws from the stuffing’ box ‘ange. Note! 1Do NOT remove the outermost screws ‘rom the fangs. 8. Place the spacer rings on the piston rod ruts and screw the hydraulic jackson to the tude Loosen the nuts. For operation of the hy- draule jacks, see Procedure 919-1. Page oro) ‘When refering to this page, ploase quote Procedure 962-1.2 Editon 217 "WAN G&W Dees ASPiston 4. Mount the two distance pieces onthe piston | 4 fod foot to protect the lower scraper ring and to guide the stufing box 5. Dismount the oylinder cover. See Procedure 901-1.2. 6. Make @ scratch mark in tiner and piston cleaning rng to ensure the eorect mount ing Remove the piston cleaning ring See Procedure 803-1. Carefully smooth out any wear ridges atthe {op of the eylinder liner by using @ hand ginder. Soe Procedure 903-1.3. + Dismanting When referring fo this page, please quote Procedure 8021.2 Edin 217 MAN 38W Diol AS Page 7 (8)| goat2 Piston i Dismantling Ben 7. Tutn the piston to TOC, The top of the piston is now tree ofthe cyl- Inger tne, 1 necessary, remove one or two cytinder cover studs, using a stud setter. CCiean the iting groove ofthe piston crown ‘and mount the liting t00 Make eure fo mount the iting tool co. ‘eat, eo that the claws ofthe iting tool entor the tting grooves ofthe piston 8. Place the two halves ofthe support around ‘one ofthe openings inthe platform. Lift the piston out ofthe eyinder and lower the piston rod foot and etfing box through the opening in the plattorm, Place the two halves of the support around te piston rod and secure the two halves with sorens, 8. Place @ cover over the opening for the pis- ton rod stuffing box in the bottom of the ey Inder unt CGean, measure and reconaition the cylin- Ger tiner. ‘See Procedure 909-1, i Page(s) When refering to tis page,please quote Procedure 902-1.2 Edtion 217 "MAN B&W Diese) VSPiston 9024.2 | Bay Dismanting 40. Turn the crosshead down far enough to per mit mounting ofthe protective rubber cover fan the crosshead bearing cap. “The protective rubber cover should remain in place to protect the crosshead bearing Journal from impurtss unt the piston Isr mounted, Low iting height 11, Turn the piston to TDC and mount the titing {0.Lif the piston high enough to alow po: stoning of the supporting tos, Place the supporting tools on the cylinder cover | studs, Lower the piston on to the supporting toots and release ihe nook of the engine room rane trom the iting too Remove the clamp trom the titing toot ana place It onthe supporting tools by means of {ho engine room erane and crossbar i Remove the crossber. hon refering to tis page,please quote Procedure O02 .2 Eaion 217 Pages (9) MAN B&W Diet NS902-1.2 Piston ay Dismanting (3 12. Lift the piston high enough to give ample room ovor the tilting t00 Mount the thing toot around the piston rod land lower the piston so that the distance places of the thing tool are In contact wit the piston, Fasten the clamp tothe ting ool Note! Do NOT it without etuting box. ‘Warning! Before iting with colar rng, csmante Iiting tool from platon crown. 13. Lit the pision to the maxémum crane height Fun the crane athwartship and, at the same time, tit the piston. pep the piston rad clear of the cylinder in fer and studs while carrying out the ting. When space consitions permit, straighten Up the piston and lead it over tothe cutout inthe platiorm for overhauling the pion, When the piston is at a suitable helaht ‘above the platform cur-aut, poston the pis- ton support around the’ pislon tod. and clamp. ‘Now lower the piston while guiding the sup- port to the plattorm cut-out ‘tor landing the piston, ensue that t rests correctly on the support. Not ‘On engines with extremely ow ting height, use the engine room double-b crane instead of tne transverse piece. Bago 10 9) Wher tering to this page, please quote Procedure 202-12 Edion 217, ‘WAN dW Dace ASPiston 902-1.3 | | Overhaul 1. Position new O-rings on the platform | 1 around the piston overhaul cut-out 2. Ease the piston down so that the stuffing D7 : ois Below the floor Lit the Ossings and assemble the two halves of tho picton support around th pis- a ton rod j Position the O-rings on the piston support. 3. Dismount tne locking wires and tho serows of the piston skirt, Land the piston skirt on the plston support. L \Whan refering fis page,please quote Procedure 92213 Edbon217 __——~—~S~*« age TT MAN BEW Oise! AS| | 9021.3 Piston neal (ed) 4. Dismount the hydraulic nuts between the rod and the piston. Soe Data, Lit away the piston crown, Thoroughly check the cooling spaces of the piston crown for coke deposits. Any coke Geposits found must be removed, see step 12 5. Dismount the serews of he cooling ol be flange. Mount the eye bolts and It out the cooling oil pipe. Clean and inspect, then re-mount the cool. ing ol pipe. Page 129) ‘When refering tots page please quota Procedure 002-13 Eon 217 MAN BBW Desel ASle Piston oF Overhaul ‘Alternatively, the piston can be dismantad in the folowing way: Note! iting f the piston must only lake place withthe piston rod stuting box mounted fn the piston ro 6, Wile the complete piston is hanging trom the Iiting tool, mount the collar round the Piston rod 60 thatthe distance pieces of the folar obtain contact with the piston, Lower the piston so thatthe collar rests on ‘the platform i Flomove the iting tools from the top of the | Piston erown. Hook the engine room crane on tothe titing crossbar and hook the chains of the lifting crossbar on tothe shackles of the cola. 77 Lift the piston, titi to the horizontal pos. tion, and land it inthis postion on a couple of wooden blocks. Remove the Ifing cross: bar and chaine from the collar ‘tach the iting bracket to the bottom of {the piston ro fost, Hook the crane on to the iting bracket 8, Lift the foot of the piston rod clear of the ‘wooden block. Mave the piston rod stufing box up the piston rod unt itis In contact withthe colle . 3 Notel | | During the it, follow with the erane to keep the crane positioned vertcally above the foot of the piston rod. Koop iting until the piston rod isin a vert cal positon When refering to this page, please quote Procedure 802-1.9 Edlion 217 Page 19 (19) NAN BAW Oita! AS902-1.3 Place the piston in an upright position with the piston crown resting an wooden blocks. Dismount the hydraulic nuts. Lift the piston fod away and land it ina horizontal postion fn a couple of wooden blocks Flemove the locking wire and the screws in the skit-and mount two eye bolts in the holes intended for diamanting screw. Lit the skirt and land i on a courle of planks, ‘Thoroughly clean and inepect all parts of the piston, Hf coke deposits aro found in the cooling spaces of the piston crown, the piston crown cooling spaces should be washed ‘outwith Carbon Remover or a. similar cloaning fluid. When all coke deposits have been diaeolved, clean and inepect the pis- ton eronn again, FRogarding check of the piston crown, see Procedure 902-1.1, Replace all sealing rings of the piston. All the new sealing rings must be coated with lubricating of before the piston Is assem- bed. Coat all sorews with Molybdenum Dieu! hide (MoS) clisaseertly Tighten all the hydraulic nus tothe tghten- Ing pressure stated in Data. For correct tightening sequence, see the sketch. ‘When refering to this page, please quote Procedure 2021.9 Edition 217 THAN GAW Diesel NS1 | | (Gad Ov 42. Lock the screws with lecklng wire Mount the locking wire in such a way that the wie is tightened if one of the screws ‘works loose. See Procedure 913-7. 18, Fllthe piston and piston rod with lubricat- Ing ol, Mount the pressure-testing tool around the base ofthe piston rad. Pressure-test the piston at the pressure slated on the data Sheet, Check the contact surfaces of the piston and the sealing rings for tightness. (Check that there are no racks inthe piston ‘When refering to is page,please quale Proved 902-13 Eon 217 MAN BW Diet A'S 9024.3 Page 15 (19){ | = a) {Chock the piston rings and piston crown in accordance with Procadure 902-1. ‘Mount the tting toot on the piston crown, Remove the protective rubber cover trom the crosshead. Paget6(19) —=«=«=«*«(Wh en veering to this page, please quote Procedure 8021.4 Edlion 217 ‘WAN BAW Disa ASPiston 902-1.4 Mounting 4. Remove the cover rom the piston roa stut- | 4 ing box opening in the botom ofthe eyin- der unt 5. Turn the crosshead to @ position 45° from De. 8. Coat the piston rings, piston rod and cylin der linor with iubieating ol Coat the O-rings ofthe stuffing box with ol Mount the guide rng for piston rings on the enlnder ner Lower the piston into the eylinder liner ~ while guaing the piston od foot through the cut-out in the stufing box flange ~ uni the piston rings are inside the tines, corre sponding tothe litng to! lacking about 30 mm in landing on the guide ring ‘han refering fo is page, please quale Procedure GIR Eon 217 Page 709) | MAN BAW Diesel ASsoa Piston Mounig (ey 1 7. Turn the crosshead to TDC wile checking ‘that the guide ring ofthe crosshead enters ‘the eerie hole in the piston rod After turning the piston fully to TDC, un- serew the adjustable claw ofthe ling too! land pull the ling too! free of the liking {groove in te piston. emove the liting tool and the gulde ring {or piston rings. 8. Mount the platon cleaning ring inthe tine. Make sure that the scratch marks on the piston cleaning ring and on the liner lin- fr are aligned. 8. Mount and tighten the piston rod nuts, See Data. For operation of the hydraulic jacks, see Procedure 919-1 When refering to tie page, please gucta Procedre 908.4 Eon 217 MAN B&W bese ASod Piston te Mounting 10. Tighten down the piston rod stuffing box by means of the screws through the inner holes in the stutfing box flange. 11.1 one oF more cylinder cover studs have been removed during the dismanting of the cylinder cover, diecard the old O-rings and mount naw ones on the cylinder cover studs, Mount the studs inthe eylinder frame, using the stud setter. 10. Note! ‘The studs should nat be fully screwed:in Instead the stud should only be screwed: ‘in untl the edge on the stud is 2.5-3.0, ‘im above the eyinder frame, see skatoh For mounting of piston cleaning ring, soe Procedure 909-1.4, 42, Smear the piston rod with molyodenum di sulphide, and turn the engine a couple of revolutions, Mount the cylinder cover, See Procedure 901-14 18, Start the engine and keep It running for about 15 minutes at a numberof revolutions Corresponding to very siow. “Then stop the engine and inepect the piston tod and stufing Box. " 7 When refering to this page, please quote Procedure 902-1. Ealtion 217 MAN B&W Dieol ASPiston Rod Stuffing Box 102-2 aw Data ‘SAFETY PRECAUTIONS. ‘Standard Tools: Soe Section 913 Sopped one ‘Block te stating mechanism Zz, Shutoff stating ai supply ‘Shutoff coating water Shutoff fut of ‘Shut off lubrication ot Lock turbocharger iors Data Det Stuffing box complete 207 ig 1-2 Sting box halt 10549 D3 Tightoring torque for ‘380.Nm stating box halves 4 Tightening torque for 360 Nm ‘stuffing box anges DS Tahtering torque for ‘360.Nm 2.6 Vertical ctonrance — 0416-030 mm uppermost rings D7 Vertical clearance — 0.410.017 mm lowermost ings D8 Ringed clearances — axemm | uppermost ings | 1.9 Ring end earances — 3xamm lowermest ngs D-40 Cheek length forthe sic Uppertost sping ‘ N. be 889 mm 1952 mm D-11 Check fnath forthe four lowarmast springs: 229mm | 1219 mm 1269 mm When referring to this page, please quote Data Sheet 102-2 Edition 10 Page 1 (2) MAN'BAW Oneal AS(aaa) Piston Rod Stuffing Box Data Spare Parts MAN BAW Diesel NS ihen referring to is paga, please quote Data Shoe! 102-2 Eaton 70 | Page2@(oad Piston Rod Stuffing Box 022.1 man Checking 1. After the piston rod stuffing box has been dismantled, see Procedure $02-2.2, check th folowing ring clearances: Uppermost sora ing ings Vertical clearance between sealing ring section and groove, (Clearance at ring ends (seraper ring). “otal clearance (scraper rig) (Clearance at ring ends (seating rng “otal clearance (seaing rings). Lowermost scraper rings Vertical clearance between scraper ring and groove. Clearance at ring ends. Total clearance. | Te ng clarancos stated in Data row rng. poly to i As a goraral gue, is recommended — | epending on he overhang iterate ana | nas own experience ~ to replace sealing tings and serapehge whan be epost Glerance valuoe have charged by more than Sox 2. Check the lenath ofthe sprinas at diferent loads. Adjust the loads to achieve the lengths stated in Data the loads necessary are outside the limits stated in Data, the springs must be discard od ‘Wan refering fo this page please GuoleProcedire 222.1 Edon@t0~—~—~*~*~S~S~S~S*« OT NON SAW Ditel AS902-2.2 Piston Rod Stuffing Box Dirantng (ed) In the period between piston overhauls, itbe- ‘comes necessary 10 inspect the plson rod ‘stuffing box, proceed as follows: 4. Turn the crosshead to about 90° from TOC. ‘Mount the rubber hose around the piston rod to protect the crosshead bearing trom impurities. 2. Remove the drain oll pipe and all innermost serews and all outer serews except fr two screws placed diametrically opposite in the stuffing box flange, longitudinally to the en- gine. 3, Mount the worktable round the plston rod 0 that the two screws can be loosened through the holes. When referring to this page,please quote Procedure 802-2 Edion 210 Pane2 TAN B&W Diesel NSI (oe Piston Rod Stuffing Box 9022.2 | Dismanting 4. Remove the two long screws from the workable, Mount them in the stuffing box through the holes in the worktable Remove the remaining two screws from the stuffing box, 5. Turn the piston to BDC, thereby witha ing the stuffing box from the cylinder trame bottom. Remove the two long dismanting screws from the stutfing box ard mount them inthe workable, 6. By means of the four short sorews in the worktable, press the stuffing box out of the flange. For overhauling the stung box, soo Pro- cedure 902-2.3 i ‘en refering fo mie page,please quote Procedure 80222 Eaton BIO ——~—=~=~*~S~S*S*«é QUT)| | 90223 Piston Rod Stuffing Box Overhaul man Outside the engine Normally, overhaul ofthe piston rod stuffing box is carieg out by routine methods in connection withthe dismanting (puling) of the pistons. During such overhauls, the piston rests on @ support placed ever one of the cut-outs in the top platform Work on the stufing box Is then carried out ‘rom the platirm below. 1. Mount two eye bolts in the stuting box flange, and hook on two tackles. Lit tho stuting box ite up the piston rod, land mount the worktable rourd the piston rod ata suitable working height. Land tho stting box on the worktable, and remove the tackles and screws. 2. Remove the O-ring ofthe stuffing Box. I the O-ring is intact and ie to be used again, move it up the piston rod and secure it {his position, for example with tape. Femove the nuts from the stuting box as- sembling bots. When refering otis page,please qua Procedure 00223 Falon 270 THAN B&W Bese IS4, Using a Piston Rod Stuffing Box 90223 ae Overhaul 8. Take out the six bots, and pull away one stuffing box hail Mount two eye bots on the stutfing box halt and remove I rom the workable, ler gauge, measure the vertical clearance of the ring. ‘See Procedure 0022 1. 5. Remove the remaining stuffing box halt and press all sealing rings and scraper rings down against the worktabl. 6. Measure the clearance between the ring segments to datermine whether replace mantis necessary. See Procedure 902-2.1, Dismantle and stack the rings in the same order as whan filed in the stuffing box Carefully clean ail the ring segments Inspect and assess the surlace quality of the sealing rings. If thelr siding surfaces have scratches oF marks, replace the rings. 17. Check the lengths ofthe springs. Soe Procedure 9022.1 8. Inepect the surface of the piston rod. It small longitudinal seraches have occurred (caused by poorly adapted stuffing box rings), smooth the piston rod surlace care- fully witha fine grained carborundum stone. In the case of coarse scratches, It may prove necessary to machine-grind the Sur- face in a workshoo 8. Clean the halves of the stutfing box hous- ing. When referring to this page, please quote Procedure 802 2.9 Editon 210 Pages MAN Baw Dita NS022. Piston Rod Stuting Box rau (aa 10. Lubricate the piston rod (inthe area where all the rng unte inthe stuffing box wil be Positioned) with moiysdenum dsulphide (os. ‘Assemble all the stuffing box ring units round the piston rod, on the worktable, in the following way: + Place the lowermost scraper ring seg- rents on the worktabe, + Place the spring round the segments, and hook the spring ends together Repeat this procedure for the remaining scraper rings. (On top of the scraper rings, assemble the two sealing ring unt (each consisting of a ‘par and an &-part tng), ‘Ascomble the 8 part sealing rng 60 that th two guide pins face upwards, place the spring round the segments and, hook the spring ends together. [Assemble the 4-part seating rng above the B:part sealing ring. Push the two rings to {gether such @ manner that te guide pins In the lower sealing ring engage with the two holes in the upper seating ring Finally, assemble the uppermost ring unit (Consisting ofa 4-part scraper ring and an -part sealing rng), 11. Use the stuffing box hall on the workable to adjust the Nelght of all the ‘assembled ring units on the piston rod unti the ring Units are. opposite the corresponding {grooves in the stuffing bax housing. Subse- {uently, push the stung bax half into con ‘act withthe piston roo, round the ring units. Pages When cotaring ots page, plates quote Procedure 902 2:3 Eaton 210Piston Rod Stuffing Box 90223 Overhaul 12, Check the ring clearance again, 12, Then place the other hal ofthe stuffing box housing on the worktable, pushing ft into place round the rings. Mount and tighten up the fited bots to the torque spectied on the Data Shest. Mount the O-ting inthe stuting box aroove +48, Mount eye botts and wire ropes, and if the stuffing box a ite, FRomove the workable and lower the stuff Ing box unt it reste against the distance pieces on the piston rod foot Remove wire ropes and screws. | ‘When referring to this page, please quote Procedure 902-23 Editon 270 Page? MAN BW Dice! AS902-24 Piston Rod Stuffing Box Meng (a 1. After overhauling, assemble the stuting ‘bax halves on top of the our screws. ‘Mount the two long screws from the workta- ble In the stufing bax. ‘Turn down the short screws so that the stuffing box lands on the flange 2. Turn the piston upwards until the stufing ‘bax isin place in the cylinder frame, Note! t “Make sure that the two guide pins inthe flange enterthe guide hoes in the bottom of the oyinder frame. ‘Mount two sorews in the flange through the holes inthe worktable, Pages) Whenrefering to hie page,please ote Frocodra 802-24 Een 270 WW me (MAN BAW Diesel A/S.Piston Rod Stuffing Box 022.4 Mounting Ba 4. Remove the long scvews trom the stuffing box and mount them inthe worktable, Remove the worktable trom the plston rod. 5, Mount and tighten ail the inner and outer ‘screws forthe stuffing box. See Data 16, Remove the protecting rubber cover from the piston rodicrosshad. ‘smear sulphide. piston rod with molybdenum ai- ‘Then turn tho erankshatt a couple of revo- | lutions. ‘Start up the engine and keep it running for bout fiteen minutes at a number of revo. lutions corresponding to very slow of idle speed. “Then stop the engine and inspect tho piston ‘od and stufing box Thon roloring to tis page, please quote Prosedure 622-24 Esion210——~—~SC~*S*~S~S*«é MAN BAW Diesel A'SPiston and Piston Rod Panel Plate 90251-204 When refering to this page, ploase quote Plate SO25T Editon 204 ~ MAN BAW Dieal NSPlate 90251-204 Piston and Piston Rod Panel Tem No. Part Desecption Part Description one 026 040 ost 063 O75 a7 089 109 110 122 134 org. 134 ) Tool pana Name plats Ling too! for piston rod foot iting tool or cyinder liner Dismanting screw Template Distance piece fr stung box i} Hook for mounting of spring Pressure testing device Workable Piston ing expander +) Too! panel, complete with foots *) Optional extrasPlate 90261-82.Piston and Piston Rod - Tools Part Description fs Prt Description Guide ring for piston Lifting too fo ston Lifting cvossbar “iting tol for piston Support for piston Support fr titing toot B82882 |FFPlate 90262-21 Piston and Piston Rod - ToolsPlate 00262-21 Piston and Piston Rod - Tools Tem Ne, Part Description tem No. Pat Description ore 5 038 051 063 87 O-ng with back-up eng, 70/80 mm. ing with back-up ring, 90/100 mm Hydraule jack Spacer ring Stud setor, MA2x4.5 Hydraulic tot for pitoa rd, piston crown, axial vibration damper and segment stopper. complete(Gay Cylinder Liner 109-1 aa | garervpnecauTions Stndard Tools: Ge Sectin 03 FE] Sere eno 1 Sick he ring ection Zz, | shutting mney Enso tui — | entero x] shut int ot = 0-00 | shtctnrearg a Loa uber ar Ome Do Ops anew. new 90D D2 Ofer. conse 8609 Do Czclng haat 2050 : | (D-4 Cylinder cover stud 205 kg | os sxonrain ae 20m | ‘anes oe Pope iam Pt 02 Tetris Ts | “eet ‘pnb pan pears ee Dem al 10ST Ean ora MAN'GBW Dvsol AS1031 Cylinder Liner Data Baw) Spare Parts. ate mamh. neon ov 908020019 Oring 3 90802022 Oring 2 908020 117 Gasket 8 02028 178 Oxing 20 Page 2) ikon refering to Wis page,please quota Data Shoet 103-1 alien 19 MAN B&W Disa! AS(oe Cylinder Liner Bi Checking 1. Dismount the cylinder cover, the piston Cleaning ring and the piston ‘Soe Procedures 9011.2 and 902-1.2. Clean the cylinder tner and scavenge ait pons, 2. Position the eylinder liner measuring tool Measure the ojinder liner with an inside micrometer at the postions indicated on the measuring too. ‘Take measurements Inthe fore-and-alt and NL ra D001. Eaton B17 Page 6 (10) Witen referring to this page, pace hs San 17Cylinder Liner Overhaul 4. Check and assess the condition of the eyi- | 4 inder ner according to the description gv ‘nin Volume I, Chapter 707. CCaretully soratch over any scores oF marks fn the eylincer liner running surface, Using 2 rough grindstone held in the hand. Using a grinding machine, remove the wear ridges at the top and bottom of the eyinder liner (where the pision rings reverse direc- ‘ior, $0 that @ smooth transition is formed, Carefully grind or chisel away any coke do- posits from the PC-ring groove. necessary, mount a new cylinder tinor. Note! fa new oylinder liner Is mounted, anew piston cleaning ring must also be ‘mounted afer mounting the piston. 5. Apply a thn layer of grease on the contact surface ofthe liner. Mount the liting tools on the liner. Tighten ‘the bots ofthe iting tool othe torque siat- {din Data, Check that there is no clearance between the bots and the liner See also Procedure 903-1.2, LL the Hive Hy ad mount new O-rings for the cooling jacket. Then place the liner In the cooling jacket. Remove the iting tools ‘Viner etering tos page,please quote Procedure 808-13 Eaton 217 9034.3 Page 7 (10)1 903-3 Cylinder Liner ay | Overhaul Se 6. Lif the cooting jacket into postion ~ mark- ing scratches jackotoylinder liner must co- incide (camshaft sid). “Turn the clamps until they fit ia the groove ‘of tho liner, and tighten the screws. Remove the tackles and the eye Botts from the cooling jacket When refering to is paga, please Guoto Procedure 008-13 Falion 217 THAN B&W Diacel ASCylinder Lin Baw Mounting 4. Loosen the water connections on the cool: | 1 ing jacket, Mount the iting tools on the yinder tne. Hook the chains fom the iting crossbar on to the liting tools, and it the jacketiner aseemby Mount the lowermost O-ring ane apply alt= tie lubricating oll on the ring 2. Check that the joint eurtaces on the oyinder frame and cylinder tner ate completely lean, Coat the joint suraces with permatex or a similar Equid sealing compound, Mount the cylinder liner in the cylinder frame, Replace the O-rings on the water | connections and mount the water connec. | tions on the cooling jacket. 