‘90012-0801 S50MC-C Volume II Edition 4 MAINTENANCEInstructions for Main Engines This book forms part of a set of books consisting of three volumes ented: Vol! OPERATION Vol. tI MAINTENANCE Vol. ill COMPONENTS, DESCRIPTIONS ‘The purpose of these books isto provide general guidance on operation and maintenance and to describe the constructional features ofa standard version of an MAN B&W main diesel en- gine. Deviations may be found in a specific plant. In addition, the books can be used for ret erence purposes, for instance in correspondence and when ordering spare parts. !tis essential thatthe folowing datas stated in spare parts orders as itis used by us to ensure ‘the supply ofthe correct parts forthe individual engines: 1. Name of vessel 2. Engine No. bit by 3. Pate No. 4. PartNo, 5. Quantity required (and description) Example: M/S Nybo - 7730 BAW - 90201-0036 «) ~ 059 10 of (piston ring) +4) he Pate No, may const of eter of hese two sete ots, a the pages are nthe press oan upsato wth now nomber: P90207-0036 0 80203-036. Furthermore, to ensure optimum efficiency, relialily and lifetime of the engine and its com- Ponents, only original spare parts should be used. ‘The designation *D" used in texts and ilustrations refers tothe information given on the data sheets inserted in the respective books. Note: This standard edion of the instruction book doesnot refer to any specific engine plat, so the design features described may fer from those actualy found on a ven engine. Furthermore, on afew points, more than one soliton may be described. {As reliable and economical operation of the diesel engines is conditional onthe correct oper- ation and maintenance, its essential thet the engine room porsonnel are fully acquainted with ‘the contents ofthis book ‘Ths book is subject to copyright protection. The book must not, either wholly or partly, be cop- ied, reproduced, made public or in any other way made avaliable to a third party without the ‘written consent ofthis effect from MAN B&W Diesel AS. MAN B&W Diesel A/S Togiholmsgade 41 Teloph.:+45 39 85 11 00 10K-2450 Copenhagen Telex 16502 manbw dk Denmark Telofaxt45 33 85 10.50 ‘as0022-0008= leTable of Contents 900 maw’ ‘Volume I! ~ Maintenance No. Edltion Title Workcards in Procedures . Ase Instructions for Maln Engine 900 Introduction 90001 0048 Cross Section through Engine 900 0031 Table of contents 900-1 0219 Checking and Maintenance Schedules 901 Cylinder Cover 101-1 0025 cylinder Cover, Data 801-1 0218 Cynder Cover 90151 0184 Cylinder Cover Pane! 90181 0084 Cytinder Cover — Tools 80161 0096 Cylinder Cover Tools 90162 0015 Cylinder Liner Extra Too! 902 Piston with Rod and Stutting Box 1021 0030 Piston, Data 98024 0226 Piston 1022 0025 Piston Rod Stuting Box 8022 0214 Piston Rod Stuffing Box 80251 0237 Piston and Piston Rod Panel 90281 0100 Piston and Piston Rod ~ Tools 80264 0002 Piston and Piston Rod - Tools 903 Cylinder Liner and Cylinder Lubrication 108-1 0030 Cytinder Liner, Data 903-1 0226 Oylinder Liner 103-1 0036 Cylinder Liner, Data 903-1 0228 Cylinder Liner 103-2 0015 Cylinder Lubricator, Data 903-2 ° 0226 Cylinder Lubricatore 108-2 0016 Cylinder Lubricator, Data ‘Wan refering otis pane, please quota Table of Contants AGG040 Eaton O37 Pago MAN BAW Desa ASTable of Contents Volume ii ~ Maintenance 900 No, Eation Tite 905-2 0227 cylinder Lubricatore 80961 0081 Cylinder Liner, Toole 90862 - 0002 Cylinder Linor- Extra Toole 80564 0001 Test Equipment Alpha Lubricator 900 eed with Connecting Red 104-1 CCrosshead Bearing, Data 904-1 CCrosshead Bearing i042 Crosshead, Data e042 Crosshead 1043 Reciprocating Parte, Data 9043 0213 Reciprocating Parts 104-4 0081 Crankpin Bearing, Data, 906-8 0215 Grankpin Bearing 1045 0025 Connecting Rod, Data 804-5 - 0219 Connecting Rod 80451 0138 Connecting Rod and Crosshead Pane! 80481 0044 Connecting