3. tf one or more cylinder cover studs have been removed during the dismanting of the cylinder cover, dlscard the old O-ings and mount new ones on the cylinder cover studs Mount the studs in the cyinder fame, using the stud setter “The studs shoulé not be fully serewedtin Instead the stud should only be screwed ln-unil the edge on the stud is 2.5-3.0 mm above the cylinder frame, see ‘keteh ihen etering t is page, please quote Procedure O0S-14 Editon 217 Page 9 (10)903-1.4 Cylinder Liner Nera Gad) 4. Mount the non-return valves for cylinder i= bation in the boces ofthe liner. ‘Scrow the pipes trom the lubricator on to the non-return valves, but do not tighten, Vent the cylinder lubricating system by ‘manually pumping each Individual pipe {through until of, without air bubbles, comos fut from the union pipeinon-return valve, ‘When this sin order, tighten the pipes trm- lyon the non-tetura valves and again pure ‘manually unl tie certain that each indivis- Lal lubricating point functions correctly 5. Lubricate the inside of the cylinder tiner with cylinder lubricating oll and mount the piston. ‘See Procedure 902-14 6, Mount the piston cleening ring, the sealing ting and the eylindar cover. ‘See Procedure 901-14. Note! Make sure to mount the piston cleaning fing correctly so thatthe scratching marks are aligned. Tighten the upper water connestions on the cooling jacket as soon as the cylinder cover 's correctly postioned age 100) When rearing (otis page,please quote Procedure 803.1.4 Eaton 277 "WAN BW Olea NSCylinder Lubricators Bay Data ‘SAFETY PRECAUTIONS ‘Stopped engine Block the starting mechanism ‘Shut of stating al supply Engage tuning gear ‘Shu off cooling water ‘Shut off ful ot Shut off brcatin oi Lock turbocharger rotors Data Det Tightening torque s0Nm ‘When refering to this page, please quote Data Shoot 103-2 Editon 08 MAN BAW Dial AS 103-2 Standard Tools: Sse Section 019 ZY Control of Lubricators arte rt tonepncing ns nb, noe oO f Pose @)103.2 Spare Parts Page 2) Cylinder Lubricators Data ‘When refering to this page, please quote Data Sheet 103-2 Editon 08 MAN 88W Duss) NS(exd\ Cylinder Lubricators 903-21 man Checking 1. Turn the piston of cylinder No. 1 to TDC. See Procedure 906-3.1 ‘The piston shall remain inthis position Gur- Ing adjustment of al lbriestors. template on the lubricator of ey- 3. Check thatthe seraich mark on the rotary clement ofthe lubricator is aligned withthe ‘mark forthe relevant cyinder number on the template. ‘the two marks are not aligned, the setting ofthe lubricator must be adjusted. See Prov cedure 903-2.3, 4. Ropeat stops 2 and 3 on all eylinders of the | 2. engine. ‘When eforring to is page,please quote Procedure 60G-27EdwoneTS ~~ age) Man Ua Drees9032.3, Cylinder Lubricators (oe) ‘Adjustment 1 1. Loosen the seraws on the counting, Mount the template on the lubricator to be adjusted 2. Turn the shaft of the lubricator so that the scratch mark on the rotary element of the lubricator is aligned with the scratch mark {or the ralevant cylinder number on the ter piate. 3. Retighten the screws ofthe coupling to the torque stated in Data. Bage2@ When volving to tie page,please quote Procedure 09.2.9 Ealion 213 ‘WAN BW Diesel NSCylinder Liner - Tools Plato 90361-73 024 — 048 When refering o this page MAN BAW Dios ASPlate 90361-73. Cylinder Liner - Tools. tem No. Part Description ae Part Description o12 2s 048 Measuring rod for cylinder liner, long Measuring rod fer cylinder tner, short Measuring tol fr eying ierPlate 90962-06 Cylinder Liner - Extra Tool tem No. Part Description ne Part Description 016 | Wear ridge miting machine 031 | Miting cutterCylinder Liner - Honing Too! Plate 0036-01 ~ ov [— 025 ‘Winon rtaring tei pape, pease quote Plat 90959 Eason OF MANBAW Dial ASPlate 90353.01 Cylinder Liner - Honing Too! ‘eo Par Dozen ae Part Description 013. | Honing too! optional) (025 | Honing stone(md Crosshead Bearing Baw Data ‘SAFETY PRECAUTIONS ‘Stopped engine Block he tating mechaniam | Shut of stating sie supoiy Engage turning gear Shut off cooing wator Shut of fel i ‘Shut off beating ot = EE] Lock turbocharger rotors Data +1 Top clearance in crosshead bearing: Max 070mm in. 0.35 mm D2 Ot wodge length, L= 20mm D's Hydra tghtening prossue 1600 bar D4 ‘Hyraue demanting proseure 1800-1650 bar D'S. Crosshead bearing cap 1400 wth bearing shel D6 Connecting rod 15800 ka D7 Boating shot ower 200g 0-8 Bearing she, upper 190%9 9 Trust pieces tightening torque ot 470m tightening angle 40° D0 Counterwoghts, ch 200-40 tg ‘When referring to this page, please quote Data Sheet 104-1 Eallion 16 MAN'BRW Ocal AS ‘Standard Tools: Seo Secton 913 ZS ~ 104-1 Q —srreonsrene = 0700 =o 2xmia,2x M20 2x M24, 2x30 xmas te 4x1 m1 439m hose Ease | \Qe oe Paget @)i tom Crosshead Bearing | Data fl ss 31 Spare Parts Patt etter oy Page 22) When rearing to tie page, ploaso quote Data Shaat 104-4 Eaton 18 MAN BAW isos! NSfe) Crosshead Bearing Baw) Checking ‘The top clearance between the journal and a new bearing shal is the result of a summation Of the production tolerances of the bearing as- sembly components, For the top clearance of a specie bearing, see the measurement in the Adjustment Sheet in Volume J, OPERATION. 1. Open the crankcase door at the relevant onder. 2. Turn the exanktivow concerned to 90° b fore BDC on the exnaust side 8, Measure the clearance in the crosshead Dearing by inserting a feelor gauge be- ‘woen the bearing cap and the crosshead Journal, exactly next to the landing surface for the piston rod foot. See Data 4. Tho difference between the actual clear lance measurement and the measurement recorded in the Adjustment Sheet (or the Clearance noted for a new bearing installed later) must not exceed 0.1 mm. If 80, the crosshead bearing must be clsassembled for ingpection See Procedure 904-1,2. 5. The wear limit fora crosshead bearing shel! Js confined to a 50% reduction of the oll wedge length (L). See Data 6. Perturther external inspection ofthe wuss: hhoad bearing, see Chapter 708, ‘Bearings’ In the instruction book, Volume J, OPERA- TION, “ihon refering to spas, MAN BAW Oiesl A'S 2 TD , 908-14904-1.2 Crosshead Bearing | Dismantling aay) 1 ‘This procedure applies tothe following two cls- ‘manting situations: + with piston mounted (steps 1 to 18) + with piston removed (stops 6 to 18) ( 1. Turn the ‘crankshaft down fer enough to jive access to the nuts and screws on the Piston rod 2. Mount two chains In the Inner sorew holes Inthe top of the crankcase, inthe athwarthe ship direction, for suspending the piston 103, ‘8, Place the spacer rings on the piston rod ‘nuts and screw the hydraulic jacks onto the studs, Loosen the muts. For operation of the hy- raulc Jacks, soe Procedure 919-1 Page 2(17) ‘When relerring to this page, please quete Procedure 9041.2 Eaition 218 ‘MAN BaW Dies NSCrosshead Bearing 9081.2 Dismanting 4. Mount alti eye bott on each side of the piston rod. 45. Turn the crosshead to TOC. Hook the chains to the liting eye bolts in the piston rod, “Turn the crosshead downward, and the pis- ton rod will remain suspended from the two chains. 6. Tum to BDC, (On some engines the guide shoes on a number of cyinders may be fited with Counterweights, Wt necessary, dismantle the counterwoights land suspend them in the top of the crank casing. When referring to this pape, please quote Procedure 904-1.2 Edtion 218 Page 3(1) NaN BW Oiael AS9041.2 Crosshead Bearing Dismanting Page aiit) 7. Mount the spacer rings around the nuts and serew the hydraulic jacks on to the studs, Loosen the crosshead bearing cap nuts, For operation of the hycraule jacks, 260 Procedure 919-1 Remove the hydraulic jacks and the spacer rings, and unseren the nuts, Femove the locking wire and dismantie me theust pleces from the bearing cap 8. Mount the iting attachments on the head (of the connecting rod. ‘Suspend two tackles from the litng brack- fs, In the athwarthship arecton Mount the liting too! on top of the cross hoad bearing cap. ‘When referring to this page, please quote Procedure 904-1.2 Edition 218 THAN BAW breso| VS(oa Crosshead Bearing 9061.2 i Dismanting 8. Hook the tackles on to the eye bolt of the iting toot and remove the bearing cap from the crosshead. 10. Check the upper part of the journal 11. Mount the wire guide in the top of the door opening, Hook a third tackle on tothe lting bracket and it the bearing cap out of the engine. Winen referring to this page, please quate Procedure 904-1.2 Eaton 218 Page 5019) | MAN BAW Dial AS1 9041.2 Crosshead Bearing (a3) . Dismantling 3) 12, Place the bearing cap on one side on a coupe of wooden plants, if necessary, dismante the locking serens to replace the bearing shel 18, Fasten tackles to the fixed liting brackets on the frame box wall 14. Turn the crosshead upwarcs until the piston rod lands on the crosshead. Ensure thatthe studs in the crosshead ft correctly in the holes of the piston rod Do nt remove the chains or ting eye bots 16. Turn to TDC and attach the tackle hooks to the iting attachments, Haul the tackles tight 4 Pages 17) ‘When referring to thie page, plaase quote Procedure 904-1.2 Ed THAN BAW biesa| ISCrosshead Bearing 9081.2 Dismanting 16, Mount the four supports for guide shoes on the crosshead guides, Carefully turn the crank down towards tho exhaust side, untl the guido shoes rest on the supports. Agjust the support brackets to the guide shoes so thatthe weight of the crosshead Is evoniy cistibutes on the four supports Haul the tackles tight, 17. Turn the crankthrow caretully towards BDC while following’ withthe tackes, thus con tinuously supporting the connecting rod. \With the crosshead resting on the supports, check the lower part of the crosshead jour nal and the lower bearing shell. Fegarding checking of journal and bearing sholls, s9@ Volume I, OPERATION, Chap ter 708, ‘Bearings’, 18.1n cases whore it Is necoscary to remove the lower bearing shot, tit the connecting rod towards the doer in the camshat side, i using the tackles. Dismount the lock screws, and turn the Dearing shell so far up that an eye bolt can be mounted Lift the aaring shal cut ofthe engin ‘When rlaning to tis page, poate quote Procedure 604-12 ion BT ——~—~SCSCSCSCSCé TTD MAN BAW Oise! AS9081.4 Crosshead Bearing (ead Mounting fay With the piston mounted! With the piston removed: 41. Mount and sacure the bearing shell in the bearing housing ‘The excess height X Is to ensure the cor- ‘eet tightening-down of the bearing shell and must net be eliminated 2, Ralse the connecting rod to an upright po- sition “Tum to TOC while “ollowing’ with the tack: les, for assembling the crosshead and the connecting rod. “Teke care thatthe studs do not damage the ‘crosshead journal 8(1) ______ Whanvefering io ls page,please quote Procedure 804-14 Elon 26 « ” me ‘MAN 28 Dieet AS PaCrosshead Bearing Mounti 8. Remove the supports from the crosshead ‘guides. Romove the tacks trom the crosshead, ‘Turn the crankthrow to BDC. 4, Lift the bearing cap into the engine. Lower the bearing cap onto tne crosshead and re- move the tackes. Remove the lifting attach ‘monts ftom tho connecting roe, Remove the Wire guide trom the engine. 5. Tighten all our crosshead beating cap nuts simutanoously. See Data, For operation of hydraulic jacks, see Soc- tion 9134 ‘Mount the thrust pieces onthe bearing cap. Tighten the screws tothe torque/angle sta. ce in Data, Secure the screws with locking wire. See Procedure 913-7. Wher refering to his page, poate quote Procedure O041.4 Editon 218 MAN BAW ince! AS Page (1)Crosshead Bearing ‘Mounting aes 6. the guide shoes are equipped with coun- Aerweights, mount the counterweights on the guide shoes. Tighten the screws and secure with locking 7. Mount the piston. See Procedure 902-1.4 With the piston mounted: 8. Tum the crosshead upwards until the piston ‘od lands on the crosshead. When mount- Ing the piston on the crosshead, make sure that the piston rod foot does not damage the threads of the studs. Page OG ‘Wen refring fo this page, plese quote Procedure 804-14 Ealion B18 ‘MAN Baw Dies NSCrosshead Bearing Mounting 8. Unhook the chains trom the iting eye bots in the piston rod. Remove the chains and {eye bolts from the top of the erankcase, from the piston rod and from the crosshead bearing cap. 10, Tum down to BDC and mount the hydraulic. ‘screws on the studs. For operation of the hydraulic jacks, see Procedure 913-1 Tighten the nuts as stated in Data, When reening to his page,please quote Procedure S044 Fain 78 MAN BBW Owa0i NS Paget(oe Crosshead 104.2 Baw Data ‘SAFETY PRECAUTIONS. Standard Tools: See Secton 913 [X] stepped engine . | Bock ne staring mechanism Zz, ‘Shutoff staring a supply Engage turning goar —o x XC] Shut of cooing watae x x 140-760 Nm ‘Shut of fel al ——== S00 Nm Shuto bicatng ot wn Lock turbocharger rotors treet 153m Data 4xtao 4x0 at amin voun unt DA Hygraule pressure = domanting 1800-1650 bar 0-2 Hygraue pressure ~tigtening 1500 ber 1D Croesheed bearing cap 1400 kg vith bearing shel sx2000%9 2% 8000 kp O-4 crosshead 5000 kg D5 Conecting od 15800 kg 1-6 Guide shoe with 180069 = = crosshead journal ae D7 Ousletplpe ~rigntening torque 250m 0-8 Studs on connecting rod = serevingin torque 6001Nm 1-9 Scraws on guide stipe ~ighteing torque 420 Nm D0 Telescope pipe ~Tightning torque 280 Nin ett Thevst pleco tightening angle 40° tightening torgue 470m 1-12 Studs on crosshead = serewingin tore conn | 1-13 Counterweights, each 200-4083 | When refering ole page,please quote Data Shoot 1062 Ealion 16 MAN BAW Dita! NSCrosshead Data 1042 — Hl Spare Parts reste, mn Fea \Winen referring to this page, please quote Data Sheet 104-2 Ealtion 16 iW Diet AIS{ Crosshead 9042.2 Dismanting 41. Dismount the piston See Procedure 902:1.2. 2, Dismount the main bearing lubricating oi! pipes. DDismount the cooling oil outlet pipe from the guide shoe. 8. Loosen and remove the screws which se: ‘ure the telescopic pipe tothe guide shoe. Inorder to reach the sorew in the corner be hind the telescopic pip, use the ctset tool along with a socket wrench, 4. Mount the retaining tool for the telescopic pipe on the stung box housing forthe tel- scopic pipe. ‘Tum the crosshead to TOC. ‘Suspend the telescopio pipe by means of the tool ‘Mount two eye bots in the top of the crank case in the fore-ande-aft direction, ‘Wher satering tots page,please quote Procedure 42.2 Edn B17 ———~—S~S~« TO | NAN BaW Ole! NS9042.2 Crosshead (ad Dismantting Bay Fane 2 08) 5, Tum t BDC. It the guide shoes are equipped with coun- ferweights, dlsmante the counterweight and remove them from the engine. 6. Mount the spacer rings around the nuts and screw the hydraulic jacks on to the studs. Loosen the crosshead bearing cap nuts. For operation of the hycraulle Jacks, $00 Procedure 919-1 Remove the hydrauic jacks and the spacer tings, and unserew the nuts. Remove the locking wire and dismante the thrust pieces form the bearing cap. Wea refering fa hs page, ploara quote Procedure 504-22 Ealiion 277 THAN BAW Dloeet NS(oad Crosshead 904-2.2 a Dismanting 7. Mount the iting tot on top of the cross | 7. head bearing cap. ‘Attach a wire strap to the engine room Hook the wire strapon tothe eye bot ofthe litng too and remove the bearing cap trom the crosshead. Check the upper part of the Fourral. 8. Mount the wire guide in top of the door opening, Hook @ tackle on tothe iting bracket and It the bearing cap out ofthe engine. E ‘When refering to ts page,please quote Procedure G0422 allen 217 | MAN BBW Oneal ASCrosshead Dismanting 8. Using the stud ster, unscrew the studs from the connecting ro. 410. Remove the iting tol from the beating cap and mount it on the crosshead. Mount the tting attachments for fixing the ‘connecting 10d, on the head ofthe connect- ing ro. Fasten tackles tothe iting brackets on the frame box wall and attach the tackle hooks to the iting attachments. Haul the tackles tig Attach @ wire strap to the engine room Hook the wire strap onto the iting toot on ‘the crossheed, and iit the crosshoad clear of the connecting rod. |. Using the tacklos, tit the connecting rod to wards the exhaust side, while turning the cranktnrow towards the camshatt side, Transfer the tackles trom one liting attach ‘ment to another as necessary. When the crankthrow is 80° after BDC, stop ‘uring. By alternate use ofthe tackles, tit the con necting rod unt it ests against a couple of ‘wooden planks in tho bottom of tha bed: Plate gual Precodire 504-32 Elion 217, ‘MAN Ba Diesel 8SCrosshead 904-2.2 Dismanting 12, Remove the guide strips and the guide | 12 scraws from the guide shoes, Note! | itis recommenced to tag the guide strips fang shim to avoid mixing them, 18, Suspend two tackes trom the eye bolts In the bottom of the cylinder frame in the fore= and-at direction. Mount an eye bolt inthe top of each guide shoe. Fomove the stop screws from the bottom of the guide shoes. 114, Hook the tackles on tothe eye bolts In the guide shoes. ‘hen refering to is page,please quote Procedure 90422 Ellon 277 Page 5 (19) MAN BAW Diseol NS9042.2 Crosshead smenting (aa) 15, Lower the crosshead unt there is access to the nuts on the end of the guide shoe jour- ale Note! ‘Make sure thatthe crosshead journal 009 not touch the crank, 16. Mount the hydraulic jacks on the studs at the end of the crosshead, and loosen tho nuts. For use of hyéraulic jacks, see Procedure 91341 Remove the nuts from the crosshead, 17. Using a stud sotter, move the four studs from the one ond of the crosshead. Repeat this procedure on the other end of the crosshead. E ‘When refering to this page, please quote Procedure 9042.2 Eaiion 217 “ ‘no tes age, Pease WAN Ba Diet NSCrosshead 904-2.2 Dismanting 18, Using the two cismanting sorews, separate ‘th guide shoe journals fiom the eross- head. 19, By means of the engine room crane, lit the crosshead to make it possible to remove the guide shoes trom tne engine. Re-postton the gulde shoe journals in the Centre of each guide shoe, and remount the gulde screws. When refering to this page, please quote Procedure 8042.2 Eation 217 MAN BEW Dee) AS904-2.2 Crosshead Dismaning cy Page a 20. Mount the wire gulde tool In the tramebox door opening, Mount a tackle outside the engine and hook the tackle on tothe fore and aft guide shoe, respoctivaly. Remove the guide shoes from the engine and land them on a couple of wooden planks, 21. Remove the stop screw from the guide shoes. Mount eye bolts in the guide shoe journals, {nd lt the Journals out of the guide shoes. Can and inspect the surfaces of the jour- ‘als and the bearings in the guide shoes, 22. Remove the crosshead from the engine, us- Ing the engine room crane and tackles. Note! When handling the crosshead, take great care that the surtaces ofthe crosshead are not soratcned or damaged. It neces sary, protect tne crosshead witha coth Land the crosshead oulsige the engine on «couple of wooden planks covered with ean rags, Clean and inspect the crosshead Inthe event of damage to the crosshead, the journals or the bearings in the guide shoes, contact MAN BAW Diesel for advice. Won refering otis page, place quote Procedure 9042-2 Eaton 217 WAN B8W Dewal NSloa Crosshead 0428 tan Mounting 1 1. Glean the crosshead and mount the iting | 1 bracket Mount the wire guide tool Ia the framebox door opening, Mount a tack outside the engine. Hook a wire rope on to the engine room crane. Lower the wize rope down through the cyl: Inder frame, through the erankcase and out (ofthe tramabex door opening Hook the wire ope and the tackle on tothe |y ling bracket mounted on the crosshead, [2 ‘and carefully iit the crosshead and ease it |? Into the crankcase 2 Lit up the crosshead enough for the guide shoes to pass. Note! ‘When hanalng the erosshead, take great | care that the surfaces ofthe crosshead are not scratched or damaged. f neces sary, protect the crosshead wi a cloth | 2. Clean the foremost guide shoe journal and i land it in the foremost guide shoe. Mount {and tighten the stop screw in te lower hole Of the guide shoe. Mount an eye bot inthe Upper le ofthe guide shoe. A. Suspend a tack fom the top ofthe crank case. Use this tackle and the tackle mount- 2d outside the engine to carefully ft the {guide shoe and ease tt into the crankcase 4, Repeat steps 2 and 3 forthe aftmost guide: shoe. Wen refering to this page, please quote Procedure 904-24 Edtion 217 Page 918) MAN BAW Die! NS9042.4 Crosshead Mounting D4 5. Lubricate the slicing surfaces of the guide shoes with plenty of clean lubricating and push the guide shoes ino postion be twoon the crank webs. Remove the guide screws and push the guide shoo journals outwards approx. 35 Lower the crosshead into position between the guide shoes and push the guide shoe Journals back on to the crosshead Mount the guide sorows and lock the screws withthe lock washers. 6. Mount the studs in the ends of the cross- head, using the stud setter and a torque ‘wrench, Tighten the studs to the tora stated in Data, 7. Mount the nuts and the hydraulic jacks on the stu, Using the tydrauilc jacks, tighten the nuts to the tightening pressure stated in Data For use of hydraulic jacks, see Procedure 9134 Remove the hydraulic jacks. Fomove the tackles and the eye bolts trom the guide shoes. Page 003) Wen rearing to this page, pease quote Procedure 804-24 Eton 217 ‘MAN Ba Diese NSCrosshead 904-2.4 Mounting 8. Mount tne shims and the guide strips on the | 8. guide shoes, 8. Litt up the crosshead with the guide shoes. Hook tackles on to the ling attachment mounted cn the connecting rod Using he tackles, lt te connecting rod un- tilt points towards the crosshead. D-9 ‘At his point, check the conation of the crosshead bearing shell ‘See Procoduire 904-1.1. 10, Lubrioate the exosshead bearing shell with plenty of cloan lubricating ai “Turn the crankthrow upwards while ollow- ing withthe tackles, until the connecting rod | beers frmiy against the crosshead. Remove the tackes, the liting attachments and the wice ropoe from the engine. When referring fo this page, ‘quote Procedure 60424 Ealtion 217 Page 11 (13) AN BAW Die AS904-24 Crosshead (ees) Mounting Baw 11. Turn the engine to BDC. Mount the studs on the connecting rod. Using the stud setter and a torque wrench tighten the studs to the torque stated in Da- rd 12, Lubricate the crosshead journal with plenty of clean lubricating ol Carefully tit the crosshoad boaring cap into the crankcase and mount it on the eross- head. Note! During handling and mounting ofthe crosshead bearing cap, take great care that the studs for the crosshead bearing cap do not soratch the slding surlace ‘the bearing shell in the cap. | 18, Mount and tighten the nuts on the cross- head bearing studs. For operation of the hydraulic tools, see Procedure 913-1 Note! ‘At this point it is recommended to check i the crosshead bearing clearance. ‘See Procedure 904-1, 18. Remove the hydraulic tools and the eye bolts from the engine. Mount the thrust places on the bearing cap. Tighton the sorews tothe torque/angle stat- fed in Data. Lock the serews with locking wire. See Procedure 913-7. Note! Only the tightening toraue othe ghten- Ing angle should be used, not bot. For correct tightening, se also Procedures 919 and 913-6. Page 2019) Wen rlerng tots pape, please quote Procedure 04.2.4 Ealion 217 ‘WAN Baw Dist NSCrosshead aw Mounting 14, If he guide shoes are equipped with coun- | 14 terweights, It the counterweights into the crank casing and mount them on the guide shoes ‘Tighten the screws and secure with locking whe. 15. Check the clearances between the guide tips, guide shoes and crosshead guices, See Procedure 9043.1. 16. Turn the crosshead upwards unt the fore- ‘most guide shoe touches the telescopic Pipe. Remove the suspension tool ftom the tele: seopie pipe. Mount and tighten the scraws which secure the telescopic pipe tothe guide shoe, Inorderto reach the screw inthe comer be- hind the telescopic pipe, use the offset too! along with a socket wrench, Mount the cooling ll cute pipe on the aft most guide shoe. 17. Mount the main bearing lubricating of pies. Mount the piston. See Procedure 902-14 ‘When refering to this age, please quote Procedure 9042.4 Eton 217 MAN BBW Ovase! AS 9042.4 D-10 Page 18°18)‘Stopped engine Block hs staring mochaniem Engage turning goar ‘Shutoff coating water ‘Shutoff elo ‘Shut ofthbrcating ot Lock turbocharger ots [x] x [x | shut of tating ar supply x bx [x| | x Data ‘Accaptanoe citer with piston in cente (F-Acireston) Nas Ore E66 Noe He Nein Ore HC, Nae ec, uo On ZEA Onn IN: New and cold engine wih staybostighoned (dos than 100 running hours) 0: Engine in service Reciprocating Parts Date Standard Tools: See Section 813 Value 0.95 mm +155.mm 0.70.mm 020m 4150 em 1.20 mm 4150.mm 5.00.mm When refering to tis page, please quote Dala Shoot 1043 Flton 14 MAN BAW Dist AS 104.3 Paget @)1043 ‘Spare Parts 21a) eeton Reciprocating Parts Data ‘When refering to his page,please quote Data Sheet 104-8 Edition 14 MAN 28W Diss) AS| (oe Reciprocating Parts 908-34 ‘a Checking In order to achieve uniform measuring condi tions on board, the ship's tim must be as close | 1 q ‘a5 possible to'0" Teen nen (OOOO length of the bedpiate. Bend each end approx. 250 mm up along esa the framebox side. See T. Fill the tube with water (possibly coloured) unt the water lovel I approx. 100 mm from ‘the end ofthe tube “Tim the ship untl the diference betwoon | the watar level § fore and aft i lees than anette comets eet Z ‘han refering fo his page, ploase quote Procedure SOT Eamona0s ——~—~=~S~S~*~*~*~*« TY MAN BBW Dito! NS Measurements are to be taken witha ruler afier BDC (the guide shoo must rest | 2. Turn the engine in ASTERN direction to 45° | ‘gains the crosshead guide), Check the clearance between guide shoe ‘and crosshead guide (E, F, G and ) with ‘a feoler gauge.904-34 Reciprocating Parts hectng (ad 8 an 8, Check the centering ofthe piston in the cyl. Inder liner by measuring the clearance {(rom the scavenge air space with a long feeler gauge) between the piston skirt and the eyliner liner In the Fore and At post tions (PF-PA), [Make sure thatthe piston is clear ofthe cy i mol PA Inder liner in the fore-and-aft rection. E 7 Measure te clearances between the coss- heed and the comecing rod (TFTA). Pee26) han refeing Wo this aga, nease quoi Prosedire 9063. Falion 208 ama ‘MAN BBW Diese AS | i(oe Reciprocating Parts 9043.1 Baw Checking 4, Measure the clearance between the guide | 4 ‘shoes and the crosshead (C and D), Measure the clearance between the guide rips and crosshead guides (J, K, Land ™, ‘The cloarance, calculated as JeC, Kec, L¢D and MD, Is adjusted by the insertion ‘of shims so that itis symmetrical in relation to the clearance between the pision skit and the cylinder liner. Dim ete, F2 Parallelism between the guide strip and | ‘ulde isto be kept within a tolerance of 0.2 ‘am per 1000 mr, ls & Mis recommended that the measured re- | futs are noted down 0 hat posse ter 2 Changes canbe asconaied H Winen refering to ts page, plaase quota Procedure BO431 Eaton 208 Pa03 8) MAN BW Dleo! NS(ee Crankpin Bearing 1064 Data ‘SAFETY PRECAUTIONS | Standard Tools: See Secton 913 X ] Stopped engine Block the stating mechanism DC] Shut of stating ai supply | Engage tuning oar [| shut of cooing wator ‘Shut of fel oi % | Shuto bricating ot Lock tubocharger rotors 2x5 m—1800 kg 2x15m1xam “Tht Data a ue une 4% 1000 kg, 2 2500 kg +t Clearances in ran xmas Dearing 2xMa0 max. 078mm rin. 048 mm D2 Hyarauc pressure: ~deranting 1900-1660 bar tightening 1800 bar 029 D4 Crankpin boring — akg lowor shot 1-5 Crankin bering cap = 1200 Kg shel sboarng sues hen refering 10 this page, ploase quote Dala Shoot 104-4 Ealbon 14 Pago @) MAN BAW Bisel NSi Data [ai ie ¥ W ef 1044 Crankpin Bearing Spare Parts Pts ma, Deon a Page 2@) When roaring otis page {vote Data Shoe 10%-4 Eaton 14 Mm IAW BAW ieee) AS‘The bottom clearance between the journal and ‘new bearing shel isthe result ofa summation of the production tolerances of the bearing as- sembly components For the bottom clearance of a speciic bearing, see the measurement in the Adjustment Sheet in Volume |, OPERATION. 1. Open the crankcase door at the relevant ovinder. 2. Tum the crank concerned to BDC. 3. Measure the clearance in the crankpin bearing by inserting @ fooler gauge at the bottom of the bearing shell in both sides. ‘See Data for bottom clearance. 4. The dierence between the actual clear- ance measurement and the measurement recorded In the Adjustment Sheet (or the clearance noted fora now bearing installed later) must not exceed 0.05 mn. Iso, the Crankpin bearing must be olsassombled for inspection See Procedure 904-4.2 ‘5. The wear timit for the crankoin bearing shells is based on an evaluation of the bearing condition atthe Ume of inspection, 6. For further external inspection ofthe crank bin bearing, see Chapter 708 ‘Bearings" in the Inctnction book, Volume J, OPERA TION. Crankpin Bearing Checking 2 Wan refering tos page,please gute Procedure 6041 Fallon 270 MAN BEW Ouse! ASrd Crankpin Bearing Dismanting 1. Turn the crank to BDC. 2. Suspend two tackles from the ling brack: in the athwartship direction, ‘Mount the wite guide in the crankcase door opening 8. Tum the erank to TOC, Mount eye bolts in each side of the erank- in bearing cap and, using shackles and Wire ropes, hook on the tackles and haul tight Loosen the crankpin bearing stud nuts, us- ing the hydraulle jacks. For operation of the hydraulic jacks, see Procedure 913-1 Remove the hydraulc jacks and the nuts, 4. Lower the bearing cap while seeing eare- fully that the studs donot damage tho crankpin journal. Land the bearing cap on a couple of planks paced inthe of pan, Inspect the bearing shel, ioaso qual Procedure 906-42 Editon 210 ‘MAN Baw Diesel AS Page 2 @) When referring to this page, pi(2) Crankpin Bearing Baw Dismantting 5. Ifthe bearing shell needs to be replaced femove the whole bearing cap from the crankcase. ‘Suspend a tackle from the ting bracket on the inside camshaft side of the frame box above the crankcase door opening. Hook the tackle on to an eye bolt on one side ofthe boating cap, Mount the wire guide in the top of the crankcase door opening Using the tackle from the frame Box inside wall, loether with @ tackle suspended trom ‘the platiorm bracket, lit the bearing cap out of the crankcase, 6. Place the bearing cap on one side on @ ‘couple of planks. DDismount the bearing shel lock screws and replace the bearing shell by a new one. ‘The bearing shells must be replaced in pais. 7. Turn to TOC, Mount the four supports for guide shoes on the crosshead guides. Carefully turn the crank down until the ‘Guide shoes rest on the supports. Adjust the support brackots 10 the guide shoes so that the weight of the crosshead is evenly distributed on the four supports 904-4.2 ‘When releing this page please quote Procodure 604-42 Ean 210 MAN BEW Desa ASCrankpin Bearing Disnaning Gad 8. Mount a ling attachment for securing the conmacting rod at tho lower end, on one side. Hook on the tackle to @ beam under the gal- tery platform and haul tight 9. Carofully turn the erankshatt downwards, while “ollowing’ with the tackle, making ‘sure that the upper part of the bearing ‘comes completely clear of the recess inthe crankshaft when the parts begin to sepa fate Continue turning the crankshaft unt the bearing surlace can be teely inspected, Inspect the bearing shell sutace and the crankpin journal 10.1 itis necessary to replace the bearing ‘shell, proceed as follows: “Tun the crankshaft to BOC. Feloase the tacklo so that the connecting ‘ois hanging freely, Paao i) Wien refring to this page,please quote Procedure 8044.2 Eaton 270 ing tom page. MAN BEW Bese AS{ (oe Crankpin Bearing 904-4.2 Saw Dismantling = — —— 11. Mount an eye bolt in the bottom of each | 11. guide shoe. ‘Suspend two tackles from the eye bots 12, Place te liting tol for the crankpin upper shell on the crank webs and hook the tack les onto te ling toot Mount the tool on the bearing shell in the ‘connecting rod, using the tackles, tight 18, Dismount the bearing shel lock screws. Lower the liting tool with the bearing shel, using the tackles. * When referring to this page, please quote Procedure 904-42 Eaton 210 Page (@) MANBEW Ouse! AS| 904-44 Crankpin Bearing ‘Mounting Ba 1. Itmecessary, replace the bearing shals with new ones. The bearing shells must be co- placed in pairs, ' Bearing shells of three mm undersize are avaliable as spares in case of journal rect- fication, Coat the bearing shell surfaces and the Journal with clean olt “The excess height X is to ensure the cor- rect tightening-down of the Dearing shell, and must not be eliminated, 2. Lift the upper bearing shel forthe exankpin concerned inlo the crankcase. Careful tit the bearing shell into position inthe connecting rod, and mount the lock 8, Remove the liting too, the tackles and the eye bolts from the guide shoes. When refering to his page,please quote Procedure 80%-4.4 Ealuon 210, ‘MAN BaW Dies ASCrankpin Bearing Mounting 4. Hook the tackle on to a beam under the gal- | 4 leny platform and on to the liting attach- ‘ment on the connecting rod, and haul tight, Carefully turn the crankshatt upwards, while folowing up withthe tackle, making ‘sure thatthe upper part ofthe bearing en- ters the recess in the crankshaft whan the parts turn together. Remove the tackle and the liking attach- ‘ment from the connecting rod '5. Turn the crosshead to TOC. Flemove the guide shoe support brackets from the crosshead guides, Vien refering to is pape, pease quote Procedure GOA-44 Elion P70 MAN BEW Duse! AS Page @)904-44 Crankpin Bearing Mounting Baw 6. Suspend the tacKes from the liting brack sin the top ofthe frame box. Lit the bearing cap assembly into the crankcase and land on a couple of planks placed in the ol pan, Remove the wire guide tool from the en- sine. 7. Hook the tackles on to the wie ropes and lit te bearing eap into position againt the connecting red Caution! During mounting, take care thatthe studs do nat damage the erankpin journal, and check tat the guide pins mounted in the Dearing cap enter the holes inthe con necting ro, Mount the nuts and, by means of spacer Fings and hydraulic jacks, tighten the crank pin bearing cap. See Data, 7. For operation of hydraulic jacks, see Proce | cure 91941. Remove the tackles from the top of the frame box. id Pages®) ‘When referring to this page, please quote Procedure 044.4 Edition 210 ‘MAN Ba BeseData (oe Connecting Rod ‘SAFETY PRECAUTIONS ] Seed ene [5] sok staring mechanism Sof staring a spoly Engage ting gear htt oon water Shuto lo | shat ot kbrcaing ot [toc toch Data | Standard Tools: See Section 913 monn van | +1 Hysraue pressure = demanting 1500-1650 bar i D2 Hydraulic pressure mounting 1500 bar — +s Crankpin basing cap + 1200Kg shall studs Dt Connecting rod 5800 kg D'S Stud on connecting rod 620m crewing torque When relang to his page please quote Dala She MAN BAW Dasa! AS 104-5 Eaiion 17 2xmi0 4x15 m1x9m 3% 3000 kg 2% 5000 Kg 140-760 10451 104s Connecting Rod Spare Parts Pte —a, een on toring a pe ae Gl at eet 1044 En 7 earn a MAN B&W Diesel A/SConnecting Rod 9045.2 Baw Dismantling Mount tackes in the following positions in- Side the crank casing: ‘A, Second uppermost bracket atthe exhaust side B. Middle bracket atthe camshatt side C. Lowermost bracket atthe exhaust side ©. Uppermost bracket at the camshatt side 2. Remove tne floor plates on the upper and middle galleries. Lower the hook ofthe en- gine room crane downto the lowermost gal- long prerraar When relening to tis page, pease quote Procedure 00-52 Eaton 214 Page) MAN BW Diesel NSConnecting Rod Dismanting 3. Tumm the erankthrow to TDC. ‘Dismount the crankpin bearing cap, and re- ‘move it rom the engine, Soe Procedure 904-42 4. Suspend the piston rod from the top of the crank casing. See Procedure 904-1 2, Diamante te crosshead bowing cap ‘Soe Procedure 904-12. 1910 this page, please quote Procedure 904-5 2 Editon 214 ‘MAN BAW Blesi ASWhen refering to this page, please quote Procedure 904.2 Eaton 214 Pages) MAN BAW Dice! A'S9045.2 Connecting Rod Dismantling oi 8. Turn the crosshead to TDC. Hook two tack les from points A and B on tothe fiting at- tachments an tne connecting rod head. Haul the tackles tight. Mount a iting attachment onthe lower end ‘ofthe connecting rod, onthe exnaust side, ‘Mount the four supports for guide shoes on the crosshead guises. Carefully turn the crank down towards BDC while following’ with tho tackles, thus continuously supporting the connecting red. “Tun the crank until the guide shoes rest on the supports. Adjust the support brackets to the guide shoes s0 that the weight ofthe crosshead is evenly distributed on the four supports ‘8. Turn the crank to approx. 9 dogroes before TDC. Hook tackle © on fo the Iiting attach ‘ment mounted on the lower end ofthe con necting rod, ‘Mount the wire guide atthe top of the door way. 10. Hook tackle D on to the ting attachment ‘mounted on the upper end of the connect- Ing 10d, on the exhaust side. Tighten up Ue tackle Remove tackle B and remove the liting a tachment from the camshaft side of the ‘connecting rod head. neering o ts page,please quote Procedure 364-5 2 Eaton B14 Peso WAN BaW Diesel AS Pages)Connecting Rod Dismanting 11, Shit tackle A from the ling atfachment on the connecting rod head 9 te iting at- tachment on the connecting ro foot. “Turn the crank carefully upwards while ole lowing’ with tackles &, Cand D, guiding the connecting rod head out of the doorway. 12, Using a shackle and a wire rope, hook the fengine room crane on tothe iting ttach= ‘mant mounted on the connecting rod head Remove tackle ©. Shift tackle D from he iting attachment on the connecting rod head to the titing at- tachment on the connecting rod foot “Turn the ongine untl the erankis ‘pointing’ towards the doorway, while “Yollowing’ with the engine room crane and tackles A and D. 18, Remove tackle A. Using tackle D, carefully lit the lower end of the connecting rod cleat of the bearing journal while, at the same time, turing the erankthrow towards the ex aust side of the engin. Note! “Take care thatthe connecting rod doos not damage the crankoin bearing journal. | pot damag 0 i 14, Using the engine room erane, itt the con- necting rod out of the engine. When re MAN BBW Dr "910 is page NS guste Procedure BFE Eilon 13i 9085.4 Connecting Rod Mounting 1. Equip the connecting rod withthe same Itt ing attachments as mentioned under ois- ranting Apply clean lubricating ol to the erankgin bearing shell and journal. 2. Lift the connecting rod carefully ito the crankcase by alternate use of the engine ‘oom crane and the tackles attached to it: Ing bracket D. 8. Hook the chain of tackle A on tothe iting ‘attachment on the connecting ro foot By alternate use of the engine room crane and tackles A and D, caretully lower the Connecting rod towards the crankpin bear ing journal white, at the same time, turning the crankthrow unt it ‘points’ towards the ‘connecting rod. Note! Take care that the connecting rod does ‘ot damage the crankpin bearing journal. 4. When the end of the connecting rod rests (on the crankpin journal, nook the chain of tackle C on fo the iting attachment on the connecting rod foot “Turn the crankthrow towards the exhaust {ido ofthe engine hilo "ollowing’ withthe ‘engine room crane and tackles A, C and D. When the head of the connecting tod is cose to the doorway, shit tackle D to the Iiting atachment on the connecting. rod heas. Romove the wire rope connected tothe en- gine room erane from th liting attachment » on the connecting rod head. saze quoie Prosedira 904-54 Eaton 314 WAN BEW bveee| AVS When rooring to tie page,Connecting Rod 904-5.4 saw Mounting 5. Tuin the crankthrow to 90° before apc | 5. while following’ withthe tackles. Shift tackle A from the lower end tothe top ofthe connecting ro. ‘Tighten up tackles A, ¢ and D to turn the connecting rod upwards. Note! “Tako care thatthe wie rope ot tackle D does not touch the crosshead bearing Journal 8. Mount aiiting attachment on the camshatt side, upper end, of the connecting rod and remove the wire guide from the door way. -* Mount a tackle in bracket B and hook this tackle on to the fiting attachment on the ‘camshatt side of the connecting rod head Remove the tackle In bracket D. 7. Lubricate the crosshead beating journal land the crosshead bearing shall with plenty Of clean lubricating ol Tum the crankthrow to TDC while follwing? with tackles A, B and C. Remove the four supports from the cross head guides. Ratiovo ‘aokles A, B and 0 ‘rom the lifting attachments on the connect: Ing fod. Remove all tackle from the con- necting rod. E i Tia ecb poe ae os Psa SEV Emin Tea MAN B&W Diet NSPage 8@) Connecting Rod ‘Mounting Baw 8. “Turn the crosshead downwards far enough to enable access tothe piston rod nuts. Unscrew and romove the piston rod nuts Mount the iting chains between the top of the crankcase and the piston rod foot. Remove al tackles and iting attachments Tum the cranktnrow to BDC. Mount the suds on the connecting rod. Using the stud setter, tighten tho etude to the correct torque, as stated in Data please quale Procedure 604-54 Editon 274 WAN BAW Disot ASConnecting Rod Ban ‘Mounting 410. Mount the crosshead bearing cap, See Procedure 904-144. Mount the plston rod on the crosshead. ‘See Procedure 904-14, 11. Tum the erankthrow to TOC, and mount the crankpin bearing cap. See Procedure 9044.4, 12, Remove the tackles from the crank casing 18, Resmount the galery Hloor plato ir ering 0 is page, please guce Procedure BO4EA Eon B14 aN aw Dies v8 9045.4 Papo)| (oad Connecting Rod and Crosshead Panel _—Plate 90451-113 e 069 5 4 047 [oct ° ° i o Oo) wey 023 _ is) Biss | 059 g 2 Je a | 7 072 (072 Oy] TO p 0 . 059 | a dg } Ol] 1O) ° ¥ _ Oy] [TO Als plier otf oO 096 106 When rearing ois page please quot Pate BOA61 Eaton 78 NAN aw Bowers =7e Peasei Plate 90451-113 Connecting Rod and Crosshead Pane! Tom No. Part Description tem No. Part Description on 023 047 059 960 o72 88 096 108 8 120 131 155 on 155 *) Too! pane! Name pate Wire guide Liting attachment Liting tool for crosshead Chain for suspension of piston Retain alr wescope pe Fubber cover wih hole Bracket for suppor of crosshead Bracko for suppos of crosshead Torque wrench offset too! Crowioot spanner *) Tool panel, complete with tools *) Optional extrasPlate 90461-55 Connecting Rod - ToolsPlate 90461-55 Connecting Rod - Tools, iam No Part Description Part Description 016 38 ont 053 065 068 400 m2 126 196 48 161 ]2-tng with back-up rng, 190/200 men O-tng wih back-up ring, $25/195 mm Stud setter, M90 6 Hydraulic ack Spacer rng Hydraulic tool for erosshead bearing bots O-ring with back-up ring, 250/260 mm O-ring with back-up rng, 960/170 mm Stud settor, M1108 Hydraulic jack Spacer rng Hydraulic tool for erankpin bearing botsI Connecting Rod - Tools Plate 9046-25 Tien raerng toe pape, please quote Plat 90482 Eon BB MANBAW Dlte! ASlate 9046225 Connecting Rod - Tools tom No. Part Description Part Description on iting too or crankpin shelCrosshead End - Tools Plate 90463-04 042 Who refering 1o is page, please quote Plato 90469 Elion 0 MAN B&W Deal NS| Plate 90409-04 Crosshead End - Tools tem No. Part Description Par Description 017 020 30 42 058 Hysraulie jack \O-ing wath back-up rng, 155/165 mm [O-ring wih back-up rng, $20/190 men Stud sotior, M7Ex6 Hydraulic tools fr crosshead end, compteay Crankshaft Deflection 105-1 Baw Data ‘SAFETY PRECAUTIONS Standard Tools: See Section 913 Stopped engine Block the stating mechanism Shutoff starting alr supply Engage tuming oar Shut off cooling water Shut offtuet of | Shutoff kircsting ot Lock turbocharger rotors Data Patan ye ut When relering otis page,please quote Data Shoot 105-7 Edion 08 MAN BAW Dae! AS1054 Spare Parts Page 2 onion Crankshaft Deflection Data When refring otis page,please quote Data Shoot 105.1 Editon 03 MAN BAW Diosal AS(ead Crankshaft Deflection | man Checking Crankshaft deflection readings should be taken waile the ship is afloat (Le. not while In dry oct). [As the alignment is influenced by the engine temperature as wel as the loading conditions, the deflection measurements should, for com: parison, always bo made under nearly the ‘same tomperature and lead conditions. 1. Place a dial gauge axially In the crankthrow ‘opposite the crankpin, a illustrated on the sketch. The correct mounting position is marked with punch marks on the crank throw. See also Chapter 708 in Volume I 2. ‘Closing’ of he crankthrow (compression of the gauge) is regarded as negative. 3. Sot the dial gauge to zero at the B1 side rear BDC. Whilst turning clockwise, take the readings for Instance when the throw passes the positions: Bt (ar bottom) ce (camshatt sce) T (top) | E (ecraust side) 82 ($ear bottom) | 412 (82181) =B | Wines refering to nis page, Pease quote Procedure 05-1. Eaion 208| 905-14 Crankshaft Deflection chosing aad 4. When taking doflecton readings for the three aftmost cylinders, the turning gear should, t each stoppage, be turned a litle backwards to ease off tho tangential pres: ‘sure on the turning whee! toeth. Ths pres ‘sure may otherwise falsity the readings. It the crankshaft deflection (alignment ind calor) is approaching the tolerance limis (G22 Vol. ), OPERATION), the. beating shells of tne two adjacent main bearings ‘must be dismantled and inspected, See Procedure 905:2.3 for overhaul of ‘main bearing, I1the bearing shells are found to bo in good ‘order, please contact MAN B&W Diesel or the engine manufacturer for checking ofthe Dedplate alignment IV the excescive orankshatt deflection ie found at the aftmost cylinder of the engine, ‘ako the alignment of the propelior shat! drive shaft must be checked by a jack-up test. Page 2) Winer refering to is page, please quote Procedure 605-.7 alton 206 ‘MAN B&W Disc ASGad) ‘SAFETY PRECAUTIONS X ] Stopped engine | Block the starting mechanism X | Shut of tarting alr supoly | Engage tuning gear ‘Shut off cooling water ‘Shut off ful of XC] Shutofthaesting oi Lock tubocharger etre Data DA Mn, beating earance D2 Max bearing clearance D2 Main bearing exp +4 Upper bearing shot 5 Lower beating shot D6. Hycraule pressure = dsmanting 0-7 Hydrauie preseure = ghtening DS Attend cover When refering 10 this page,please quote Data Shoot 105.2 Eaton 16 MAN BAW Dio! A'S Main Bearing Data 085mm 0.85 mm 210049 108 kg 1189 11600-1650 bar 1500 ber 105.2 Standard Tools: See Section 913 b Quam O2% 7 + Paget @)105-2 Main Bearing Data | Spare Parts Pte — aN Deston oy 9210000 108 Serew 2 21210000 121 Min bearing, upper shell 1 1210-00 131 Main bearing, lower shel 1 | = oe ——— Page? @) When refering to thie page,please quot Data Shoot 105-2 Elion 16 MAN BBW Diss! NSMain Bearing 905-21 Checking 1. If there is too large a difference in the crankshaft deflection readings. (autolog), ‘See Procedure 905-1.1, check the Indu al bearings. 2. Insert the measuring tool and measure the clearance between the upper bearing shell and the journal Note! The besrng clearances for a new bear Ing, as Stated in Data, ae for guidance only 3 The diference between the actual clear- ance measurement and the measurement recorded in the Adjustment Sheet (or the clearance noted for @ new bearing Installed lator) must not exceed 0.10 mm, I it does, tho main bearing must be dlsassembied for Inspection. See Procedure 905-2.2. For evaluation of the bearing, see Volume |) OPERATION, Chapter 708, “Bearings' Wher referring to the page, please quote Procedure 9052.1 Eaion 222 Page 720) MAN BAW Oisal NS905-22 Pa eee Main Bearing smarting (aa\ Dismantling of Main Bearing In the folowing, the bearings are divides into two categories! + the main bearings + the must shaft end journal bearing (the attmost bearing) ‘Check and write down the top clearances be: fore carying out ary dismanting, 1. Disconnect the lubricating ol int pipe from the main pipe ‘Tum the crankthrow to 60° after TOO. Note! Be sure thal the crosshead for the neigh outing cylinder is in a higher postion than forthe cylinder you are working on, otherwise it wil be Impossible to lit the cap. 2. Mount pulley E on the web plate above the bearing cap. Note! “Two versions ofthis pully are available, ‘hus enabling the mounting ofthe puley fom alther side of tne wed plat, Remove the stop screw trom below the {guide soe and mount the other pulley Fin ‘the bottom ofthe guide shee. 3. Mount an eye bott on the opposite web Diate. jaase quote Procedure 905-2.2 Ealtion 208 THAN B&W Disel ASMain Bearing 4. Mount tackles in the folowing positions: “ [AL Suspended from a wire strap below the crane beam. B._ In tho ting bracket in the top of the crank casing, camshaft sie. CC. In the ling bracket below the 00" way. D. In the eye bott on the wob plate ‘opposite the pulleys, 5. Assemblo the main bearing tightening tools, using the wooden box as a guide for correct assembling. 