Rod - Toots ‘90482 0020. Connecting Rod ~ Tools 905 Crankshaft, Thrust Bearing and Turning Gear 105-1 0008 Crankshaft Deflection, Data 905-1 0207 Crankshaft Defection 105-2 0028 Main Bearing, Data 905-2 0230 Main Bearing 105-8 0024 Thrust Boaring, Data a 9058 0217 Thrust Bearing 105-4 0003 Journal Bearing, Data 905-4 9208 Journal Bearing 1055 0021 Axial Vibration Damper, Data 905-5 0221 Axial Vibration Damper Page 2 ‘When referring to this page, ple ey Workcards in Procedures aor Sage quate Taba of Cartons AB0040 Elion O03 MAN BW Ole ASNo. 405-7 905-7 1058 905-8 90581 90561 90562 90568 90565 90570 906 106-1 906-1 906-1 1062 906.2 1062 1063 106-3 9063 106-4 906-4 1065 906.5 1066 906.6 90651 0661 ‘Wher refering otis pape, pease quote Tabie of Cantante AB0040 Elion O03 Table of Contents Volume i Edition Tite 002 0201 0002, 202. 0088 ons oor oor 002 Tacho Pick-ups, Data Tacho Pick-ups ‘Angle Encoder, Data Angle Encoder Crankshaft, Thrust Shaft, Main Bearing, Pane, etc Main Besving and Thrust Bearing — Tools CCrankshat - Toole Tuning Wheel ~ Toots Main Bearing —Liting Tools Thrusishatt— Tools Mechanical Control Gear 02s 20a ozs 007 208 08 002 020 0203 core ons. 002. 001 201 0179 062 Chain, Data Chain Chain ‘Chain Tightoner, Data ‘Chain Tightoner (Chain Tightener, Data Camshat, Data Camshaft, Data Camehatt Camshaft Bearings, Data Camshaft Bearings Moment Compensster, Dat Moment Compensator oplacement of Gams on Gamshatt, Data Replacement of Gams on Camshaft (Chain Drive and Camshaft Panel (Camshaft - Tools MAN BW Distal A'S Maintenance 900 Workcards in Procedures sahamentovo Table of Contents Voline = alnorance (aN No. Edition Title Workcards in Procedures ‘ming osnanng Owrtoa! Mostra smart 90682 0040 Camshaft ~ Toole 907 Starting Air System 107-1 0002 Starting Al Distributor, Data 907-1 0204 Starting Alr Distributor 407-1 0005 Starting Alr Distibutor, Data 807-1 0207 Stating AlrDistibutor 107-2 0022 Starting Air Valve, Data 907-2 0211 Staring Ar Valve 908 Exhaust Valve 108-1 0017 High-Pressure Pipe, Da 908-1 0212 High-Pressure Pipe 108-2 0025 Exhaust Vale, Data 908-2 0221 Exhaust Valve 1089 0017 Exhaust Valve Actuator, Data 908-3 0212 Exhaust Valve Actustor 908-3 0218 Exhaust Valve Actuator 108-4 0015 Exhaust Valve Roller Guide, Data 908-4 0210 Exhaust Valve Roller Guide 408-5 0002 Exhaust Valve Cam, Data 908-5 0203 Exhaust Valve Cam 108-7 0020 Exhaust Valve Spocial Running, Data 908-7 0210 Exhaust Valve Special Running 90851 0169 Exhaust Valve Pane! 90861 0036 Exhaust Valve - Tools 90882 0025 Exhaust Valve - Toole 90863 0009 Exhaust Valve - Extra Toole 909 Fuel system 1081 0035 Fuel Pump Lead, Di Page <7 When refring is pe, plese gute Tale of Corer aero 25)Table of Contents Volume il - Maintenance 900 No. Edition Title Workeards in Procedures Cheng mate Oral Mast 9081 0231 Fuel Pump Lead Ee 108-3 0025 Fuel Pump Cam, Data 909-3 0213 Fuet Pump Cam 109-4 0024 Fuel Pump, Data 909-4 0216 Fuel Pump 109-5 0025 Fuel Pump Top Cover, Data 9085 0208 Fuel Pump Top Cover 409-6 0021 Fuel Pump Bawel Assembly, Data 908.6 0212 Fuel Pump Bartel Assembly 109-7 0011 Fuel Pump Suction Valve, Data 908-7 0210 Fuel Pump Suction Valve 109-8 0022 Fuel Pump Puncture Valve, Data 909-8 0213 Fuel Pump Puncture Valve 108-8 0011 Fuel Pump Shock Absorber, Data 908-9 0212 Fuel Pump Shock Absorber 109-11 0031 Fuel Vatve, Data 909-11 0220 Fuel Valve 909-17 0228 Fuel Valve 109-12 0028 Spindle Guide, Data 00012 0817 Gpindle Guide 108-13 0018 Non-return Valve 909-13 0204 Non-return Valve 108-14 0040 Fuol Ol High-Pressure Pipe, Data 908-14 0205 Fuel Oll High-Pressure Pipe 908-14 0210 Fuel Oil High-Pressure Pipe 109-18 0029 Fuel Pump Roller Guide, Data 909-15 0210 Fue! Pump Roller Guide 108-16 0013 Fuel Pump Special Running, Data 909-16 0209 Fuel Pump Special Running 90951 0396 Fuel Valve and Fuel Pump Pane! 90961 0059 Fuel