6. Mount the liting tool on the main beating [s, tightening tool. Dismanting ‘Whar rloring otis page,please quote Procadure 6052.2 Eatin 228 MAN BAW Ouse NS Page (2)905-22 Page 4 2 Main Bearing Dismantling 7. Attach tackles A and B, and it the main bearing tightening tools into the engine. 8. Release tackle A. Remove the wire rope ofthe iting tool from the chain of tackle A Place the wire rope ofthe iting toot around the wheel of pulley F mounted in the bottom ofthe guide Shoe (insert the wire rope trom below) and attach the wie rope tothe chain of tackle €. Hook tackle A on to the wire rope ofthe It Ing ool attached to tack B. “Taghten tackle © and roloase tacklos A and Bat the same timo, until the lifting tool Is suspended vertically below pulley F Remove the chains of tackles A and B. When relering to tis page, Peace quote Procedure 806-22 Falion 222 THAN B&W Diesel AS8, The main bearing tightening too! now has fone free wire rope. Place this wire rope ‘over the horizontal ror and around the vertical roller on pulley E, mounted on the web plate, and connect Ito tackle A, ane tighten up. Be sure the wire rope does nat touch the edges on the guide shoe. Release tackle © and remove the wire of the main bearing iting too! trom the chain of tackle C. 10. Carefully release tackle Ato land the main Dearing tightening tools on the main bear: Ing studs. Screw the extension studs of the main bearing tightening tool on tothe main bear Ing studs. Make sure tat the extension studs are fully screed on to the main bearing studs by ‘checking tha the top of the measuring rods inside the extension studs are tush with the {op of the extension studs. Connect the hydraulic jacke to the high- pressure pump via the distrbutor block anc high-pressure hoses. Note! | For compressing the hydrautic jacks of the main bearing tightening tool, a soe- cial larg tommy br is avallabe for tun ing the nuts above the hydraulic jacks. [Res a ace EN Bleed the hydraulic system and reise the pressure as indcated in Data Loosen the nuts, using a tommy bar. 12, Remove the yale main bearing tools from the engin. Unscrew and remove the nuts from the ‘main bearing studs. For operation of the hydraulle fools, 800 Procodure 919-1 When referring to thie page, ple MAN Baw Olsel AS Main Bearing Dismantling quot Procedure 60522 Ellon 222905-22 Main Bearing 13, Page (20) 18, Mount the main bearing Iiting too! on the main bearing cap, and place the wie rope a shown, CCaretuly it the main beating cap clear of the studs. 14, The iting too! has one tree wire rope. Place this wire rope around the whee! of pulley F mounted in the guide shoe. Hook the wire rope on to the chain of tackle C. Tighten tackle C and release tackle A, unt the main bearing cap is suspended vertical- ly below pulley F. 418, Remove the wire of the iting too! from the ‘wire of tackle A. Ramove tha wire ofthe lit ing tool from pulley E mounted on the web plate. When reloring fois page,please gusto Procedure 005-2.7 Fon 222 Vian B&W Desa ASMain Bearing Dismanting 16, Hookthe chain of tackle Don tothe shackle | 16. mounted on the side of tne main bearing lifting too. Tighten tackle Dang release tackle Cat the same time 17. Hook the chain of tackle B on to the tree ite rope ofthe main bearing iting Yoo Attach the chain of tackle A around the wire rope of the main bearing liting tool Tighten tackle A to pull the wire rope of the ‘main bearing liting tool clear of the guide shoe. Tighten tackle B and release tackle Cat the same time, Note! Make sure thatthe wire rope ofthe main Dearing iting tool does not scrape against the edges ofthe guide shoe. 18, When the main bearing cap is hanging ver ‘cally Below tackle B, remove tackles A and © When rearing MAN BW Dito! AS Page. Pease quote Procedure GO5-2.2 Ealion 222 Pago 7 (20)905-22 Main Bearing Dismanting Baw) 18, Mount a wire rope with two shackles on the litng too. 20, Lift the bearing cap out of the engine and land iten the gallery 21, Mount the bearing shell iting too! on the Upper main bearing shell and remove the shall rom the engine, Pesee (20) When rearing toils page, pvase auto Procedure 505 2.2 Eaton 228 se 0(20) toni page. WAN Baw Dea ASMain Bearing aw Dismanting 905-22 22. 1 the crankshaft is turned withthe bearing | 22. cap dismounted, use the two stops to pre vent the lowor shal from being rolled out | not already done, check that there Is Clearance between the journal and the main bearing shel inthe two adjacent main bear ings. 28, Remove the secews from the erosspiace (only screwed in for safe Keeping) and Screw them into the threaded holes of the hydraulic jacks for tightening the holding down bots. When refring to tis page, please quote Procedure 805-22 Elion 22 MAN BAW Dice NS Page 8120)Main Bearing Dismanting fase | 24 lace te cospioe inthe bodpat wih fre ends ering onthe cose ger, and piace the nr tee beneath te ean ‘teas eer Tighten the serews againet the crank webs. Connect the hydraulic jacks to the high- pressure pump and raise the pressure unt the erankshatt has been lited carrespond- Ing tothe clearance in tne adjacent boating. Page 10 5) Note down the pressure for lator reference. 25, Check that the clearance between journal and bearing shel, and between bearing shell and main bearing suppor isthe same on both sides, tobe sure that the crankshatt has been ited straint vertical. not, ad- Just the position of the jack unt the crank: shafts lied correctly IY re-positoning of the jacks does not sut- fice for ensuring a vertical tt, place a 5. tonne jack between the sidewall and the Crankthow, and correct the fit inthis way ‘To avoid air suction, be sure the pump oy!- indor is facing downwards. When refering otis pag, please quct Procedures 605-22 Eon 222 ° ° WAN Ber Oise ASey Main Bearing Dismanting 26. Dismourt the locking eorews. 26. Place the dlsmanting tool on top of the tow ter boaring shel. Make sure thatthe flap on the dismanting tool enters the ol grove in ‘the bearing shell. Pull the lower bearing shell round and up Lunt it es over the main bearing journal, 27. Take out the lower shel the same way as the upper shel. Note! ‘Never remove the tools for iting the crankshaft before tho lower main bearing shell has boon remounted. 18 t proves necessary, replaca the bearing shells with new ones, ‘Regarding checking of joumel and bearing shell, soe Volume | OPERATION, Chapter 708 “Bearings”. ‘iter etaring this page, ploase quote Procodure 00522 Eaton 222 MAN BAW Disal AS Page 11)Main Bearing (oa Dismantling Baw Dismantling of journal bearing in the thrust shaft end ‘This section ony apples tothe bearing instlleg aft ofthe thrust beating. The bearing atte fore end of te thst bear ing is to be dismantied in the same way a8 the other main bearings. 2, Remove the screws from the cover placed over the thrust bearing. Mount an eye bol, shackles and wire rope on the cover. Hook fon a tackle and lit the cover away 30. Disconnect the lubricating oll pipe used for Iricating the Journal bearing ‘WAN BAW Does! AS| Main Bearing 905.22 Dismanting S31. Assemble the main beating tightening tool ‘and mount the lfing tool on te main bear- ing tightening tool, @5 shown. 2. Using a tackle, land the main beating tight. {ening tools onthe journal bearing studs. Screw the extension studs of the main Dearing tightening toot onto the main beat~ Ing studs. Connect the hydraulic jacks to the high- pressure pump by means of the distibutor block and high-pressure hoses. Note! For compressing the hydrautc jacks of the main bearing tightening tool, a spe- cial large tommy bar i avalabe fr tut: Ing the nuts above the Fydraullc jacks. | Bleed the hydraulic system and raise the pressure as Indicated in Dat. Loosen the nuts, using @ lommy bar Remove the hydraullo main bearing tools from the engine. 8. Unscrew and remove the ruts from the bearing studs. For operation ofthe hydrau: lic tools, see Procedure 913-1 24. Mount the titing too! on the bearing cap. Hook a tackle or the engine room erane on to the wire rope of the liting toot When reerring to this page, ploave quote Procedure 90522 Edlon 222 Page 19 (20) MAN BBW Ouse! AS905-22 Main Bearing Dismanting 35. Using the iting tool, remove the bearing cap from the engine. Note! hat the bearing cap does not_| threads ofthe bearing studs. damage 36. Mount the bearing shell iting tool on the Upper bearing shel, and remove the upper beating shel trom tho engine. 87. Place the crosspiece under the turning wheel as shown. Mount a dial gauge to ‘measure the it ofthe crankshaft. Connect the hydraulle jack to the high-pressure = pump, and raise me pressure unt the Crankshaft has been lifted max. 0.2 mm, Page 14020) When ralaring to tis page, pease auole Procedure 9052.2 Eéilon 222 THAN BW Diesel AS(oa Main Bearing 905.22 Be Dismanting 38. Dismount the lock screws from the lower Dearing shel. Pace the dlemanting toot on top ofthe low ‘er bearing shel, making sure thatthe flap ofthe dismanting too! enters the ol groove in tne bearing shel, Pull the lower bearing shell round and up- wards until it lies over the main bearing Journal. 989, Take out the lowor shol from the crankcase in the same way as the upper shel Note! Nover remove the tools for iting the Crankshaft before the lower main bearing shell has boon remou It ft proves necessary, replace the bearing shells with new ones. @. 1 Regarding checking of journal and bearing shell, 8¢2 volume 1 OPERATION, Chapter 708 "Bearings", | ‘When referring to thie page, please quote Procedure 906-22 Eilon 222 Page 15 (20) 1 MAN BaW Diet AS905-23 Main Bearing (oa Overhaul Baw 1. Glean and inspect the bearing shells. For Judging the condition of the bearing, see Volume |, Chapter 708, ‘Bearings’ It the bearing sels are damaged, contact MAN B&W Diesel for advice, It replacoment of a beating shell is neces- ‘sary, both shells must be replaced, as the ‘wo shell are matched parts. 2. Belore remountng: + Check the bearing support for damage land burs. If damage is found, contact MAN B&W Diesel for advice, ‘+ Maks sure that all parts are clean, use ‘on-futly cloth to clean vetween journal {and main bearing suppor. + Lubricate the bearing journal, the main Dearing support and the back of the shell age 16 20) “Whoa refering to tis page, please quale Procedure 005-23 Fit 222 WAN B&W Diogel ASMain Bearing 905-24 man Mounting 1. Using the bearing shel! iting to, the pul Joye and tackles, it the lower bearing shell info the crank easing and land it on the crankshaft journal Place the guide tool for the lower beating shell on the main bearing support. Remove the ling too rom the bearing shell. Lubricate the journal, the lower bearing sholl and the bearing suppor wlth clean ot Place the lower bearing shell onthe journal and push it down by hand. To ensure thatthe shel is correctly mount- | 4, check that the distance from the main bearing support tothe shel is equal in both sides. Remove the guide too! when. the lower Dearing shell has been mounted. Mount the locking serens in the bearing support Lower the crankshaft and remove the fy- ‘raulc jacks and the crosspiece from below the crankshat Wipe the contact suraces between te up i Det andthe loner bearing sels clean with [2 nom piace of cot ‘When referring to this page, please quote Procedure 905-24 Edion 222 ~~ Page 17 (20) WN BAW Deel NS905-2.4 Main Bearing Mounting "] 4, Land tne upper bearing shel on the main ural nthe sro Ways te Tower bear ing shel ‘Make sure that none ofthe edges of tho up- | per beating shel are resting onthe edge of the bearing support necessary, place the special tool between the studs and press the shel into place. Clean tho contact surfaces betwoen the bearing support and the bearing cap. Make sure that no ollis lft on the comtactsurtac- 5, Mount the iting too! on the bearing cap. Using the lifting too! and the tackles, ht the beating cap into the crank casing in reverse ‘order to dsmanting. Soe Procedure 905-22, stops 20-19, 66. Using the pulleys mounted inside the crank casing, move the bearing cap into positon vertical above the cranksnatt bearing Journal in the reverse order to dismanting See Procedure 905-2.2, steps 18-13. age 18 0) Wine retaring to hi page ploaze quota Procedure G06 2.4 Ealion 222 WAN BAW Bloat ASMain Bearing Mounting 7. Land the bearing cap caretuly on the upper Dearing shel, using the beating cap Iting tool. “Take care not to displace the upper bearing shell Remove the titing tool from the bearing cap. Screw the nuts on to the main bearing tude Using a tommy bar, tighten in small alter- rate steps the nuts on both sides of the bearing cap. 8. Using the tting toot and the pulleys, it the ‘main bearing tightening tool into the crank Casing and into postion vertically above the ‘main bearing studs, in the same way as d= sorbed for eismanting. ‘See Procedure 905:2.2, steps 4-9, Caretuty release tackle Ato land the main bearing tightening tools on the main bear: Ing studs. Wien rtering to tia page,please quole Procedure 9062.4 Edin 222 MANBAW Oso! NS Page 19 (20)905-24 Main Bearing Mounting 8. Screw the extension studs of the main bearing tghtening tool on to the main bear- Ing studs. Make sure thatthe extension studs ara fully Serewed on to the main bearing studs by checking thatthe top of the measuring rods Inside the extension studs are fush withthe top of the extension studs Connect the hydraulic Jacks to the high pressure pump by meane of te distrbutor lock and high-pressure hoses. ‘Note! For compressing the hydraulic jacks of the main bearing tightening tool, a spe- ‘lal arge tommy bars avalabe for tur ing the nuts above the hysraullo jacks, Bleed the hydraulic system and raise the pressure as indicated in Data Using the hydraulic jacks, fuly tighten the ruts on both sides of the bearing cap. For tightening pressure, see Data. | ‘Romove all tools from the engine, For operation of the hydraulic tools, see Procedure 919-1 40, Mount the lubricating cil pipe on the main bearing cap. | Repezoeay Wen rearing otis page, please guote Procedure 5 2.4 Eailon 222 WAN B&W Desc] ASSAFETY PRECAUTIONS. [x] Stepped engine XC] ck he vain mechan [oc] sh rig a uty 1] engage ng pear shat cola wat shat ot etl FE] Sat caving ot Lock twoecharger tre Data D1 Stopper fore D2 Stopper—aft 1-3. Thust bearing segment +4 Hycraute pressure ~dsmanting DS Hycrauc pressure =Nghtening Ds Cover ‘When roaring otis page,please quote Data Shoot 1059 Edin Fa aS MAN BAW: ‘Thrust Bearing Data 63kg 59k9 40 kg 100-1650 ber 1600 bar 1000 kg Standard Tools: See Section 913 ZA ft 24m 19m @ Q mao B® vor Paget @) 1053Spare Parts ‘Thrust BearingThrust Bearing 905.31 Checking “The olearance inthe thrust bearing was meas- tuted during the testbed trials ofthe engine and noted down in the ‘Adjustment Sheet which is inserted atthe front of Volume I, OPERATION. For a new engine the clearance is 1.0-1.5 mm, and for an engine in service it must not exceed 2.0 mm. For dismanting the segment stopper, see Pro- ‘oduro 9053.2 41. There is a wear groove of 1 mm in the up- ppermost thrust segment. (The segment with thermometers), Insert the feeler gauge in this groove on the foremost side of the theust cola It a fealer gauge of 0.1 mm ie not able to enter the wear groove, the thrust bearing must be overhauled ‘hen refering this page,please quote Procodure 905-31 Edion 212 ~*~ OT Ma Bea905-3.2 Page 2) Thrust Bearing Dismantling Baw Remove the cover above the thrust bearing Remove the lub. oil pipe from the aftmost main boating shell Remove the lub. ol pipe above the thrust segments, Loosen and remove the nuts from the seg- ment stoppers. For operation of the hydraulic jacks, see Procedure 913-1, Scrow an eye bolt into the stoppers that are ta be removed Suspend a tackle above each stopper and hook the tackle on tothe eye bot Remove the stoppers trom the chain dive above the thrust segments. (aneAD or ASTEAN) that are fo be taken out ring to this page, please quote Procedure 005-3.2 Edition 212 (WAN B8W Dest NSThrust Bearing 905-3.2 Dismanting Wd @ tackle above the segments ro to be removed. For turring-up the thrust segments, mount the segment foo! on the chalmhesi 5. Turn up the segments, one at a time, by ane It before turning up the next ‘Segment. See Procedure 905-24 Note! Never rem v8 more than o atime. ‘When rfering tc his page, please quote Procedare 60532 Eatin 212 Page 3 ©) Wh MAN BAW Ole AS905-34 Pasea) Thrust Bearing Mounting 1. Suspend a tack’e above the segments hich are to be mounted Mount the segment tool on the chalnwheet Land the segment on the journal and re- ‘move the eye bolt from the segment. Carefully slide the segment on to the set mont tool. Turn the engine to enable ois- mantting of the next segment ‘See Procedure 905-32 2. After the fast segment has boen mount: tur the segment tool up and ismount guste Procedure 8053-4 allan B12 WAN B&W Basel 1S‘Thrust Bearing at Mounting Mount the segment stoppers and the nuts Mount the hydraull jacks ang tighten the tuts on the stoppers. See Data, Mount the lub. oil pipe forthe thrust seg- ments. Mount the iu ol pipe forthe atmost main ng. '5, Mount the cover above the thrust bearing | When referring to hs page, plesse quale Procedire SO534 Ean PVE rage 5) | MAN BaW Diesel A'SData ‘Axial Vibration Damper SAFETY PRECAUTIONS [3] Stopped engine | Block the staring mechanism X | Shut of starting ar supply | Engage turing gear ‘Shutof cooing water ‘Shuto fuel ot % | Shuto sricating of Lock turbocharger rotors Data Pet Osten vn wt DA Damporhousng, upper part 2280 kg 0.2 Tightening torque ~ studs 160m D3 Tightening prossure— ruts 1800 bar D4 Tightening torque — hotizontal screws 2690 Nm DS. Tightening angle potaontl sorews a8 D6 Cleerarce atointe emm [Gite for al vibration iat pale, mpape Simm) 19/22] 25] 28| 31] saf a7 ‘s2nm] 99/115) 13:1] 147] 10} 100) 196) Ccaltoration of spring Spring forthe mide seating Hing to ON-Chocklongih 2502 mm () S44/-5N—Checklength 8600 mm 1 984/5N—Check enh 4500 mm ‘Spring forte outer sealing ing lo ON-Checklenghh 2140 mm U) 9848N—Checclength 2720 mm 12 T3x48N—check engin 3400. mm When refering to this page, please quote Data Shest 1055 Ealtion 12 MAN BAW Disal AS Standard Tools: Soe Sacton 913 Paget105-5 Axial Vibration Damper Dain aN I i Spare Parts. Pte, estan oy o12itscer O19 Spring mid ol eval 1 9121130020 Spring — side al als 2 12130098 Locking ke 1 91211300296 Locking plate 6 o12t1on0 152 Oil seal~ mide ol sont 1 | 912ttse 164 Ol seaside ol seals 2 4 Page? When refering to tis page,please quale Data Shoo! 105-6 Eden 12 MAN BRW Diesel NSElectronic 1. For checking the effectiveness of the axial Vibration damper in service, @ proximeter probe with bracket is mounted on the lower part of the end shield a engines. age 2 The proximeter probe Is not standard for For engines without a proximeter probe, ‘s00 instead Mechanical ehecking on Axial Vibration Damper Checking ‘The cable from the probe Is connected to ‘monitoring box which is mounted on the &x- haust side of the framebox and towards the forward end of the engine. 2, The peak-to-peak value displayed in mm on the monitoring box should be compared withthe original valves obtained during tho 0a trial, and with the fits given below. It the peak-to-peak value does not exceed the permissible valuas, St, given in Data, i Is not necessary to overhaul the damper. When referring to this page, please quote Procedure 9065.1 Edition 213 MAN Baw Ose! AS Paget @9055.1 Paez @) Axial Vibration Damper ay Checking Et Mechanical 3. When checking the effectiveness ofthe lal vibration damper in service (which is ecommended every 8000 hours), @ special ‘measuring tool has to be mounted in the shield on te forward end of the engine, in frder to measure the axial movement ofthe crankshaft fore end, ‘The actual measurement ebiained should be compared with the original values ob- tained during the sea tal, and wit the im. its given on the next page. 4. Tha following procedure should be tol: lowed: ‘Stop the engine Unscrew the two plugs frm the cover at the front end of tha engine. 5, Screw the shat piece into the fore end of the crankshaft, through the large hole inthe ‘Screw the measuring arm into the small hole so that th arm is perpendicular to the shaft piece, ‘Attach a pencil to the arm. “To oblain the correct measurement, the tip ofthe pencil should protrude 10 mm | [rom ne ena ore arm. hen veering to hs page, please quote Procodire 005-51 Eon 273 THAW BRW Olesal A/S‘Axial Vibration Damper 905.5.1 Checking 6. The measurement should be taken at the same r/min as used during the sea trials (preferably 80% and 100% of MCF), Start the engine and press the measuring farm against the shaft piece with one hand, With the other hand, move a sheetvblock af paper, clipped on to a solid backing plete, Highly downwards against the tip of the pene To ensure a certain inertia, the backing plate should have a mass of approx. -2 kg ‘The axial movement recorded on the paper biock must be measured with a side gauge as shown in the sketch, Hr the peak-to-peak distance a in mm does not exceed tha values, 52, given in Data, i is not necessary to overhaul the damper 7. Note thatthe S2-imits are only valid for a standard measuring tool with L1= 38 mm and L2 = 200 mm, Hf a non-standard measuring toot 's use, i the S2-mits must be adjusted as follows: B 22 xs ui *k For St-lmits, see Data ‘When referring to this page, please quote Procedure 805-6.1 Edtion 213 Pages (@)‘Axial Vibration Damper en Dismanting 1. Overhaul of the axial vibration damper ‘takes place from the trent end of the en- sie. Disconnect and remove the two of pipes ‘rom the axial vibration damper ard the oi i for the foremost main beating Dismount the small cover onthe end shiold and the upper part ofthe end shield Iv the crankshatt is fted with a counter- ‘weight, turn the crankshaft until he coun- {erweight is at its lowest possible position, 2, Loosen and remove the horizontal screws from the damper housing upper part. Loosen and remove the hydraulic nuts by Pages @) Using the hycraulc jacks forthe axial vibra- tion damper. ‘Wien refring to Wis page,please quote Procedure 505-52 Fain 213 "MAN GW Dies AS(ead Axial Vibration Damper 905-5.2 fees\_ Dismanting ‘Suspend a tackle ouside the engine ‘Mount the litng tool in the top of the damp- fr housing upper part. By means ofthe tackle, separate and raise the upper part of the damper housing to. Position In which itis possible to change the fl soals and springs. Secure the upper part by Inserting ‘wo Ssorews in the damper housing Only the upper part ofthe housing needs to be iifted, while the lower hall remains ‘mounted on the bedpate ‘When reforing to hs page, please quot Procedure BOS=2Eaiion aia ~*~ RE) MAN B8W Dist NS9055.3 Axial Vibration Damper rau Ged 1. Dismantie and remove the springs ftom the teflon rings. Flomove and discard the teion rings. |When mounting new teflon ings, ist Insect the lower half af the rings in the lower part ‘of the housing, ‘Then pross the tension springs into the ‘groove between the teflon ring half an the housing Note! ‘The lower hal ofthe tetlon rings wil, protrude above the centreline D-6 | 2 Mount att tne upper nalves of the tetton ‘ings in such a way that there is clearance atthe joints ofboth the small and the large rings. Sea Di [Now hook the tension springs into place, ensuring that they are centralised in the ‘grooves ofthe tation rings. Pages) Won raring otis page,please quota Procedure 80553 Falion 279 MAN BW Died AS(ea) Axial Vibration Damper fase Mounting 1. Unscremhelease the upper part of the {éamper housing. Use the two guide pins in the lower part To ensure the correct posi- Vioning ofthe upper pat. ‘Mount the horizontal screws Tighten the screws. See Data Mount and tighten the nuts on the studs. ‘$20 Dat For operation of hydraulic tools, see Proce- duro 918-4. ‘hop refering to tis page, place quote Procedure BOSE ation 213 MAN BAW Dito! NS Page)Page @ Axial Vibration Damper 8. Mount the upper part ofthe end shield and the small cover on the end shel. Mount the ol pipes for the axial vibration damper and tie oll pipe for the foremost ‘main bearing, uote Procedure 90554 Fallon 273, When refering to is page,Crankshaft, Thrust Shaft, Main Bearing, Plate 90551-191 Etc. Panel Lo 135 027 ‘st When refering to tis page, please quote Plat S055 Editon TOT MAN BAW Diesa A'SPlate 90551-191 Crankshaft, Thrust Shaft, Main Bearing, Ete. Panel ra Part Description a Part Description 015 |) Toot pane! 027 |Name plate 040. |Puley for wie 052. [Pull for wire 064 [Pulley for wire | 976 | iting tol for main bearing cap 088, |Dismanting to! for main bearing shell 080. | Mounting too fr thin bearing shel 100 | Tool for segments 114 |Lifing attachment 123, | Retaining tool for main bearing shel 185 |Liting tot 147 |Eyebot 100 Wee 172. | Mounting to! fr thin bearing shell 196 | Tightening gauge | 018. |+) Too! pane, complete 196 | wit fools +) Optional extrasPlate 90561-69 Main Bearing - Tools asa quote Plate S056 Eaton 6@Plate 60561-69 Main Bearing - Tools tem No. Part Description Par Description oat 04s 057 069 070 094 08 116 153 168 190 200 212 iting beam iting attachment Nut Hydraulic jack, upper Hydraulic jack, lower Extension stud with check pin Supporting block Littng toot O-ring with back-up cng, 170/180 mm ing with back-up rng, 18040 mm Stud settor, M98 x 6 Special nut M 95 x6 Hydraulic to! for main bearing, completelead Crankshaft - Tools Plate 90562-1Plate 00552-105 Crankshatt - Tools — Tem hem aa Part Description A Part Description 015 | iting oo! for trust shalt 027 | Liting too for main bearing shell (040 | Foelor gauge set, complete Jo.s5- 1.05 mm 052 | Feeier gauge set, complote 0.60-1.10mm (064 | Liting 00 for erankshattCrankshaft - Tools Plate 90564-13 : éPlate 90564-13 Crankshatt- Tools my No. o16 28 oat 053 Part Daecrpton tom No, Part Description Measuring too for axial movement, complete Shaft piece Measuring arm Handle for mounting of shatChain Data ‘SAFETY PRECAUTIONS ‘Stopped engine ‘Shutoff tating ar supoly Engage turning gear | ‘Shut off coling water Shutoff fut ot x [><] Bock the starting mechanism x x % | Shutoff brcating of Lock turbocharger rotors Data rt beeen vine ut D1 Max. wearofteat 08 45" chain wheel 40mm D2 Original engin, 45° chain (hain pitch x fo nis) 10708 em Bs Max. length, 45° chain (chain pitch 10 fink). 1081.3 mm 0-7 Max, wear of eet on t*chain whee! 0.9mm 0-8 Original length, 1 chain (han pitch x 0 nis) 238.1 mm 0-9 Max. length, 1" chain (chain pen x 10 rks) 2405 mm When referring to this page, please quote Data Sheet 106-1 Edition 15 MANAW Duet AS Page)‘Spare Parts Page 2 @) Chain Data ‘When refering to Bis page, ploase quote Data Shoot 106.1 Eaton 15 MAN BBW Bose NSey Chains faasd Checking 906-141 1. The engine is equipped with two sets of chains: + the drive chains for the camshaft + the arive chain tor tne eylindertubricators Both gots of chains are to be checked and, W necessary, dismantled and mounted in the same way. Notet “There are two este of dismantling and ‘maunting tools available, one for each ‘so of chains, 2. The diive chains for the camshaft can be accessed trom within the chalnwhoel frame. 8. The drive chain forthe foremost eyin bricatore can be accessed by removi ‘over in font ofthe fuel eam of eyinder No, 4 ‘The drive chain for the altmost cylinder t- bricators can be accessed by remaving the cover infront of the exhaust cam of the af ‘most cylinder Note! in drives forthe oyinder lubrica tore are not equipped with guideways or chain tghteners, When refering to is page, plosse quote Provedure 806-1.1 Eaton 276 MBN B&W Dial A'S Paget 8906-161 Chains Sears Ga\ Carty out the inspection as follows 4. Make a. general inspection or loose bots and screws. Inspect lube oil pipes for damage, and check jet nozzles for possible stoppages or ‘elormations Examine the rubber track ofthe guideways ‘or cracks oF other damage. ‘Replace the guideway i bits have started to be “plucked out” of the rubber track 5. Check the teeth of the chain wheels. If ab- ‘normal wear is found, take a measurement (00 Data) Measurements are best taken by placing @ short strlght-edge over points A and B and thon moaouring the distance D-t 6. abnormal wear I observed atthe bottom ‘ofthe teeth, make a érawing in scale 1:1 of the teeth and wear profil. Measure the geometty of the bottom and ‘ote down all available measurements in- Cluding D-A ané D-B on the drawing. D-B is ‘best found by placing a short straight-edge between the tip ofthe two teeth. For assessing the measurement resulls, contact MAN BSW Diesel In most cases, soratches caused by the ‘side plates ofthe chain will be found on the ‘sides ofthe teeth. Such scratches can gen- ‘erally be considered normal Pane 215) ‘Wen refering to this page,please quoleProvedire 7 Edlon 274 TaaN B&W Disa AS7. The chains for the camshaft ive are | & matched together to ensure an even load ditibution ‘To keep such matching chains in thet pas, the side plies ofthe autor ink nearest) |g yg ‘the assembled link have been marked with D-2 T yor month day and can mumber || D8 | Example D-3——— No. order, | a basse a } ot = baose0 10 le _u (6105801, possible Sd chan) ae No.2 order, e 840520 2A. 840520 28, (40520 20, possible rd chain) (On the same links there is an arcow (>) which inieatos the mounting erection Check the chain for eracks on possibly de- feotive rollers and side plates. (Check thatthe chain rollers can run freely i and that the chain links can fly move on | the pin and bushing (that they are. not “seized” between the pin and the bushing) It is normal, however, that the rollers get light, circumferential seralches during the runningsin period. These fine scratches are ff no Importance and need not be consid- red Its recommended that each single link Is checked. 8. Check chain wear by measuring the length of 10 chain links and comparing the resut With the value given in Data, . W necessary, adjust the chain tightener. Soe Procedure 906-2 3 | When refering to is page, plaase quote Procedire 06-14 Eatonate ——~—~S~*~*~« OY | MANBaW Deal A'S906-1.2 Chains Dismantling Bay It may become necessary to disassemble the chain if, for instance, cracked rollers or seizures between pin and bushing have ‘been discovered curing the inspection. ‘See Procedure 906-17. ‘Note! Everytime @ chain ink is disassembled, new link must always be fited as the link pin press-fit ie desttoyed when breaking the chain ‘When @ new links fted in one chain the corresponding lnk in the other chain ‘must also be renewed 4. Remove the tension on the chaln by loos- ‘ening the chain tigntenor. (See Procedure 906-2.) ‘Turn the engine until the slack part of the chain, with the chain link that isto be dis- assembled, is In a favourable postion for the work 2. Mount a wire raund the lnk rollers a short distance ftom the disassembly polnt, and tighten the wice lightly witha tack ‘Protect the link rallrs over which the wire is wrapped, Note! the chain is to be completly removed, ‘contact MAN B&W Diesel for further information. The ‘riveting of the pins that ate to be pressed out is to be chiseled or ground away. ‘3, Place the chatn bursting tool over the outer cal link, and dismentle the link by alter- nately tightening the screws on the too. = ‘Wien refering to this pag, please quote Procedure 906-12 Edin 214 "WAN Baw Dace AS(eas) Chains 906-1.4, fan) Heurting Bolore assembling the inner and outer links, clean the pins and bushings. 4. Combine the inner chainlink with the outer ‘chain ink and maunt the compression tool Force the loose side plate of tho outer tink Into place by alternately tightening the screws on the compression 1901 i 2. When the link has been assembled, remove the compression tool and lock the pin ends by riveting ‘Repeat this procedure until the chain has been assembled Flomove the tackle and wire and adjust the i chain tension | (See Data and Procedure 905:2.3). When refering to tis page, please quote Procedure B08..4 Ealon 21 PHe5 6) MAN B8W Disa ASData (oad Chain Tightener 106-2 SAFETY PRECAUTIONS Standard Tools: See Secton 913 99H eons Bock he stating rachanm AZ, shat ots sry Engage tuning gear e=eE Shut of cooing wat ‘Shut off ust ot —rt ‘Shut of tubeating ot Lock turoecharger rotors TEER] E Data al bean ve nt D4 Clearance 100mm D2 Clearance 04 mm D3 Tghtering angle or nut © m0 Wen rolering otis page,please Guote Data Shoot 105-2 Eaton 1@ Page 1 @ MAN BAW Deal NSSpare Parts Poe? omton Chain Tightener Data Ban ‘When refering fo this page,please quote Data Shoot 106-2 Eaton 14 i MAN BAW Deol AS(oe) Chain Tightener Baw Adjustment ‘Agjusiment ofthe chain tightener damper isto lake place when the indicator arrow has ‘reached the bottom ofthe scale 1. To adjust the damper, loosen nuts A, B, © and D. ‘Screw down nuts ¢ and D, to enable ad- Justment of the camper piston, 2. Turn the engine so thatthe slack part ofthe chains ison the sam side as the tightening wheel. It the chain drive is equipped with ty- ‘weights continue the turning’ unt the fy- welgnts, ae hanging vertically downwards, ‘When refering to his pap0, please quote Procedire 606-2. Eaiion 213 MAN BEW Dezel AS Pago 76)3. With the fyweights inthis position, tighten rut B on the chain tightener bolt unl there Is @ clearance between the shaft and the tut as stated in Det 4. Tighton nut © against tho contact face of the piston rod, see Data, Check that tere is contact between the piston rod and nut B, he page please que Procedure 0623 Eton 273 peaee Wan Bawoesci ns ‘Page 216) When reiering|Chain Tightener 906-2.3 () ‘Adjustment 5. Tighten nub. Lock nuts © and D with the tab washer Tighton nut A Lock nuts A and B withthe tab washer. 6. Finally, adjust the Indicator to the ‘zero! Point on the scale. ‘When refering o this page,please quote Procedure 608-23 Edian B13 Page 3) MAN BAW Diowet NS906-2.3 Rego 46) Chain Tightener Adjustment ‘The damper can be blocked as follows: 7. Loosen nuts A, B, C and D to free the chain ‘ightoner bot ‘Screw down nuts © and D, to make it pos- sible to mount the special eistance piece, “Turn the engine so that the slack part of the chains is on he same sige as the tightening whee 1 the chain drive Is equipped with ty- Weights continue the tuening unt! the t= weights, are hanging vertically downwards When refring ote page, please quote Procedure 606 2.9 Elton B13 re teimepsge. MAN BAW Diset Arut as stated in Data, D2. 10. Mount the special distance piece around ‘the pipe onthe chain ightener between the damper and rut ©. her refering fo this page, ploase quote Procedure OOS23 Eaten B19 NAN BAW Dito! NS Chain Tightener ‘Adjustment — Page 5)Chain Tightener ‘Adjustment 11, Tighten nut © against the contact face of the distance piece, see Data Tighten nut D. Lock the nuts withthe tab washer. 12, Tighten nut A. Lock nuts A and B withthe tab washer. When reoring io this paga, please quote Procedure 0052.3 Eaton 278 THAN BAW Diesst NS‘SAFETY PRECAUTIONS X] Stopped engine Block the stating mechanism Shutoff starting air supply Engage tuning goar ‘Shut of coating water ‘Shut of fui cit ‘Shutoff reating ot Lock turbocharger rots =ELEPE Data Fa Deon 0-1 _Pingauge fortop dead cont of eraniow No.1 (Check measurement D2 Pin gauge for camehatt (Check measurement D'S Max permissible change in toad angle corresponding to Camshaft Data Standard Tools: See Section 913 oe 1192mm 607 mm ea 68mm ‘Won referring fo his page, plosce quote Data Shoot 1068 Eaion 1@ MAN BAW Dees! AS 106-3 Pager)1063 Spare Parts Pate. mon Pape? Camshaft Data When lei hs page,please qnte ata Shoe 106-9 Eaton 14 steno HSN Saw Dios NS' (oa Camshaft 9063.1 aw Checking 4. Turn the erankthvow for oylinder + to TOC, Turn in the aveAo direction to ensure that tne tension ofthe chain on the chain ive 's correct. If necessary, adjust the chain tension. See Procedure 906-2.3, Check the TOC of cylinder + against the ‘mark on the turning whee! 2 Check the TOC poston withthe pin gauge fon the cxankthrow, Dt i When veering otis page, ease quote Procedure 906.31 Eaton 209 Page 8) 5 2 i 3906-3.1 ‘Camshaft Checking maw 3, Position the camshaft pin gauge in the cen- ‘re punch mark, and measure the deviation, ifany, in lead angle, For max. permissible change, see 0-3. 4. Check and, tnecessary, aust the eyinder wbricator, See Procedure 909-2.1 and 909:2.3. Check the setting ofthe stating air distrib D-2 tutor, ‘S00 Procedure 907-1.1. 5. When checking the camshaft postion, also D-3 ‘check the running surface of the cams. [As the ingpection must include the entire surface of the cam, the cam should be turned one complete revolution during the Inspecton, ‘The running surface of the cam must bo completely smooth and bright. 6. If tght scratches are ascertained, remove E_J them by carefuly polishing the cam in the ection of rotaion with a fine carborun {dum stone. Such light scratches can ap- pear ifthe roller guide and the cam are not correctly aligned, {In the event of heavier scratches or direct oe flaking ofthe material on the running path, MAN B&W Diesel should be contacted for U further instructions. ‘When refering to is page, plesse quote Procedure 906-31 Eaion 209 ‘WAN B&W Deal ASCamshaft raw ‘Adjustment 1. If the chains prove to be so heavily worn that the deviation between the measuring polnts and the pin gauge has reached the ‘maximum valve stated in Data, MAN B&W Diesel should be contacted for further in structions ‘ihen refering to is page,please quote Procedure 065.8. Een 209 MAN BW O10 AS Pages®)SAFETY PRECAUTIONS. stopped engie Bock the staring mechanism Shit of tng a supoy Engage ting ger hit of coon water Shut let [RE] sito iating ot [] coat acre ts Data DA Weight orboarng cap D2 Tightening torque ~ serous lor beating exp 2-8 Clearance between cap! Dearing Ravsing D4 Max. wear of baring she! When referring to this page,please quote Data Sheet 106-4 Eaton O7 MAN'BAW Diesel AS Camshaft Bearings Data Standard Tools: See Section 913 —_ @ — 3s wo wom __ 106-4 As fr Page @)105-4 Spare Parts 9001-00 588 8061320072 Bearing shel Page 2) Camshaft Bearings Data 4 1 Wihon refering tie page, pos "quot Data Sheet 106-4 Eaton OF MAN Baw Dios! ASCamshaft Bearing 906-41 maw Checking + oh | 41. Dismount the inspection covers from the front ofthe camshaft housing CCheck for wiped-out metal at the bearing fends, and for ftagmonts of metal in the camshatt housing In the event of any signs of anomalies, the bearing shell must be gismantied fr loser Investigation and, it necessary, the bearing shall must be replaced. ino anomalies are found during the visual inspection, dismanting need only bo car- fled out in connection with Class surveys. NAN BBW Disst AS Page ®906-4.2 Pago 26) Wen veering o thie peae, ae Camshaft Bearing Dismanting Caution! Before dsmanting any camshaft bear- Ings, the main chain must be relieved of tension by loosening the chain tightener to avold damaging engine parts. ‘See Procedure 906-2. Remove the inspection covers from the ‘camshaft housing. Remove and discard the gaskets. Dismount the plug screws from the base piate above the bearing la question. Lt the roller guide of the exhaust valve ty- ‘raul pump. See Procedure 908-7. Dismount the lubricating ol! connecting bine. Using a socket spanner mauntod on an ex- tension, loosen the bearing oap screws ‘through the outer holes in te baseplate, Through the mide hole in the baseplate, ‘serew the liting tool into the bearing cap. Hook a tackle on tothe ling tool and ltt ‘the bearing cap clear of the camshaft. 2 quale Pracedire G06-4.2 Eaton 207 ‘MAN B&W Deal NSCamshaft Bearing Caan Dismanting 4. Place the hydraulic jack in the camshatt housing in front of the fuel cam, ace a dial gauge on the camshaft, and lit the camshaft 0:30 mm, Press lightly on the upper edge ofthe shell totuin the shell up over the camshatt Femove the shell rom the camshaft hous- ing, Wien rearing to this page,please quote Procedure 606-42 Eaton B07 MAN BAW Dies NS906-4.3 Camshatt Bearing Overhaul Baw) 1. For assessment of the bearing condition, see Volume | OPERATION, Chapter 708 ‘Bearings Inspect the entiro surtace of the bearing Journal for setzures. W seizures are found on the bearing journal surface (on account of bearing breakdown), Polish the surtace witha fine careerundum stone to re-establisn a bright and smooth surface. By closely examining the sliding surtace of the bearing shell visualy, an Impression tan be formed of whether ine lubrication of ‘the bearing surtace has been insufficient or entirely missing. Normally, camshatt beat- ing damage only occurs due to faulty lubl- cation, Measure the thickness of the bearing shel! with a micrometer to check the amount of Page) © Whe alia oi pie laze gate Paced E43 Eo 7Camshaft Bearing 1. Glean the bearing journal, the bearing sup- Port and the bearing shell. 2. Coat the bearing shell with ol, mount the shell on the camshaft, and turn tito place, Using a caliper at both sides ofthe bearing shell, check that the bearing Is positioned absolutely horizontally 3. Lower the camshaft and remove the alal ‘gauge and the hydraule jack trom the en: sine 4. Lower the bearing cap on to the camshatt. Remove the iting tool trom the bearing cap. Lihen refering fo his page,please quote Procedure G06-44 Editon 207 MAN BAW Dies! NS Mounting 2 906-44{900-44 Camshaft Bearing i outing (Gas 5. Mount the bearing cap sorews, Tighten both screws lightly. Using a socket spanner mounted on an ex tension and a torque wrench, Ughten the serews tothe torque stated in Data. Note! ‘To ensure thatthe bearing cap is not alispiaced, the tightening must be done in stops as foiows: 1. Tighten the outermost screw to half the torque stated in Dat. 2 Tighten the innermost serow to half the torque stated in Data, 3. Tighten the outermost screw to the full torque stated in Data. 44 Tighton the innermost serew to the full torque stated in Data Ll _ 6. Check the clearance betwaen the bearing cap and the bearing housing, ‘Mount the lubricating il pipe on the bearing cap. Mount the plug screws in the baseplate 7. Clean the camshaft housing and mount the inspection covers, fitted with new gaskets 6 quote Procedure 0-4-4 Eaion 207 | Passe “When vetoing to tie page, pe ‘MAN BAW Diesel NSChain Drive and Camshaft Panel Plate 90651-162 ‘Whor rtaring otis pape, please quote Plato 00651 Eton Y62 MAN BAW Dial ASPPlate 90651-162 Chain Drive and Camshaft - Panel [tom ] Aa Part Desetiption Tem No. Part Description | 219. |* Too! panet (020 | Name pate 44 |Pin spannor 056.4%" Chain assembling tool (068 4 ¥e" Chain disassembling tool 093. |1* Chain assembing ool 103. |1* Chain cieaseembing too! 115-| Distance pieoe for chain tghtoner 019. |*) Too! panel, complete 115 | with fools +) Optional extrasPlate 90661-55 Camshatt - Tools aa Part Description Part Description Fe |_| 013 Pin gauge for eamshatt (025 | Pin gauge for cranksCamshaft - Tools Plate 90663-11 q] q 110 | —— Wen rearing o is page, pase quote Pato 90663 Eaton 17 MANBEW Deal A'SPlate 90663-11 Camshaft - Tools tom Tom a Part Description | art Description or4 [Gasket | 26 | Snap-on coupting (051 | Sealing ing (063 Screw 75 | Flange 87 |Nut 000. | Hydraulic tools for coupling 110. | Hydraulic jack fori of camshattN ‘SAFETY PRECAUTIONS ‘Stoppod engine Block he arg mechanism ‘Shutoff staring a supply Engage tuning gar ‘Shutoff coating water Shutoff tuto ‘Shut off lubvcating oi Lock turbocharger etre COCLBEE Data ate Starting Air Distributor Data ‘When refering fo this page, please quote Data Sheet 107-1 Eaton 09 MAN BAW Dizol AS Standard Tools: See Section 913 1074 Paget @107-4 Starting Air Distributor Oata ean) Spare Parts ra-tente, —apn o sorooni010 —Patonvaheske : i | Baa) Whanrearing spo, pease aol Data Sat 1074 Ean 3 MAN 88W Diss! ASay Starting Air Distributor sor. ta) Checking 1. Turm the engine to bring the piston of cylin der No. 1 to TDG. Check the postion with the pin gauge. See Procedure 9063.1. 2. Remove the email end cover of the dist utor housing. 38, Chock that the TOC marking sevatch on the starting cam Is posoned vertically at the valve side of cylinder No. 1 4. necessary adjust the position ofthe star ing cam by toosening the centre screw and | turning the starting eam unl the TOC mar ing seratch is positoned verioaly at the valve slide of cylinder No. 1. Then tighten the centre screw. When veering to is pag "ion 70 MAN Bat Dezel A'S z 3 a 5 3Stating Al Distrbutor vt cP) Dificuties in starting can be caused by the staring alr dstibutor valve slides “sticking” {Gee Volume |, Chapter 703), so that those are Not activated and pressed against ine cam dut- Ing the starting procecure, This can be caused by too high humiity in the ‘main starting ar system, which can result in the formation of rust, and also by dit, preventing the side valves from functioning In both cases tis necessary to clean the valve slides and the liners in the sistributer Rousing to remove din, rust and foreign patil Experience will show how often this Is neces- sary to provent starting difcules, as diferenc- {88 will Be found from plant to lar. 1. Blank off the main stating air and the con- {rol air If this isnot possible, lock the main starting valve in the closed position with a padloes. 2 Remove all the pipes from the end of the isvibutr. Loosen and remove the screws from the small and large ond covers. Dismount the fend cover which gives access to the side valves, 8. Turn the camshaft unt the sot in the star- Ing cam is opposite the pin of the valve 4. Remove the serawe and the cap from the particular valve side in question. Fomove the guide sorew forthe valve slide. Pages) uote Procedure 07-13 Eaton 210 ‘WAN dW Boe ASay Starting Air Distributor 907-4.3 an ‘Overhaul | | '5. Remove the complete slide valve (with % spring and the upper lines) from the estib- ior housing by meens of a brass mandrel 16. Pross-in the spring and remove the two part lacking ting, 7. Remove the upper spring guide, the spring, the lower spring guide and the upper liner ‘rom the valve sis. {th ‘Wan refering this page, pease quote Pecodwre U7 1S Ediion210———~« GOS) MAN BAW Diseol NSors Starting Ai Distributor Ovtau (ea) 8. Clean all the sliding surfaces on the valve side. Lubricate all parts with Molypdenum Disulphide (MoS) Clean the iners and the distributor housing. Tost that the valve slide moves easly inthe liners, Note! Polishing with emery cloth or steel woo! must not take place as tis will cause Scratching marks on the sliding suraces ofthe pision valve slide or distributor housing — 9. Place the upper tint, the lower spring [0 Suide, the spring and the upper spring ‘uide over the vane slice, 10. Press-in the spring and mount the two-part locking rng Mount the complete slide valve In the dl ‘ributor Rousing by means of a brass man Gre. (Check that tha soto the starting cam |s opposite tho pin of the valve slide, when mounting). Lubricate the groove in the starting cam with Molybdenum Disuiphide (MoS) Pages 8) When refering otis page, pleaso gute Procedure 907-1.3Ealuon 270 WWaN G&W Bless VSStarting Air Distributor a Overhaul 12. Mount the guidé screw for the valve slide. Mount the cap and the screws on top of the side valve 18, Finally, mount the two end covers and con- nect the main starting alr and the control ‘hon refering to his page,please quot Procedure 807-13 Eaton 210 MAN Baw Diesel AS 1% Pages 6)(om) Starting Air Valve 1072 aw) Data SAFETY PREGALTION® | Sanaa Tots: esac 18 [X] Stopped engine 1] Beco nary materi Zz pe serene coare Engage tuning ger ( ‘Shutoff coating water ‘Shutoff fuel of| ‘Shutoff hbresting ol Lock tutbocharger ots Data et Deion vas ut Det Weight of stating a valve 75 kg D2 Valve tightening angle eo D3 Piston ightering torque 140.Nm nen rearing to is page,please quote Data Sheet 107-2 Eatbon 09 Paget MANS Diesel NS[| tov2 Starting Air Valve Dat Spare Parts Pase-temio, atin om 90704-048.081 Locking wire 1 90704-048 196 Oring 1 Page a When refering to tis pape, please quote Data Sheet 107-2 Eaibon 02 MAN BAW Dowel ASStarting Air Valve Checking 1. When the starting air valve has been over hauled, see Procedure 9072.3, connect & supply of working al to the control air inlet atthe top of the valve Check thatthe valve opens approx. 15-20 2. Shutoff the alr supply CCheck that the vive closes fully. 8. Repeat stops 1 and 2 a couple of times, ‘ian refering to is page,please quote Procedire 007-21 Editon 207 NANBAW Dla! AS Paso907.22 Starting Air Valve Diora (ey 1 1. Shut off the stating alr and contro alr inet. | Dismount the control ir pipes Mount two eye bolts inthe top cover ofthe valve. Hook a titing wire on tothe eye bolts. Unscrew the txing nuts of the stating valve flange. | 2. Lit way he starting valve DA tt Page) When refering tts page,please quote Procedure 807-22 Fallon 207 eee WAN aw Disa ASStarting Air Valve 907-2.3 Overhaul Place the starting alr valve hortzontaly ina | 1 bench vice provided with “sat” jaws, Remove and discard the O-ring from the valve housing. 2 Loosen and remove the screws trom the top cover. Dismourt the top cover. 3, Remove the locking wire Use the face wrench for the spindle as a back-stop when loosening the two sorews which tighten the piston to the spindle. Remove the sorens, When unscrewing, the plston will partially be pressed out ofthe valve housing due to the spring force. Liter refering ths page,please quota Procedire G07 29 Ean 207 a Pages) MAN BAW Diol AS907-2.3 Starting Air Valve Overhaul 4. Remove the piston from the top end of the valve housing. ‘Take out the spindle fom the bottom ond of the valve housing, Remove the spring fom the top end of the housing, 5. Apply grinding paste, e.g. carborundum No. 200. Grind the valve housing seating with the grinding ting 6. When lapping the seatings of the spindle and valve housing to match, use the face wrench to rotate the spindle As grinding paste, use e.g. carborundum No, 800. Page 4 (6) ‘When referring lo this page, please quote Procedure 907-23 Edition 207 Pose WAN GW Disea AS(oad) Starting Air Valve 9072.3 fen Overnaut 7. Thoroughly clean the valve housing and all the paris in dese! olor kerosene. Lubricate al! internal parts and aliing eur faces with, 2.9, Molyodenum Disuiphide, MoS. Insert the spindle in the vale housing Then mount the spring inthe housing round the spindle and, finaly, place the piston on top of the spindle 4, Fit the disos and the two screw, \When tightening the screws, the piston will compress the spring Tighten the screws continucusly until the piston faces tightly against the spindle. Use the face wrench as a backstop. | Tighten the screws tothe torque stated in Data Lock the screws with locklng wire. Fr correct use of locking wie, see Proce- ure 913-7, 2 ©. Mount and Ugton the op cove. J ko Fit anew O-ring onthe valve housing. ITI}. 10, Check the starting alr valve See Procedure 907°2.1, If the valve is not to be mounted in the en- gine immediately, cover all openings with Plastic to prevent dit trom entering the = valve during storage. co When refering to ths page,please guote Prosedure 00723 Ealion 207 Passe MANBaW Diet A'SStarting Air Valve owing (aa\ 1. Caretuly clean the starting valve bore in the oylinder cover ang, if necessary, recon- dition the seat forthe starting valve In the bore, see Procedure 901-1.3. Itnot already done, ft a new O-ring on the ‘overhauied valve and lubricate with ‘Never ‘Soize' of Molybdenum Disulphide, MoS, For overhaul, see Procedure 907-23. 2. Mount the valve in the cylinder cover 8. Mount the nuts and tighten-up alternately, in at least three steps, to an angle of 40" Loosen the nuts again and repest the pro- cedure to reach the full tightening angle, see Data, Mount the control air pipe and turn on start- Ing air and control at. ‘When refering otis page,please quote Procedure 07-34 Eaton 207 THAN B&W Diesel ASSAFETY PRECAUTIONS ‘Stopped engine Block the starting mechanism Shutoff tating air supply Engage tuning gear Shut off cooling water Shutoff ft ot Shutoff lubcating ot Lock tuibocharger rotors Data et Omen ve ut DA Weiphtothigh pressure pipe 100 kg D2 Tightening torque = high-pressure pipe 190m High-Pressure Pipe Data Standard Tools: See Section 913 ZA, ==> 12001 108-1 When referring fo this page, please quote Oaia Sheet 108-1 Eattion 09 MAN AW Dine! AS Paget)108-1 Spare Parts sono 178 90806000225 90806-00250 Page? @) ing High-Pressure Pipe bat Ga wewg hen eeing to is pao, please aooe Data Sheet 108-1 Eain .W Dieseay High-Pressure Pipe Baw Dismantling 908-1.2 1. When replacing the hydraulic high-pressure pipe, the exhaust valve or the hydraulic ac- tuator, check the high-pressure pipe seal- ing suraces, 2. Batore dismanting the high-pressure pipe, stop the camshaft oll pump, Loosen the screws for the high-pressure pipe and it he pi ‘actuator to let {through the drain holes in the actuator. 13, Remove the screws In both ends of the high-pressure pipe. LR the high-pressure pipe away from the engine. When raoring 0 is page, pease quote Procedure B66:1.2 Eaton 277 MAN daw Oitet NS PageHigh-Pressure Pipe Overhaul eas The two ends of the pipe are identical and should both be overhauled as follows: 1. Remove the thrust piece from the actuator ‘and exhauet valve, FRomove and discard the O-rings from the thrust piece and the thrust flange, 2. Lit the thrust ange upwards, Flomove the spring ring from the sleeve. Pull the stoove off the pipe. 3. Remove the screws and the two-part dise from the thrust flange. Pull the trust tlange off the pipe Femove and discard the O-ring S a Paez ‘When reoing to tis page,please uote Procedure 008-19 Faion 207 WAN dW Bacal AS(oa) High-Pressure Pipe Baw Overhaul 4. Clean and inspect the contact suriaces of the high-pressure pipe and the thrust piece. UW necessary, grind the contact surfaces by :meane of tho grinding mandrel ‘Start grinding with a coarse grinding past, for example Carborundum No, 200, and fin: ish witha fine gringing paste, for example Garborundum No. 500. Ater the grinding, clean the high-pressure Pipe and the thrust piece 5. Assemble the high-pressure pipe In the re- verse order to disassembling 6. Mount a new O-ing on the thrust flange and the thrust piece. emount the thrust plece on ihe actuator and exhaust valve When refering to this page, lease uote Procedure 08-19 Elion 277 MAN B8W Deo! NS 908-1.3 Pages)908-1.4 High-Pressure Pipe Mounting ma 1. not already done, mount new O-rings, tu- Dricated with alle camshaft lubricating ol, fn the thrust flanges. ‘Mount the high-pressure pipe on the en- ie Note! ‘When mounting the high-pressure pipe, {ke care not fo damage the eealing sur faces ofthe pipernrust pieces, 2. After ting the pipe to the exhaust valve fad actuator, mount and tighten the screws by hand, Final, tighten the screws diagonally o the torque stated in Data, using a torque span- For correct use of the torque spanner, see Procedure 913-5, 8. Check the system for tightness, When relring this page, nse aie Proseare Ra Eaon 371 o MAN BBW Diesel A/S:(am) Exhaust Valve 108-2 Data ‘SAFETY PRECAUTIONS Standard Tools: See Sexton 919 [5<] stopped enine | Block the staring mecheniem ZS | Shuto staring a supey | Engage wing gar | shut of cootng water ad [| shat ofetot De] shut of beatng ot i 3] Lecktubocharger os 2x0, 2xM6 Data Fat. Deserstion vaue unt || =O D1 Exhaust va, compete 300 ks 52 Echos wave hong 100g 03 Oloyinder 609 D4 Arojinder ‘2010 Do Sone 009 Doe Bato pioce 19099 57 Oleyinder, ine ote a 140.20 0-8 Fesonengs min hikness 52mm 5.9. Win stare piston sam to Nx. tance to ison si2mm +11 Nin lame of si stm 107.8 5-12 Tahenngtrqurot onder "360 Nm 5-18 Tghtenng tre sees or ting ache 240Nm b-14 Tehtonng true “yenn 0.80 Nim 5-18 Opening pressure sie vale 2tbar 18 Grindog ang, vate sind ——s0.7" D7 Grinding angle, botom piece «800° 18 Max gringo set 230mm 0:19 Gap a otom piece tom D0 Mex. aot of plo komm Bt Max gining fede 200mm 2 tyra presse " “Gearing 1500-1650 br 029 Fy pressure vung 1500 bar 26 Max darter, op 1008 mn 3-5 Max deter bom s2.0mm O26 Arpiston 40kg Dar Toner tau, ange no andr eann thon rearing is pa, sae ice Daa Shot 106? Eaton TB ——SCSCSCS~S~*« MAN B8W Bisel AS108-2 Exhaust Valve Data Gas) Spare Parts | Pite—tem ie, oseriton ay | soeotoxot Packing : | sonotsenose att ‘ | onotsnco86 Dae : seeorme 48 une obra 1 soooreese2 Org 1 sooorsnaett Casket 3 tonotinazs0 ng ‘ sonorseasa reg 2 soo0iiens06 Castel 1 a ee 1 | sosots4o7 Song ring : 1 | swootceen Oring 1 soonrnaset ——_Sesig ng 1 senotien708 aa 1 sonotiea7it Og 1 sonotien778 ——Sesingrrg 1 | eosotsa14 Singing 2 soonsiextse ——_Pionsing 2 Poet Wan refaring oe page,please quote Dala Shoot 108-2 Eatin | MAN Baw Dies! NS1. Before mounting an overhauled exhaust valve In he engine its recommended that the valve be checked as follows: + Lift up the valve with the engine room crane (which makes the valve oper) + Connect compressed air to the preu- matic piston. The valve should’ now close. + Check that a 1.0 mm fesler gauge can be Inserted about 15 mm into gap Ga, 10 ensure that there i @ olearance between the outer parts of the seating faces of val housing and the spindle. Soe Procedure 908-2.3. + After shuting-off the compressed air ‘supply and releasing the vent plug screw locate just above the ball cock onthe ait cylinder, the exaust valve should open, + Alter doing this a couple of times, leave the valve closed and shutoff the com= pressed air. The vale shoule remain osed for a least 18 minutes, 2. When the exhaust valve Is mounted in the «ylinder cover, and the cooing water inlet to ‘ne cylinder cover and exhaust valve. fe ‘open, check the tightness of the easing ‘ing Between the bottom piece and the ox- haust valve housing by ensuring that water {does not flow from the small Bore on the ‘manoeuvring side of the exhaust valve If wator does flow trom the bore, the ex haust valve must be diemounted’ and the sealing rings replaced, Exhaust Valve Checking When referring to this page, please quote Procedure 8082.1 Eaiion 275 MAN SEW Oita NS Page ten908-2.2 Exhaust Valve Dismantling Baw 1. Closé the cooling water Inlet and out, and sain the exhaust valve Dismount the high-pressure pipe or the by- raule vaive actuation. ‘See Procedure 908-12. Disconnect the cooling water outlet pipe tom the exhaust valve Dismount the return ol! pipe trom the ex- haust valve 2. Dismount the air pipes forthe sealing a ar |" rangement andthe pneumatic exhaust valve. 3. Remove the plate jacket with insulation ftom the intermediate pipe and remove the screws which attach the intermediate pipe to the inlet pipe of tho exhaust receiver. When refering fo this page,please quote Procodire 908-22 Falion 213 "WAN 28W bless NSExhaust Valve Dismanting 4. Remove the protectve caps trom the ex aust valve studs, and mount the four hy: sraulc jacks, Connect the high-pressure pump to the jacks by means of the Blood the hydrauile system and raise the pressure as stated in Data. Then loosen land remove the nuts. ‘See Procadure 913-1 5. Attach the crane to the eye bot fited on top of the valve and it the exhaust valve away. Carefully clean the exhaust valve bore in the cylinder cover and recondition the seat- ing and sealing surtaces of tna bore, it re- quired See Procedure 901-1.3. For overhaul of the exhaust valve, see Pro- cedure 908-2.3. hen to this page, pica rosedure 06-22 Eaton 755 908-23, Exhaust Valve | Ove (ad) 1, Place the exhaust valve on wooden sup- port on the platiorm. Femove the eight nuts and the safely ‘strap from the oil cylinder. Remove and discard the O-ing trom the ait cylinder. 2 Lit away and place the oll cylinder on a ‘wooden support Dismount and inspect the O-rings and_ tho thvust piece of the hydraulic high-pressure pipe for marks. DDismantle the thrust piece. Remove and discard the O-ring Dismantle the exheust valve rotation indica | ter 3. Loosen the screws and remove the ting bracket from the ol cylinder to gain access to the orice plug. Flomove and discard the gasket Uneerew and clean the orice pivg Flamove and discard the sealing ase Chock and clean the bore for the orifice plugin the top of the ol yiinder. Pages @)—~—~=~S~S~SS( no etering to his pago, pease quote Procedure 900.23 Elion 278 "WAN BAW Oiael AS(oes Exhaust Valve 9082.3 Overhaul 4. Place the oll cylinder in a horizontal posi- tio. Remove the flange and take out the piston, Inspect the inside ofthe tiner Inthe ol ey- Inder for scoring and measure is diameter. 1 the diameter ofthe finer exceeds the val- ue stated in Data, dismantle and replace the liner. It necessary, screw two Mi2x100 mm seraws into the dismantling holes of the lin- ‘2 fo pull the liner clear of the oil cylinder. Note! ‘Make sure to turn the sorews evenly. |uming each screw only one revolution at atime, | 16. Release the safety valve from the air cyin- dor to let the air escape from below the pis- ton. Remove the four screws from the Flange on top of the air piston and dismount the flange. ‘Loosen the air piston from the conical lock- ing ring by means of a tia hammer, and re- ‘move the conieal locking ring. ‘han retorring to is page,please quale Procedure SOB aaEamonzTs ~*~ OSD MAN BW Drool A'SPages a Exhaust Valve Overhaul Baw 7. Pass titing straps through the four bores of ‘the valve housing and Ifthe valve housing cloar of the valve spindle. ‘Take care — when the internal O-ing Inthe air piston and the internal rings forthe seal ing arrangement at tho bottom of the ar cy- inder pass the groove forthe conical ing at the top ofthe spindle, ‘8. Unscrew and remave the lock screws which retain the bottom piece. Lit tne valve hous- ing approx. 10 mm. tthe bottom piece has become stuck, use a tin hammer to release it. Lift the valve housing away and land it on a couple of ‘wooden planks, Remove and discard the O-ing trom the ‘9100v0 In the top of the botiom picco ‘Vien reering tots page,please quote Procodre 906-29 Fallon 775Exhaust Valve 908.23 Overhaul Bottom piece: 8 = 9. Inspect the seating of the bottom piece carefully for damage and check with the ° bottom pioce template Gs Not Before using the bottom piece template, ‘thoroughly clean the contac faces on the | vaive housing soat witha eta Brush, D-417 ‘Allmeasurements should be taken at four | | diametrically oppasste points on the ci- ‘curfacence of te batiom place seating, Samal drt mast the bt seaing ue ecpaate ence nbs sen ena baw east Josten te embonion Seneer ine | wastes cer For turer evaluation ofthe bottom ploce ‘Seating, 68 also chapter 707 in the Instruction book, Volume I, Operation ‘Take measuroments Gy and Gs, using a fooler gauge. Compare the results withthe figures stated in Data 0-18 and D-19 10. IF burn marks are visible on the bottom piece Seating OF Gx does not equal D-19, THEN the valve housing seat must be ground IF the tomplate rests on the lower surface In the groove, ie. @ = 0, THEN the bottom piace seating must not be ground, regard- loss of burn marks or Gs. Instead the Bot- tom pioce must be reconditioned, Contact MAN B&W Diese! for advice on ro- conditioning. | ‘When referring fo this page, please quote Procedure 908-2.9 Eaivon 215 Page 7 @i)908-2.3 Exhaust Valve Ovetal (aN 11.1 tis necessary to grind the seating, pro- ceed as folio Before placing the bottom piece on the grinding machina, turn the grinding head Away from the grinding table. Mount and secure the botlom piece in the grinding machine. Using a. dlal gauge, ‘check that the bottom piece is correctly ‘centered, ‘Adjust tho grinding head to achiowe the cor- rect grinding angle as stated in Data, Note! 12, f D-17 ° ‘As the grinding angle is vary important for te correct operation of the exhaust valve, make absolutely sure that the grinding head is correctly adjusted. Regarding the use ofthe grinding machine, '8e0 separate instructions from the grinding ‘machine manutacturer, 12. During the grinding, use the bottom piece fomplate frequently to ensure that max! ‘mum grinding isnot exceedad, see step 8 ‘After grinding, inspect the bottom pie seating again, using a feeler gauge and the bottom piece template, to measure how ric ard tas boo grou vy 13, Grind the recess so that gap G3 equals D-19 as stated on the Data shoe 18. After grinding the inside seating ofthe bot ‘tom piece, grind the outside seating using ‘carborundum 200 and the special gtnging toot Note! ‘Turn the special grinaing too! by hand, alternately turning clockwise and ant Clockwise. ‘Grind until a smocth surtace is achieved. ‘Glean the bottom piece. When reforing ois page,please quoi Procedure 906-29 Fallon 273 MAN B&W Desal AS(oes Exhaust Valve 90823 Baw Overhaul Valve spindle 4 14. When iting or transporting the exheust valve spindle, use the special valve spindle ‘ting tool. 15, Inspect the seating ofthe valve spindle for ‘burn mats. (Chock the bura-otf Ft ofthe valve spindle by measuring at each ofthe points A, B, C, D and E, indicated by means of notches in the spindle template, Note! ‘Before using the spindle template, thor- ‘oughly clean the contact faces on the valve spinle witha steal brush ‘All measurements should be taken at four diametrically opposite points on the ci Ccumference of he valve spindle ‘Smail dont marks inthe vaWve opindle seating are acceptable and need not be ‘ground away, provided thatthe dent ‘marks do.not allow blow-by of exhaust gs from the combustion chamber tothe ‘exhaust gas receiver. For further evaluation of the valve spindle ‘seating, see also Chaptor 70710 the Insiniction hank. Value |. Operation 16, Measure the gap G, between the spindle i tomplate and the seating of the spindle. 17.1F burn marks are visible on the seating, the spindle must be ground. IF gap G; exceeds the maximum allowable value D-21, see Data, OR the bur-off Fy ‘exceeds the maximum allowable burn-of 20, the spinale must not be ground. in- ‘stead the spindle must be rocondtionod. | (Contact MAN BAW Diesel for advice on re- : conditioning. When refering otis page, please quote Procedure 9082. Eaton 215, Pages NAN BaW Olea! AS460 620 Page 10 21) D-11 Exhaust Valve Overhaul i 418. Mount and secure the spindle in the grind- ing machine. Using a dial gauge, check that the spindle ie correcty centered, ‘Adjust tho grinding head to achieve the cor- tect grinding angle as stated in Data. Note! ‘AS the grinding angle is very important to the operation af the exhaust valve, make absolutely sure to adjust the orinding head eorrecty Regarding the use ofthe grinding machine, ‘Seo separate instructions fom the grinding ‘machine manufacturer. During gringing, measure gap G, frequent ly. The max. grinding of the spinale, see Data, must not be exceeded. It the max. grinding tint is reached, and burn marks ar stil viibie on the seating of the spindle, contact MAN B&W Diesel for advice on reconditioning, Clean the spindle, 419. Check the spindle stam for wear in the area between 460 mm and 620 mm measured ‘rom the top of the spindle, It the stem clameter is less than stated in Data, or the hard facing layer is worn away, | contact MAN BAW Diesel for advieo. "When refering to his page, please quote Procedure 908-23 Eaion 15 WAN BAW Dlecel ASExhaust Valve man Overhaut 20. Dismount the air piston from the air cyin- der, and check the teflon guide ring and te flon sealing rig for wear. Dismount the sealing ai control box trom the air cylinderivalve housing. Mount two eye bolts inthe alr eyinder and lsmount the air eyinder. Remove and dlscaré the O-ring on the ait eylncer. CCloan the air cylinder and check the run ning surface for wear or possible scores, 21, Remove the protective cap from the salaty valve mounted near tho bottom of the air ylinder and dismount the safety valve from the air eytinger. Place the safety valve in the prossure test ing device, Connect the testing device with the high Pressure pump by means of a hose. (Check the opening pressure, see Data I the opening pressure isnot correct, loos- fen the lock nut and, using a screwdriver, fadjust the safety valve untl the correct pressure is indicated, ‘Tigmten ine tock mut ana test me opening pressure once more, 22. Mount a new gaskel and a new O-ring on the safety valve. Mount the safety valve in the bore near the botom ofthe alt cylinder. |when mounting the salety valve in the aie cyfinder, use only the machined faces én the valve housing and tighten, see Data, Finaly, mount the protective cap ‘Wan refering fo is page plaase quote Procedure 906 2.3 Elon 215. MAN BW Dito NS Page 17Exhaust Valve Overhaul 23 Remove the screws and dismount the flange of the surfing box. Romove and discard al the O-ings. 24, inspect the bushing in the spindle guide for oar. See Dara, 11 It proves necessary to replace the bush: Ing, pul It clear by means of four dsman- tng screws. 25. Mount a now O-ring in the groove inthe top ‘ofthe bottom piece, Land the exhaust valve housing on the bot- tom piece Mount ang tighten the screws which retain ‘the bottom piece. Note! Remember to tighten the screws in iag- ‘ona sequence, 25, Page 221) Viton retaring to this page, please quote Procedure 908-23 Palion 278 VAN BAW Diese AISlea Exhaust Valve 908-23 paw Overhaul 26. Lubricate the Inside of the bushing in the spindle guide with plenty of lubricating ol Carefully land the exhaust valve housing with the bottom piece on the exhaust valve spindle 27. Mount the O-rings on the stuting box. Note! ‘Make eure to mount the O-xings correctly, 00 the sketch, ‘Mount the stuffing box flange. Mount and tighten the screws. ‘When refering to is page,please quote Procedure 90623 Galion 218 ——~—~=~*~*~*~*« SY9082.3 Exhaust Valve | Overhaul aw | ———— 28, 28, Lubricate the inside of the alr cylinder with | lubricating ot Carefully land the air oylinder on the ex aa D-4 aust valve housing. Note! Take care not to damage the Oings on the outside ofthe etuting box. 29, Remove the titer plug screw from the seal- Ing air control unt Coan and chock the fier plug sorow, and replace the Ong ‘Alter checking, re-mount the filer plug Loosen and remove the screws and cover the sealing alr valve spindle in the contrat uni. Remove the valve spindle and check the sealing rings and the spring. If necessary, replace them. ‘After checking, mount the valve spinale and ‘pring, and tighten the cover. Fags) When veering io is page, please quote Procedure 808-2.3 Eaton 215, "WAN GaW Desel NSExhaust Valve Overhaul 30. fi Is necessary to replace the rings, cut | 90 them and remove them, Be caretul not to damage the edges of the ring grooves in the piston. Mount the new O-+ings inthe grooves ofthe air piston. ‘Before mounting, heat the now teflon rminctes. rings in 100°C het water for at least five \When mounting the telon rings, be care- ful not to damage the running surfaces. After mounting, compress the tetion rings by means of the conical ring. This is done by pressing the air piston through the con 31. Fil the sealing ale chamber and the lowor part ofthe air ylinder with clean lubricating 32. Fit the conical guide ring forthe a pis fon the ai olin. Lower the air piston over the valve spindle down Into the air evince. Note! Fing To avoid damage, fake great care when ‘the internal sealing ring n the alr piston [passes the groove fr the conical locking Remove the conical uide ring from the air enlinder. ‘When referring to this page, please quote Procedure 806-23 Eaition 275 MAN BAW Dieel AS Page 15 (21)Exhaust Valve Overhaul 2a 4 35. Page 16:23) Mount the conical locking ring and tit the ar plston up around the locking ring, Mount the flange on top of the alr piston ‘and, by means of the four screws, tighten the air piston and the flange together. Femove the eye bots Remove the piston rings trom the ol piston ‘and check them for weat I the thickness ofthe rings has worn down tothe minimum, see Data, ciscard the ings land mount new ones. Check that the TOP mark on the piston rings faces upwards, wien mounting. Mount the piston on top of the spindle and ‘check the tunetioning of the damper piston Connect compressed alr supply to the space below the air piston, so a8 to keep the valve closed, and to keep the air cylin- dor in close contact with the valve housing Pace the measuring tool onthe air cyinder across the piston. Whe reforing to is page, please quote Procedure 008 29 Ealion 278 WAN GaW aoe A/SExhaust Valve 90823 Ban Overhaul 186. Check the mesh of the damper piston by | 96. checking the distance from the upper edge ofthe crossbar tothe top ofthe damper pis- ton, See Data, WY the measurement ig outside the value stated in Data, an adjustment must be made by changing the disc in the damper Piston ae follows: S37. Place the piston in the special tool Press out the dige with the centre screw, Ht necessary, replace also the spring and the piston, 38. Assemble the dampor piston withthe new disc in the special toot 37. Place the piston upside down in the tool and press the disc into place inthe piston. Check the mesh once more, repeating points 35 and 36, ~S Y ZX RANT When refering to this page, please quote Procedure 908-23 Editon 215 Page 17 21) MAN BAW Disal AS| 908-23 Exhaust Valve i wt (ea 39. Mount the piston and the flange in the ol foylinder. Mount the screws and tighten to the torque stated in Data 40. Return the oil cylinder to an upright post Won. “Mount a new sealing disc inthe bore forthe orice plug. Screw the orice plug ino the bore, Place a new gasket on top ofthe ail eyin- er Mount the iting bracket an the oll ylindr. Mount the serews and tighten to the torque stated in Data, 41, Mount a new O-ring on the thrust piece. Mount the thrust place in the ol cyinder. Mount the exhaust valve rotaton Incleator fitted with new Ovings. PaseTei2) When releing to this page, paase quote Procedure 008-23 Edlion 27 “see 18 2) ina tons pace, THAN BSW Died ASBan Overhaul 42, Mount a new seating ring in the groove on | 42. a iter efering to is page, please quote Procedure G08 23 Eaton 215 Exhaust Valve the outside of the air cylinder Mount the overhauled ol eyinder on top of the air cylinder. Mount the safety strap and tighten the nuts. ‘Soe Data Disconnect the compressed a. Biow through th orice pipe inthe exhaust valve housing with compressed alt to re- move any obstructions. Also blow through the pipes ofthe sealing alr contol unl. Mount the sealing air contra unt onthe air | onlnder. MAN SW Dose VS 9082.3 D-3 Page 19121)908-2.4 Exhaust Valve | Mounting 1. Mount @ new O-Fing on the bottom piece land on the bottom of the exhaust valve housing. Lubricate te O-rings and ine tnreads ofthe studs with molyodenum disulphide (MoS) Position the valve in the cylinder cover bore, guiding tin accordance with the ox hhaust flanges and the guide pin on the ex: haust side of the exhaust valve Not Belore mounting the valve on the engine, connect compressed airto the pneumatic piston to keep the exhaust valve closed during the mounting 2 Mount the nute and the hydraulic jacks. Raise the pressure tothe value indicated in Data and tighten up the nuts. For use of the hydraulic jacks, see also Procedure 913-1 Relieve the system of pressure, remove the hydraulic jacks and the high-pressure hose, and ithe protective caps. When refering to this page, please quote Procedure 808-2 4 Ealion 215 aN BAW Diesel AS Page 20)Exhaust Valve 9082.6 Mounting 2, Connect the Intrmediate pipe tothe flange at the exhaust receive, Mount and tighten the screws. [tach the insulation jacket 4. Mount the cooting water oust pipe on the ‘exhaust valve, Mount the high-pressure pipe and the re- i turn ol pipe, 862 Procedure 908-1.4 ‘Mount the air pipe forthe sealing ar control | nit ‘Open the lub ll supply an the cooling wa- ter supply tothe exhaust valve. ; Disconnect the compressed air and con- [3 Dee ope i Caution! ‘The al supply tothe exhaust valve must always be connected before turning on the oll supply tothe exnaust valve actua- ter. ‘This is very important, because other- wise the valve will open more than Intended, 5. Check the tightness of the sealing ring be- tween the botiom piace and the exhaust valve housing. See Procedure 908-1.1. ‘hon refering to ts page, ase qucte Procedure 90624 Eaton 216 ———~—~*« TT) MAN BBW Dice! NS |Exhaust Valve Actuator 1083 SAFETY PRECAUTIONS. ‘Stopped engine ‘Block the starting mechanism Shut off staring ar supply Engage turing gear ‘Shut off cooling water ‘Shutoff ut of ‘Shutoff ibang of Lock turbocharger rotors ?| DEEPER) Det. Safety valve cap nut tightening lerque 400 rn 0-2 Weightohycrautc actuator 360 kg D3 Unerinolloyiner, inside diameter max +402 mm 4 Piston sings, min thickness DS. Hydrouic actuator ~demanting pressure 1500-1650 bar D.6Hydraubc actuator = Ughtening pressure 1900 ber “tightening torque D8 Screws for inet ~tghtering torque ‘When refering to this page,please quote 0: MAN BW Olses! NS Data 758m 22Nm Standard Toole: See Section 913 A, rf = 10-120 Nm, 140700 NM @ am txam way 4x1i 1083 ‘Spare Parts 208052 052 0805 eee 135, 0805-0 147 90805: 363 Page 212) Exhaust Valve Actuator at aan beettoe oy Satety vaio spang 1 Sealing disc 1 Liner 1 Non-atum valve 2 Piston rings 2 ‘ier referring to his page, please quot Data Shoe! 108.3 Eaton 1 ‘MAN BAW Dies! NSay Exhaust Valve Actuator aw Checking 4. The non-oturn valve A is bult nto the oll inlet pipe to tho actuator. To check the valve, dismantle and clean it {and connect a supply of working air (7 bat) to the outlet side ofthe valve (the sige fac- Ing the actuator) Ifthe air flow can be fet atthe inlet side ofthe valve the valve must be overhauled. When refering ois page, please quote Procedure 90621 Elion 214 NAN BAW Dito! AS age 8)908-32 Exhaust Valve Actuator Dismantling >) 4. Stop the engine and shut off he il supply. “Tur the camshaft so that the roller rests on the cireular part ofthe cam. [Remove the inspection cover of the roller guide housing to check the postion of the ‘exhaust cam. Dismount the oll inlet pipes and the drain Pipe from the exhaust valve. Dsmantle the high-pressure pipe. ‘See Procedure 9081.2. 2. Release the mountings for the indicator ‘tive trom the actuator housing. 8. Screw the extonsion stud ofthe spring com- Pression tool into the top of the actuator Piston, and mount the rest of the spring ‘Compression tool on the actuator housing 4. Turn the spindle ofthe spring compression tool anti-clockwise to compress the actua- tor spring. For convenience, a pneumatic Impact spanner may be used for turning the | spine | of im! 3. Page2——~—~*~*~*«rataig to ig, ase ate Posed 808.3? ion 74 ‘WAN Baw Dies ASExhaust Valve Actuator 5. Mount the spacar rings and the hydraulic jacks over the nuts. Pump up the hydraulic jacks tothe dismanting pressure, 2s spec- lod in Data. Loosen and remove the nuts. For use of hydraulle tools, s00 also Proce: ure 913-1 6. Turn the spindle ofthe spring compression toot clockwise to release the actuator spring ‘When releasing the spring, he actuator housing wil move upwards Remove the spring compression too. 7. Fit eye bolts inthe liting holes ofthe actu ator housing, and nook on tackles and a it- Ing wite tops. Using the engine room crane, it away the actuator housing Remove the spring. ‘8. Remove the locking plat, and turn the pis- ton 90° to releage it from the bayonet jin Femove the piston from the roller guide. ‘Overhaul the actuator housing and the pie- ton as required. ‘See Procedure 908°3.3. {Whe rearing ois page, pease quote Procedure MAN BBW Oise! AS Dismanting 5. Eton 278 9083.2 Pages 6)9083.3 Exhaust Valve Actuator Overhaul 3) 1 + 1. Giean tho piston in kerosene and wipe dry D-4 4 wath a clean piece of cloth. “Take ofthe piston rings and check them for wear. If the fing thickness has worn down to the minimum (soe Data), discard the rings and mount new ones. Check that the TOP mark on the piston rings faces upwards when mounting 2. Inspect the sliding surfaces ofthe piston to ensure that tere are no seraichmacks of seizure marks. 8. Unscrew the guide screw trom the cylinder. UUnserow the cap nut and remeve the parts ofthe safety valve, necessary, screw two MSKe0 mm sores Into the valve seat and use these to lit the valve seat out ofthe at eyindor. Discard the spring ofthe safety valve and tha sealing cise of the guide screw ages) When raring to this pape, pease quote Procedure 909-3. Eon 274 THAN BW Dieal AS(Gea\ Exhaust Valve Actuator Overhaul 4. Dismantia the special dis Remove and discaré the O-ing. '5, Tit the actuator to a horizontal position. Clean the liner Inside the oi eyinder, and Inopect the bores for deposits. {Chock the liner inside the oil cyinder for possible scores and measure it for wear, 6. Ifthe ner is seized or has worn dawn to the ‘measurement statod in Data, the liner must be dismantled and replaced. Remove the sorews ofthe line. ‘Screw two M12x100 mm screws into the ‘lsmantiing holes ofthe liner to pull the ln- {er clear ofthe oil cylinder. Note! Mi tur the two eerews evenly, tum each serew one revolution at aime. Mount a new liner inthe ol eyllner, Mount and tighten the screws to the torque stated in Data, hen refering to is page, please quote Procedure 6063.3 Eaton 214 MAN BaWDitel NS Page908-3.3 Exhaust Valve Actuator (es\ ‘Overhaul =i 7. Return the ol cylinder to a vertical poston, Mount a new O-ring on the special dsc. Mount the special disc inthe bore atthe top ofthe actuator, 8. Cioan all the parts of the safety valve Mount the parts along with a new spring in the bore at the top of the actuator Mount the guide screw fited with & new sealing dsc Mount tho cap nut over the parts of the safety vale and tighten tothe torque stated in Data ‘When refering to is page, please qucte Procedure 908-93.3 Elion 274 Viaw BW lesa AS(ad Exhaust Valve Actuator 83.4 fs Mounting 41. Mount the actuator piston inthe roller guide and turn 90° to lock It nthe bayonet joint Mount the locking plate and tghten as stat- fd in Data. Lubricate the piston with plenty of camshat lubricating of 2. Mount the epring on the roller guide. Care- fully lower the actuator housing on to the piston, taking care not to damage the piston Fings or the threads of the studs. ‘3, Screw the extension stud of the spring com- Pression tool into the top of the actuator piston and mount the rest of the spring ‘compression ool on the actuator housing When referring to this page, please quote Procedure 908-34 Edin 214 Page? (8) MAN daw Dee! NS908-3.4 Exhaust Valve Actuator Waning (a 4 4. Turn the spindle of the spring compression tool anti-clockwise to compress the actua- tor spring and to lower the actuator housing ‘nto the roller guide bushing. For conven lence, a pneumatic impact spanner may be used for turning the spindle, 5. Screw the nuts on to the studs. Mount the spacer rings and the hydraulic jacks over the nuts. Pump up the jacks tothe tghton- Ing pressure, as spectied in Data. Tighten the nuts, and remove the hydraulic jacks land the spacer rings For use of hydraulic tools, see also Proce- dure 919-1 6. Remove the spring compression tool. 7. Mount the oi inet pipes and the drain pipe from the exhaust valve ‘Mount the hydrauitc high pressure pipe. ‘See Procedure 908-1.4. | Pages) Whan lering to tis page,please quote Procedure 6063.4 Faiion 274 aaa ae ‘WAN Ba Doe AS(oe) Exhaust Valve Roller Guide te Data ee Zz, Fl ‘Shutoff eootng water ‘Shut off fut ot Shutoff lubricating ot Lock turbocharger otors | Data Pe, oe va Ut Det Weight of rte guid, complete 2a0kg D2 Max clearance rolerushingshet pin 05 mm 0-3 Min-max, clearance role guide! guide pate 03-19 mm ¢ When refering to mis page, MANGA Diwal AS ‘SAFETY PRECAUTIONS. Standard Tools: See Section 913 108-4 jeaso quote Dala Shoe 108-4 Editon 10 Paget)Exhaust Valve Roller Guide man Checking ‘The exhaust valve roller guide oan be par tially checked while mounted on the engine, using the folowing procedure Lit the aller guide. Soe Procedure 908-5. Remove the camshat Inspection cover. Turn the engine to provide the maximum space betwaen the roller guide and the cam die. Check the movabilty of the roller by turing this by han to ascertain f the roller moves freely and without unnecessary resistance or "hare" paints [Also inspect the surface of the roller for possible damage marks, seizures or Scratches. Make sure that no vaces of bearing metal axa in the rller guide hous- ing check the clearance In the side bearing by liting the roller relative to the roller guide land measuring the diference in distance betwoon the cam dlge and the roller inthe ‘upper and lower positions ofthe roller. [A more sullabe and relable method is to check the roller guide and the bearing blearance when the roller guide Is ds: For aismanting ofthe roller quide, see Pro- codure 908-4.2. Inspect the surfaces ofthe roller guide and the roller for damage marks, seizures or 908-44 soratohes, Jo measure the clearance in the roller guide slide bearing, place the roller guide Vertically upside down on a couple of planks with the roller hanging freely Place a dial gauge against the roller. Then lit the roller as much as the clearance per mits, which makes it possibe to read the clearance D-2 directly on the dil ‘Won refarring to tis page, ploase quote Procedure 806-47 Eaton 214 MAN BAW Dise! A'S Page 14)908-42 Exhaust Valve Roller Guide Demanding (Gam 1. Dismantie the hydraulle actuator above the ‘exhaust valve rlle: guide, ‘Seo Procedure 908-32. 2, Mount the roller guide iting tool as follows: + Lift the lock sing of the tool up on the shat ofthe tool + Place the too! in such a manner that its foot rests on the thrust piace in the bayo- ‘at joint ofthe roller gue. + Turn the 100! 90° so as o allow the foot to engage propery in the bayonet joint. Lower the lock ring, thereby securing the foct in the locked positon Lit the roller guide out of the roller guido housing, using the crane. Take care not to ‘damage’ the siding surfaces of the roller ‘guide when iting. | Page2 ‘When rearing otis page, pease quote Procedure 808-42 Eaton 211 THAN BAW Dlooa WSExhaust Valve Roller Guide 908-43 Baw Overhaul 1. Inspect and check the exhaust valve rol quide. ‘See Procedure 908-4.1 2. It ts recommended thet the roller guide should ONLY be overhauled/dismantiad if + tregularies when turning the roller, + damage tothe roller, + larger clearance than stated on the Data sheet, + solzure marke on the slide surfaces, have been observed during the checking of ‘he roller guide. Note! For cisassembling ofthe roler guide, ‘contact an MAN B&W authorized repair shop. ILin the roller guide bushing. han veering otis pape, please quate Procedure 006-43 Fallon 277 MAN BAW Deel AS Pages908-44 Exhaust Valve Roller Guide | owning Ged) 1. Mount the ling tool forthe roller guide as o follows: Lit the lock ring of the tool up on the shaft ofthe lool Place the to! In such a manner that te {oot rests on the thrust plece in the bayo= et joint ofthe roller guide. “Turn the tool 90° so a to alow the foot to engage property inthe bayonet joint. so eS + Lower the lock ring, thereby securing the ‘oot in the locked positon, Lubricate the slicing surfaces of the roller and the roller guide, and lower & caretuly into the roter guide bushing Remove the iting ook 2. When mounting the roller guide, chock the clearance between the roller guide and the. ‘Guide plate maunted in the roller guide lin- “Turn the camshatt so that he roller quiae is lifed approx. 20 mm. Check thatthe cle lance between the roller guide and the ‘uid plate at both sides is within the limits slated in Data 3. Mount the actuator ‘See Procedure 908-34. Wher relering otis paga, please quote Procedure 308-4.4 Ealion 277 Page 44) MAN BAW Dios ASGe ‘SAFETY PRECAUTIONS ‘Stopped engine | Block the stating mechanism ‘Shut of starting ai eupply Engage turing gear Shut ff cooing water X | Shutoff tue of X | Shut ftiubieaing oi Lock turbocharger totore =] hon re MAN'BAW Drea! AS Exhaust Valve Cam Data | Standard Tools: See Section 913 fering to this page, please quote Data Sheet 108-5 Edition 07 108-5 Page)1085 ‘Spare Parts Deerton Exhaust Valve Cam Data please quote Data Shes 108-5 Eaton 07 MAN BAW Diss ASExhaust Valve Cam 908-61 raw Checking 1. Turn the crankthrow of the cylinder oon- cemned to TDC. Check and note down the {angle indicated on the turning wheel. 2. Turn in AHEAD direction uni the roller guide {measured on the activator plunger) i ited 47.0 mm, and calculate the angle A, which Is the number of degrees the orankthrow has turned from TOC position to the present poston. Continue turning aKEAD until the roller guide (measured on the activator plunger) is lifted 17.0 mm, and calouiate the angle B, which is the number of degrees the ‘tankthrow has turned fom TOO postion to the present positon. Note! | | When calculating the angles A and remember to lake into. scale on the turing wt £360 to 0 (zer0) degrees, 3, Caleulate the fead angle as: mater! 2 ‘The llustration shows the postion of the ‘exhaust cam when the piston of the rele: vant oylinder is in TOC. ‘Soe the Adjustment Sheet in Volume |, OP- ERATION, Chapter 701, for the “lead an- ‘g10" of th plant in question. 4. The cam lead angle can be checked visu- aly by reading directly the scale postion of ‘he exhaust cam over the marking scratch on the camshaft and comparing this angle with the angle stated In the Adjustment Sheet ‘At the same time, it Is recommended to ‘heck the postion of the camshat with the pin gauge. See Procedure 806-3. When refering to this page, please quote Procedure 8066.1 Editon 277 Paget (2) MaNBaW Diet AS‘SAFETY PRECAUTIONS. ‘Stopped engine Block he staring mechaniam ‘Shutoff staring a supply Engage tuning gear Shutoff coating water Shutoff ful of| LEER X | Shut oftttresting ot Lock turbocharger otrs Data DA Woightothighpressurepipa 62 kg De Satety valve tightening torque 65m non refering to this page, please guote Data Shoet 108-7 Eaton 70 MANBEW Diet AS Exhaust Valve cal Running - Data Standard Tools: See Section 913 ZY 108-7 reeExhaust Valve ‘Special Running Disengagement or re-engagement ofthe fuel pump roller guide or the exhaust valve rier guide must only take place at fongine standetl Engine trouble might require that @ cylinder be taken out of action. The engine can continue ‘operation with the fuel and exhaust eystems of a single cylinder disconnected. See Volume | Section 704, ‘This can take place with the exhaust vave locked in ether the open othe closed postion. Either way, carry out the folowing procedure: 1. Stop the engine. ‘Stop the camshaft oil pump. Lt the relevant fuel pump roller guide. See Procedure 909-10.1. 2. Dismante the hycrauic high-pressure pipe. Soe Procedure 908-1.2. 3. Dismantie the connecting sleave and the ol! inlet pipes. Digcard the sealing rings. Blank fff the connections trom the main ol pipe withthe plugs and union nuts. shaft housing. Turn the engine unt the ex aust roler guide is at TOC. '. Position the liting tool on the actuator and serew the spindle ino the top of the actua: tor piston Tighten the lowermost nut on the tool to pull up the roller guide as far as possible. Tighten the upper nut ofthe tool against the tower nut to secure the roller guide in this position 6. Ifthe eylinder isto operate with the exhaust valve closed, the air supply must remain connected tothe air cylinder of the exhaust valve, No further action fe required. han refering to his page, please quote Procedure 6067 Eaion 209 MAN BW Dito! NS 908-7 Page)908-7 Exhaust Valve ‘Special Running maw) 7 a He exlader Isto operat wth the extaust f | valve open, continu te procedie 8 allows 7. Turn off the air tothe exhaust valve, Flemove the safety valve, mounted near the bottom of the air cylinder, to lt the alr in side the air eylinder escape. 4— f | 8. Dismmantie the rotation indicator on the alt fylinder and mount the tool for opening of & io the exhaust valve, We) “The tool will keep the piston of the air ey Inder in the bottom position and thus keep the exhaust valve open. { Paez Wien aforing to his page,please quote Procedure 008-7 Falion 200 HAN BBW Diaeal ASExhaust Valve Special Running ‘Aft overhaul of the cylinder unit, re-engage the exhaust valve gear as follows: | 8. Loosen the nuts of the litng tool to lower | ‘he roller guide on to ne exhaust cam. Re- move the too! 410. the engine has been running withthe 6x haust valve open, remove the tool mounted i in the air eyinder and mount the rotation in loator and the safety valve. Note! “The rotation indicator should only be left | inthe engaged positon for short periods | ot time during operation ofthe engine Leaving the rotation indicator inthe ‘engaged position continuously might damage the exhaust valve due fo the for. malion of a wear groove in the air piston fof the exhaust valve Fe-connect the air supply tothe air cylin er, ‘Mount the oil init pipe and the connecting slogve on the actuator housing, aftr ing | ow sealing rings on the connacting loove. 12, Mount the hydrauilc high-pressure pipe. See Procedure 908-1.4 13. Engage the fuel pump roller guide. Soe Procedure 909-10.1. er een 1 epee, Dease use reece 7 Eon 209 908-7 Page 3Exhaust Valve Panel Plate 90851-160 When rlaring to iis page, pease quote Plate S85) Eaton Y60 MAN Bei Ditel ASPlate 90851-160 Exhaust Valve Panel Tem Ne. Part Description i art Description ore 28 053 065 or 89 080 m2 124 136, 148 150 161 173 185 197 207 ors 207 +) To0! panel Name plata Ling tool Ling toot (Cone ring Pressure testing device 0-50 bar (Gauge fr valve spindle Gringing mandrel for high preceure oes Foo or opening of exaust valve Measuring tool Too for hydraulic piston Gauge for valve seat Liting too or valve spite Ling too for exhaust valve goar ringing rng for eshaust valve seat Test too for blow-off valve ‘Compression too for fuel and exhaust spdnge *) Too! panel, complete with tals *) Optional extrasPlate 90861-97 Exhaust Valve - Tools tem Tom a Part Daseription ra Past Descsption (046. | Grinding machine, completa When ordering spare ps tothe Chris Marine manual lease rferPlate 90862-29 Exhaust Valve - Tools Won roaring to tie page, Please quote Plate 60802 Elion 2 MAN BBW Deal NSPlate 90862-29 Exhaust Valve - Tools Tom No. a6 28 oat 053 065 or Part Description tem No, Part Description yarautc jack Spacer ring O-ing with back up ring, 170/180 mm tng with back-p ring, 125/135 mm tua sotor, MESxS Hydraulic tool for extaust valve studs, complete| (om Fuel Pump Lead 109-1 Baw Data ‘SAFETY PRECAUTIONS, Standard Tools: See Section 918 [2] sempeeraice 1] Block hearing mechanism Zz, X | Shut ot starting air supply | Engage turing gear ‘Shutoff cooing water ‘Shutoff ue ol ‘Shutoff riatng of Lock turbocharger rotors Data D1 Measuring tol constant om 0-2 Lead change at 1 index mark on Park 4mm D3. ppacchange at 1 mm change oTlead 2abar D4 Index range of Pack 0-14 bar When refering to tis page, please quote Data Sheet 109-1 Edliion 19 Pago 1 (2) MAN BAW Dleal AISData Fuel Pump Lead Spare PartsFuel Pump Lead Checking 1. The fuel pump lead a (= the effective lead) 's defined asthe distance the top of the fet ump plunger is ited above the upper ‘edge of the upper cut-off holes in the fuel pump barrel when the piston ofthe cylinder foncened is In TOC, ‘The measuring too! constant D-t fe calcu lated at the point where the fuel pump plunger passes the upper edge of the upper futoft Roles at ViTindex D (zero). 2. Tum the engine in aieAo direction unt the ‘main piston of the cylinder concerned is ex aclly at TOC. See Procedure 9063.1. 909-11 Note! The correct distance x can only be meas- Lured when the fuel pump plunger Ie ints elvary stroke. ‘Won refering fo is page,please quote Procedure G65.17 Ean 221 MAN BBW rane! NS Pose)‘909-1.1 Fuel Pump Lead Checking (Gea) 3, Glose the fuel ol Inlet and outlet valves ‘Open the fuel pump drain cock, enabling ‘the ol to escape, 44. Flomove the pin In the forked lever which ‘connects the actuater and the VITindex ‘arm. Pull out the VITFindex arm to index O (22re) Dismantle the suction valve and the pune ture valve Sao Procedures 909-8.2 and 909-7.2. Note! ‘Before dismantling any pat of the tue! pump, make sure thatthe pump has been rlieved of pressure and thst all ot has been drained off Page? 8) When refering to tis page, pease quote Procedure 900-11 Eon 221 MAN BW Dis ASFuel Pump Lead 09-14 wee Checking {6 Mount the measuring tool ontop of the fuel pump top cove. Push the measuring pin fully down Into the ‘threaded hole in the top ofthe pump plunge Measure the distance x rom the top of the meaguting in fo the top of le crossbar, The fuel pump lead is thon calculated as: a=x—DA if the VItindax ie net "0" when measure ments takes place, the VITindex must be Incorporated into the calculations of the fuel ump fead: = x= D-t - “Vrhindex”. See Data, Note down the result for future reference, For adjustment of fuel pump lead, see Pro- cedure 909-1.3, 7. Remove the measuring tool from the fuel pump, place the O-rings on the suction valve and re-mount the puncture valve in the top ‘See Procedures 909-7.4 and 906-84 Close the fuel pump drain cock. ‘Open the fue ol inlet and outlet valves. iron seein io swage please gute Procedure 9097.1 Elion 221 Pages 6)‘Adjustment of the maximum combustion Bressure of a single cyinder can be effect. {ed by moving (relatively) the cut-of holes of the pump barrel in elation to the top of the pump plunger. 1¥ the maximum combustion pressure ie to bbe increased, corresponding to an increase of the lead a, increase the index on the Prac t8ck (VITindax arm), relative tO the increase required (advancing the injection moment), It tne maximum combustion pressure Is 10 bbe decreased, cortesponding to reduction of the lead a, decrease the index on the Poactack (ViFindex arm), relative to the decrease required (Fatarding the injection D-4 moment). 2. Before adjusting the pump lead, itis recom- | mended to disconnect the pump barel from | _ Petree auce orestsereseneau —Prorind 3. Adjust the servo alr cylinder by displacing Meet | © (eer so thatthe camber height X Is evan ly distributed. Adjust the Praxrack (VITindex arm) by dleplacing the connecting link E in accord ‘ance with the dlagram. Inordor to dlatributa any possible deviation, correspond to Index 7.0 On the Prue taCk 4. Ater this acjustment, assemble the fuel ump, ‘See Procedure 909-6. After some readings in sorvce, it may bo necessary to make a final adjustment ofthe rn reassure of the corresponding yin cer. 5. Adjustment of the Pax can be cartied out fon the individual fuel injection pumps by first removing pin B and then adjusting tink The link can be adjusted by approx. In ox marks ‘When refering to this page, please quote Procedure 908-1.3 Edition 221 WAN B&W Dimes AS Pagemd Fuel Pump Lead y Adjustment 6. If no further adjustment is possible accord ing to the above procedures, the cam disc has fo be agjuste, See Procedure 909-3. When referring to this page, please quote Procedure 8087.3 Edlion 221 MAN BBW Owe! NS 909-1.3 Passe)SAFETY PRECAUTIONS X] Stopped engine X | Block the staring mechanism X | Shuto staring alr supply Engage mr shut ot cooig wate shut otvetol Shut ot etn of [Lease or Data VIT System Data Standard Tools: See Secon 912 Ze When refering 0 hie pape, posse quot NAN BAW Diet NS a Shot 108-2 Ealnon 09 109.2 Paget109-2 Spare Parts ate No. esepton Page? VIT System Data ‘When roferring to this page, please quote Data Sheet 109-2 Edition 03 MAN BAW Diese AS(aaa VIT System Bay Adjustment ‘The engine may be equipped with ether a me- | chanical or an electronic VIT (Variable Injection Timing) system, Hf the fuel qualty has changed or if the fuel umps are worn, the Pay Will change. Adjust- 1 Ing the Pray ofall the cylinders is done by ad: justing the VIT systom inthe folowing way: Mechanleal VIT system 1. The pilot valves have been pre-adjusted to 05-55 bar contrcl alr proseure, corre sponding to 05-8.0 mm pressing-In of pin 5 He ‘To check a pilot valve already mounted on the engine, remove the inlet ang outlet pipe connections at A and P, and connect & pressure gauge at A and a pipe with work ing air (oressure 7 bay) at Py on the pilot vale. Check that the pressure on the pressure (gauge and the pressing-n of pin Cis in ac- cordance withthe curve Any necessary adjustment le done by turn- ing adjusting serew 8. 2. Fine adjustment of the Pmax pressure in the breakpoint (for all the cyfinders) Ie to be carried out by axial clsplacement of the bracket withthe pilot valve Roleaso tho screw and nut which secure the bracket with the pet valve tothe larger bracket through the Slotted hoes, Increase the Prax pressure by moving the pilot valve toward the lever. Decrease the Px pressure by moving the pilot valve away from the lover 5 See also Volume |, Chapter 708. ‘When refering to ie NAN BEW Oise AS Pago909-23 VIT system “Adjustment Electronic VIT system 3, The adjstment should be based on a set of indicator diagrams taken when the en- dine is running just above the breakpoint. 4. On the panel in the engine room contrel room, change the Pofss value in accord- lance’ with the required increase or de- crease in the Pay pressure. One graduation mark on the Pages Seale cotre= sponds to a change in Pay of 1 bar, 5, Check the adjustment by taking @ new set of indicator diagrams vile the engine Is running jst above the breakpoint. 6. The UP converter mounted on the engine Tecelves a 4-20 mA signa I from the eleo ‘tronic control system and converts this ito 14 0.5:5.5 bar control alr pressure Posner 7. To check the adjustment of the IP convert- operate the pane! in the engine control room to supply various signale Ito the UP convertor. For operation of the panel, see the panel ‘manuiacture’s instructions. On the pressure gauge mounted on the contol airline after the IP converter check that the control air pressures from the VP ‘converter are in accordanca withthe curve 8. Ifthe control alr pressure is not In accord- lance withthe curve, the IP converter must be adjusted. Remove the need of the VP converter and adjust the YP converter ac cording tothe manufacturer's Insitutions ‘uote Procedure 09:23 Eaon 208 Bagee@ ~~~ atoring fo ie page “ida seen 2(a ‘SAFETY PRECAUTIONS X ] Stopped engine Block te stating mechanism [XC] Shut of stating ar supply % | Engage turning gear [| shut ot cooing water | shut oft tuto [2] Shutoff kabricating of [| Leek turbocharger ors Data 1-1 Lead change at index mar On Pa "00K 2 pax change att mn change of ad D8 Index range of Page tack When refering to is page MAN BW Disel A'S Fuel Pump Cam Data 109.3 ‘Standard Tools: See Section 213 ZA id ny 29 bar 0-44 bar 1xamaxtm EE QS Paget1093 Fuel Pump Cam Data Spare Parts Pate nen Deestton 90801-00585 Gasket 1 Poe? Wien refering tote page, please quote Data Sheet 109-9 Elon 78 ee) " et MAN BSW Diesel ASFuel Pump Cam 9093.1 Es Checking 1, The lead € ofthe fuel cam Is defined as the number of mm the plunger is ited from its bottom positon when the main piston isin Toe. The load of the fuel cam dle nation of two readings, namely @ and b. Soe the sketeh, 2. Close the fuel oll niet and outlet valve, Open the fuel pump drain cock, enabling the oil 1 escape, ‘When refering to is page, ploase quate Procedure G60 1 Elon B72 MAN BAW Diwol ASFuel Pump Cam Checking Page When reforing tie page, 8. Dismamte the suction valve and the punc= ture valve, See Procedures 909-72 and 909-6.2, Note! Botore dismantling any part of the fuel pump, make sure the pump has been falioved of pressure and that all ll has been erained of 4. Remove the inspection cover infront of the {al eam from the camshaft housing 5, Turmthe engine, while noting the postion of the cam through the inspection hole, Stop turing when the rollers onthe lowest art ofthe cam, Le, where the roller guide, ‘and thus the pump plunger, is in the lowest position ‘quote Procedure 609.3, Ealion 272 THAN BW Digs ASFuel Pump Cam tsa hocking 8. Mount the measuring tool ontop of the fuel ump top cover. Push the measuring pin fully down into the ‘threaded hole In the top ofthe pump plung- Measure the distance x from the top of the measuring pin to the top of the crossbar Note down the result as b 7. Turn ahead until the main piston ofthe ey Inder concerned is In TDC. Soe Procedure 906-3.1, 8. Again measure the distance x from the top ff the measuring tool to the top of the crossbar. Note dawn the result a a, ‘The lead € ofthe fuel cam is thus ab. Example: Reading a = 87, ‘with main pisten in TOC, Reading b = 70, ‘with plunger in fowest position on e-bea7-7 7 Note down the result for comparison with the testbed resute and for future reference For adjustment of fuel cam lead, see Pro cedure 905-3.3 Mount te cover onthe camshaft housing 10, Mount the puncture vate andthe suction Soe Procedures 609-74 and 00-84, 1, Close the fue pump dan cock. Open the ue! oil inlet and outit valves, rng fo hs page,please quote Pracedire B6531 Eaton B72 MAN EW Dial AS909-3.3 Fuel Pump Cam Adfustment Before austing If Bmax I8 10 be adjusted by adjusting the fuel cam lead instead of adjusting 16 Prag tack, i Is recommended to set the Pnax rack tO its mid- dle positon (index 7 ata contol air pressure of { [itiily) | 223 bao petore agusting the tual cam toad (See Procedure 908-1.3) , 1. Supply @ control air pressure of 2.75 bar D-1 Y Note down the deviation x between the Llopersne D-2 present position of the Pay rack and is middie position, /| ter austig Maintain the pressure of 2:75 bar, and ad : Just the Prge rack to its middle position i ‘The deviation x must be incorporated into Present position (before adjusting link E): Index mark 9 (at 2.75 bar) fon) Lome on Middle positon (ater agusting link i 0 eee Deviation x 8.7 = 42 Index marks Purpose: To increase Pras 9 bat. Data: ‘Ae + ram change of fuel oam load corre sponds t0 Prax boing altered approx. 2-3 bar, the cam lead is fo be altered approx. i 3mm. Calculated change of fuel cam lead: Change of fuol cam lead + deviation x: 8+ 2= 6 mm change of fuel cam lead ‘The naw fuel cam lead ie then caleulated ‘The present fuel cam lead + the calculated change of fuel cam lead. See Procedure 9093.1. Note down the new fusl cam lead. When retring to ie page,please quote Procedure 3063.9 Eaton 212 MAN BBW Disa) ASFuel Pump Cam ‘Adjustment 2. Make sure that the reversing mechanism is in atea0 direction Remove the inspection cover trom the cam: shaft housing, Bofore dismanting any part of the ful ump, make eure thatthe pump has been ralieved of pessure and that has been drained of. 3, Dismount the pipe connections and the puncture valve from the fuel pump tap cov er, and mount the measuring too Measure the fuel cam load using the meas- uring too Soe Procedure 909.3.1. Compare the fuel cam load withthe valve Inthe Adjustment Sheet, and adjust the fuel pump cam as necessary. 4, Turn the camshaft until there is acoees to the oll cts in the fuel cam through the in- spection opening Remove the plugs trom the ol ducts (using, for instance, a serew-crver Inert three copper gaskets in each oll duct, Mount snap-on couplings in the olt duce, but do net tighten them. Fit hoses between the snap-on couplings and the distributor block and between the distributor block and the hydraulo hign- pressure pump. hen refering to is page, Place uote NAN BAW Dial A'S pane09.33 Fuel Pump Cam Adjustment fae 5. Mount the special spanner on the fuel cam disc, ensuring that the two pins enter the holes In the cam, 6. Apply light pressure tothe hydraullo system and, after venting the system, tighten the ‘snap-on couplings. Raise the nydraulic pressure unt ol seeps ‘ut along the camshat under tne cam disc. ‘Turn the cam dise, using the fited spanner, Until the desired change of lead is read a rectly on the measuring tool. (The neces sary turning of the cam asc fs calculated as described in Procedures 909-1.1 and 909 3.1) ‘Te increase load and Prax turn the eam dise AAD, ‘Te reduce lead and Pax turn the eam dige ASTERM, 7. After completing the desired turing of the cam disc, relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. ‘Alor at east 36 minutes — the oam must be ‘aliowod time to “att” — before mounting the plugs again in the of ducts of the cam die ‘Aer carrying out agjustment, measure the fuel pump lead again See Procedure 909-1.1, and re-adust the cam if required. Note down and lle the new resuls for pur- [poses of comparison with future measure- ‘ments and adjustment. _, 8. Mount the inspection cover on the camshaft housing. 9. Re-mount the suction valve and the pune- ture valve. ‘See Procedures 909-7.4 and 908-8.4, Page 8) Wan ering to tis page,please gubie Procedure 209-33 Fallon 212 THAN BAW Diees| AS‘SAFETY PRECAUTIONS. ‘Stopped engine Block the starting mechanism Shutoff stating i suply Engage tuning gear Shut off cooling water ‘Shutoff tue ol ‘Shutoff itricatng of Lock turbocharger rotors E Omen 1-1 Tightening pressure pump Pousing ruts 1500 bar 5.2 Pump housing, complota 750Kg 0.2 Bottom pate ekg ‘D-4_ Dismanting pressure - pump housing nuts 1500-1650 bar DS Serening-n torque — top cover suds 400 8m when referting to this page, please quote Data She MAN AW Dies A'S Fuel Pump Data 109-4 Standard Tools: See Section 913 ZX —- == 40-700 axim team sant 5108-4 Eaton 19 Paget @)109-4 ‘Spare Parts 0001-163 054 8000-162 066 0001-169 078 0901-169 091 0001-169 208 ‘0001-169 170 Page ze) Data Fuel Pump Deepen Gasket Gasket Plug scrow Packing Gasket Felt ing oy 1 3 2 1 1 2 Wen refering otis page, pleas quote Oata Shoot 109-4 Ean 19 MAN B8W Disa! A'SFuel Pump 909-4.2 Dismanting 1. Close the fuel ol inet and outlet valves, (Open the drain cock, enabling the oll toe cape Before dismanting any pump, make sure thatthe pump been relioved of pressure and that all ol has been drained oft. 2, Dismantle the fusl pump top cover. ‘See Procedure 909-5.2 3. Dismant the barreliplunger assembly. See Procedure 909-62. 4. Remove the screws holding the fuel of inlet pipe between he fuel pump and tho fuel in- let valve Remove the fuel oil inlet pip. Flomove the screws holding the fue oll aut- let pipe between the fuel pump and the fue} outlet vaive Femove the fuel ol outiet pipe. Discard the gaskets. Femove the drain pipes from the fuel pump Remove the contol air pipes from the ac- tuator for the VIT index arm. ‘When refering to this pape, please quote Procedure 80842 Eaton 213 Page 1) MAN Baw Dose AS900-4.2 Fuel Pump Dismanting 6, Place four spacer rings over tho nuts of the fuel pump housing, and screw the four hy- ‘raul jacks onto the studs, Connect the high-pressure pump to the jacks by meane of the dstbutor block ang the high-pressure hoses. Using the vent sorews ofthe hydraulic nuts, vent the system and increase the pressure fa stated In Data For operation of the hyaraulle tool, see Procedure $1941, Loosen the nuts by applying the tommy bar through the slots inthe Spacer rings. Foliove the system of pressure. Disconnect the high-pressure hoses trom the jacks. Finaly, remove the hydraulic jacks. and spacer rings, and unscrew the nuts. 7. Fitthe iting tool using the top cover studs/ ruts, and ifthe pump housing away “Tako care not to damage the threads of tho studs Land the fuel pump on wooden planks. uote Procedure 909-42 Editon 373 WAN BAW Disa ASFuel Pump 909-43 4. the fuel index arm or the VIT index arm | 9. of the fuel pump Is moving too tight, the regulating and timing systems of the fuel ‘pump must be overhauled, 2. In order to carry out this overhaul, the top cover and plungeribarcel assembly of the fuel pump must have been removed, and the fuol pump must have been dismantled ‘rom the pump base and landed on wooden planks. ‘See Procedure 909-4.2. See Procedure 9095.2 i Soe Procedure 909-62 8, Dismante the actuator and actuator brack- at. 4. Tithe fuol pump housing ino a horizontal positon an the wooden planks. i 5. Dismentio the screws and the bottom plate ‘rom the fuel pump housing. Ifthe bottom plate is stuck, loosen it by | sorewing two M1Ox120 mm screws into the ‘noes ofthe bottom plate. ‘ihan reforing to is page, please quote Procedure 0004.3 Eaiion 218 Pages MAN BBW Datel A'Si 909-4.3 Fuel Pump ‘eta ey 8. 6. Dismantie the: + Fut index aren + Sleeve + Regulating guide 7. Dement the: + Guide serew + VIT index aem + Timing guide Remove the caps and the cover fom the ‘back of the fuel pump housing, Remove the orifice plug from the front side ‘of the fuel pump housing, Discard all sealing rings and gaskets. Pagez@) When reforing ois page, lease guoleProedire 800-49 Eaton 273 / Pees Tae ‘ant a Dia 8Fuel Pump 9094.3 saw Overhaul 8. Dismantie and inspect the plug screws in | 9. bot sides ofthe fue! pump housing, 1 eroded, replace the plug sorewe, 410. Clean all the dismantled parts of the fuel ump thoroughly in diesel olor Kerosene. Blow dry with compressed ai. (Clean all inside surfaces of the fuel pump housing. Blow through al the bores ofthe fuel pump housing with compressed ait 11, Mount new sealing rings and gaskets. Mount the caps, the cover and the orice plug Mount new sealing rings on the plug sorews land mount the plug screws. Note! Lubricate the tieads of ll the parts with Molybdenum Disuiphide (MeS,) before mounting, 12, Mount new sealing rings on the unions. Note! ‘Soak the seating rings in lubricating of before mounting ‘2 ‘Wher refering to this page,please quote Procedure S05-43 Fallon 213 —~—~=~SCS*S*~S~S~S~S~« OS) MANES Diet A'S| 909-43 Fuel Pump Orr (aa Mounting 13. Lubricate the following with molybdenum sulphide (MoS) + all interna surfaces of the fuel pump housing + the siding sutaces of al parts ofthe regulating and timing systems, + the teeth ofthe: regulating guide timing guide VT index arm fuel index arm 14, Mount the VIT index arm and the guide ‘Adjust the positon ofthe VIT index arm so ‘that the serateh mark ie aligned with the ‘centre of he fuel pump housing, 15. Mount the timing guide in the fuel pump housing “The timing guide must be mounted in such ‘away that the eeratch marks on the timing ‘uide, on the VIT index arm and on the fuel pump housing are aligned, 16. Mount the sleave in the fuel pump housing, ‘ensuring that the notch in the side of the sleeve Is aligned with the pin hole In the fuel pump housing. A ie Pages®) When elering to this page, ploase quote Procadure 9004.3 Ealion 213, MAN BAW Dlaeel NSFuel Pump Gaa\ Ove 90943 17. Mount the fue index arm, ‘Adjust the position ofthe fuel Index arm £0 that tho scratch mark onthe fue index arm is aligned withthe centre of the fuel pump housing 416. Mount the regulating guide inthe fuel pump housing ‘The regulating guide must be mounted so that the scratch mark on the. regulating ‘guide is aligned withthe seratch mark on ‘ho fue! Index arm. 19, Mount the bottom plate on the fuel pump housing, 20. Return the fuel pump to a vatical postion. ‘Mount the actuator and actuator brackat on the sige of the fuel pump. Pae7909-4.4 Fuel Pump Mounting 41. Before mounting the fuel pump housing, make sure that all slicing faces anc threads fare cleaned and Wbricated with MOLYROTE antiition spray D321R oF molybdenum dh sulphide (MoS) ‘See Procedure 919-11, 2. Mount the lifing too! on the fuel pump top cover studs. Lift the fuel pump housing on to the pump base, taking care not fo dam age the treads ofthe studs Remove the iting tool 3, Mount the nuts on the studs and seven down, Place the spacer rings, one arcund each fut, and mount the tydrauic jacks on the studs Connect the high-pressure pump to the Jacks by means of the dstbutor Block and the high-pressure hoses. Use the vont screws ofthe hyeraulc nuts to vent the system, and then increase the pressure as stated in Data, For operation of the hydraulic tools, see Procedure 919-1 “Tighten the nuts by applying the tommy b though the lols inthe spacer rings. Peeve tne syste oF pressure Fialy, remove the hydraulic jacks and ‘Spacer rings trom the nus. Fae) ~ Wan reenng to tis page, please quote Procedure 908-44 Ealion 273 ‘WAN dew Diese ASFuel Pump 4. Mount the drain pipes on the fuel pump housing. Connect the contr! air pas to the forthe VIT index arm. tu 5. Fit new gaskets on the fuel pump inlet and coutlt pipes. Mount the pipes between the {el pump housing and the fuel ol inlet and outlet valves, 6. Mount the barcel assembly in the fuel pump housing. Seo Procedure 909-64 7. Mount the top cover on the fuol pump hous Ing. See Procedure 909-5.4 8. Mount the combined suction and puncture valve, the tain oll pipes, and the com: pressed air pipes. See Procedure 909-7.4 9. Close the drain cock and open the fuel oll Inlet and outet valves. Mounting 6. ‘Winn refering to his page, ploase quote Prosodure 609-44 Eaton 273 MAN B&W Dies NS Page‘SAFETY PRECAUTIONS. X_] Stoppes engine | Block the staring mechanism X | Shut of starting supply | Engage turing gear ‘Shut of cooing water Shutoff fuel ol ‘Shutoff ubricetng [Foc tucoacharger rotors Data ot eetin +t Weight of top cover (2-2 Max. milinglgrinding ameter of seat D2 Tighoring torque — top cover Fuel Pump Top Cover Data Zs —z ————= 140-760Nm @ a0 19019 26mm 700m When refering to this page, please quoto Data Shost 109° Eaion 19 MAN BAW Distal AS Standard Tools: See Section 913 Paget (2)1095 Spare Parts, 0901-169 017 0901-169 532 0901-169 556 Fuel Pump Top Cover Data Desreton Seating ng Lock sn Gasket 7 ear =] When roering ots page,please quo aaa Data Shoot 109-5 Elton 19 MAN BW Diesel ASFuel Pump Top Cover BR 1. Shut off the fusl ol inet and outet valves. Open the drain cock (at the bettom of the ump housing), and drain off any ol loft in the high-pressure pipe and the fuel pump. Note! Before dismanting any part ofthe fuel pump, make sure thatthe pump has been relieved of pressure and that al oll has been drained oft Dismount al drain pipes and the contol air Pipe. Digrmount the high-pressure pipes between the top cover and the fuel valves ‘Soe Procedtre 909-14.2 2. Unserew the lock pin from the plug screw. Unscrew the plug screw. Discard the tock pin and the seating ring. Mount an eye bot in the top of the suction valve. Remove the top cover fixing nuts and ‘mount the dismanting screws for top cover in the two threaded holes. Pull the top cover with suction valve and puncture valve fee by tightening the ols- ‘manting screws, When the top cover is loose, remove the ismantiing screws. and hook the engine room crane on to the eye bolt 3. Lit the top cover carefully of. For overhaul of top cover, puncture valve and suction vaive, 886 Procedures 909-5.3, 908-7.3, 909-83. Discard the gasket ie MAN BAW Dies A'S Dismanting 9095.2 faring otis page, please quot Procedure 600 62 Ellon 274 Page)9095.3 Fuel Pump Top Cover Overhaul 1. Dismount the puncture valve from the top ‘See Procedure 909-82. s Dismantle the suction valve trom the top ‘See Procedure 909-72 Dismount the pipes frm the top cover Remove and discard the sealing ring from the top cover. Fl the oll ducts ofthe top cover with vi line or heavy grease. ‘Screw the guide, with the miller, into the high-pressure pipe theead. Mil the seat unt a smooth surtace is achieved. Note! Mako eure thatthe maximum diameter of | ‘ho seat Is rot oxcoades. tor conplaing te ling use con: 10d airto blow the vaselina/ grease out from the ol ducts CCiean the top cover with dese ollgas oll, and blow dry with compressed at. Note! Make sure that all bores and threads insse te top caver ae absolutely lean, | If necessary, recondition the seats of the {vet oil high-pressure pipes. ‘See Procedure 909-14.3. Pago2(@) When afoing to this page, please quote Procedure 000-6.9 Eaton 214 MAN B&W Blea! NSFuel Pump Top Cover Overhaul ‘5. Before mounting the new sealing ring on ‘he fuel pump top cover, heat the sealing fing to 200-240°C for approx. ve minutes. No Do not exceed the temperature limits 66. Mount the cone on the fuel pump top cover. Pace the sealing ring withthe ‘on tho cone. pring inside ‘Make sure that the ‘open’ sige ofthe seal- In ring is facing the lower end ofthe fuel ump top cover, se the sketch. Use the pusher tool 1 pust the seating ring into the groove, After mounting the sealing ring, compress it by pressing the “sizer too! over the sealing ring. 7. Mount a new or overhauled suction valve in the fuel pump top cover ‘See Procedure 909-7-4 Mount a new or overhauled puncture valve in the uel pump top cover See Procedure 909°8.4 Mount the pipes onthe fuel pump top cover. When ralering ois page, please ue Prose MAN BAW Dial AS 20859 Elion 278 [fs ] a5 3)