Ot System — Toole ‘When refering to is page, pease quote Table of Contnis AS0040 Ealion 37 ~~ gE NON BSW Daal900 Table of Contents Volume ll—Maintonance No. Edition Title ‘Workcards In Procedures meting Oemaeg Ova! Stig samen 90962 0058 Mounting Tools for Fuel Pump Seals 90963 0009 Fue! Valve Toole 90966 0001 Fuel Vawve Nozzle -Tools 810 Turbocharger System 110-1 0025. Air Cooter Element, Data 810-1 0222 AirCooler Element 110-1 0629 Air Cooler Element, Data 910-1 0228 AirCooler Elomant 110-2 0008 Non-Retumn Valve, Data 910-2 0206 Non-Return Valve 1108 0002 Auxiliary Blower, Data 8108 0206 Aunillay Blower 110-5 0005 Turbocharger Turbine, Data 810-5 0208 Turbocharger Turbine 110-6 0018 Water Mist Catcher, Data 810-6 0214 Water Mict Catal 81051 0041 Cooler and Turbocharger Panel, Exhaust 81051 0042 Cooler and Turbocharger Panel, Aft 91081 0058 Ale Cosler System — Tools O11 Safety Equipment 111-1 0021 Safety Valve, Data 91141 0209 Safely Valve 111-2 0008 Reliet Vave, Data 911-2 0211 Reliet Vave 912 Assembly of Large Parts 112-1 0007 Holding-down and End Chock Bats, Data 8121 0008 Holiing-down end End Chock Bolts (Cast Iron) Page 8m ‘When referring to this page, please quote Table of Contents ‘0040 Eaiion 6061(Ga Table of Contents Volume Il - Maintenance No. Edition Tite 1122 oco7 9122 207 782225 0000 792226 0002 4123 0008 9129 0209 91261 0057 91263 0051 Holding-down and End Chock Botts, 0: Holding-down and End Chock Botts (Epoxy) Checking Hycraulcally Tightened Holding down Botts, MC Engines Checking Side Chocks and End Chocks with Bolis, MC Engines Stay Botts, Data Stay Bolts Large Parts ~ Toots Hydraulle Tools for Helding-down Bolts and End Chock Bots 913. General Tools 9131 0210 e184 0201 9135 0205 913.6 0205 919-7 0206 913-11 0204 91351 0037 91356 0058 91357 0005 81358 0013 91359 0008, 91380 0003, 91351 0052 91352 0064 91953 0035 91354 0059 91386 0063 91386 0064 91988 0004 When refering t this page, please quote Taba of Contents 420040 Exton 008) Hydraulic Tools Standard Tightoning Torques ‘Torque Spanner ‘Tightening Gauge Screws and Nuts Lubricating Procedures ‘Accessorie for Hydrauile Toole Liting Toos, ete. Open Ended Spanners Open Ended Sugging Spanners Torque Wrenches hors ‘Combination Spanners| Ring Stugging Spenners + Spanners Open-Ended Spanners Intrumente Instruments ‘Working platforms MAN BAW Diol NS 900 Workcards in Procedures Contig aang Ont sine Page?)The Checking and Maintenance Schedules indi cate tha intervals at which iis ceered appropt ate to inspoct the individual components of the engine and to carry out overhauls, necessary, based on the engine condition or on time ertria ‘The stated Normal hours of service should only be Used as 2 guide, as cfferonces inthe actual Checking and Maintenance Schedules vil decisively influence the actual service sls, and thus the iniervals between necessary overhauling Design modiications may necessitate a revision ‘ofthe Insitutions, in whicn case the revised in. siructions and changed overhauling intorvals, ‘any, wl apply and supersede those orginally is service conditions, the quaty ofthe fue ilo Iu bricating ol, the treatment of cooling water, ee sued (se8 6.9 our Service Leto). ‘The procedures are divided into three categories: Condition checking procedures marked under the heading Normal hours of service with aC, {eal withthe service condition of a number of engine compo- ‘ents, and form the basis for estmating whether further over. | hauling is necessary, In @ numberof eases the condition | checking procedures refer to Volume! o! he instruction book, in Which more detaied descriptions and working procedures can be found, Contiton-based overhauling procedures: those procedures which under the heading Normal hours of Service are marked with an O, and opposite which, under the heading Overhaul to be based on procedure No, (column *), 4 procedure number is stated This procedure number normally ‘eles to one ofthe above con- ition checking procedures which form the bass ofthe overha For this reason, the intervals stated are fr guidance only. ‘Time-based overhauling proce- ures also marked with an 0 unde: the headings Normal hours of service or Based on observations, aro tha procedures where an actual basis for ectimaton is lacking. It's recommended, therefore, to carry out these procedures atthe overhauling inter vals stated ae a basi. \Whare a symbol O or Cis incicated In Based on observations {Column 8), this is due 1o the fact thet special corvice conditions ‘ay make checking or overhauling necessary beyond the actual standard schedules indicates. ‘ier eforing to Wis page, pleasa quote Maintenance Schedules 600-1 Eaton 275 MAN BAW Disel AS 16Ken Checking and Maintenance Schedules ‘900-1 Baw . Vi See voume operon” 1 Chea newlovriuld pars wot 6007500 Rous 1: Adjustrano ba earind out 3: Baead on obaeratons (C: Cheek the cnaton : Ovetnaulo be based on proce Noe tera DM: See matersnseuctons (0: Overhaul be caret out ‘Neal oie serve 000) Nos Procedure wiel«lelelwleal 901 cylinder Cover (When refering tos pape. please quote Mantonance Schedules SG0-1 Eaiion 21 ———~Paga 2S) MAN Ba Datel NS| (oad Checking and Maintenance Schedules 900-1 i Vi Soo Vouma Operon” 1 Chest newovrnads pars wot S00 TE00 Fours 1A: Aajstrant be ear ot 3 Based on observations (C: Check he contin : Overhslto be based on procedure Noo forte 1M: Soemater nrtone (0: Overhaul tobe canodout Teal ous sen OG No, Procedure wl2[«lele{wle] None exaust vaes: hone vte 600 fours oven 6000 (Wen referring to hs page, please Guoia Maintenance Schedules 00-1 Eaton 278 ——~Page 9) MAN Baw Ditel NS(a) Checking and Maintenance Schedules 900-1 Ve See Viana TOpraion™ 1A: Aajstmont to be erin ot : Crek te conaion MM Soematersinarctone (0 Oven tobe cared out TW: Check newoveaued pas wher S00 G0 Faure 2B: Sased onabservatons 'P: Overhaul tobe based on procedure Noo torts Tima bore a unica 6000) Perorserreasi Sateen eres Hira |12 Spincte Guidemon-Return Vave ‘Checking and adjustment of tring gear eviten Ther refering o his pape, please quote Malnienance Schedles 9001 Faion 278 MAN B&W Diesel AS Paes)Checking and Maintenance Schedules 900-1 Vr See vena Opera” TW Check nowoveiaub pars sor 0 700 ous A Adjustment be cated ut Baro on observations : heck the condor Overhaul to ba bases on procedure Noe lero MU: See mater inductions (0: Ovehau tbe eared out Toma fours a serves 67005) No. Procedure wl2tal[s[elwle] ep lor2 Assombly of Large Parts ots cane Tota Eee: os ‘Won ratering ois pape, please quale Maintenance Schadsles 6901 Eaton 719 -Page 56) MAN BAW Diet AS(Ga) SAFETY PRECAUTIONS Stopped engine P=] Block he starting mechaniem Shut of stating ar supply Engage turning oor ‘Shut off cooing water Shut offal ot Shut off ubriceting of Lock turbocharger rtore moe xx] Data DA Weight of exhaust valve std D2 Weightofey cover compl, Ds Weight of cooing jacket D4 Serowing-n torque for exhaust vale suds DS Scrowingin toque for staring valve cde 6 Screwingn torque for ful vale etude 1-7 Weight of high pressure pipe exnaust vate) D8 Hyrule pressure for ejlner cover ‘smarting tightening D9 Tightering torque ‘uel of high-pressure pipe (et pupa valve) Det0 Tigtering torque. high pressure pipe (exaust vale) When referring to this page, please quote Data Sheet 101-1 Edition 25. NaN Baw Diol NS Cylinder Cover tort Data ‘Standard Tools: Soe Secon 918 Zz, —= —o ——== sos000n 2010 | pemeeat 33m. 8x1m 170% 40% ~ —s sonm | Qe 45m Le conn a aie 1500-1650 tar 100 er conn 6m Pagetor : Cylinder Cover Spare Parts | eat i, cept oy 801Gte 14 Orings 2 | 80r0t20% 188 Sealing Hing i sosazve% 201 Orings 4 Page 2) ‘Winenreering to tis page please qvote Data Sheet 107-1 Elion 25 ‘MAN BAW Dioss NS‘S5OMC-C 1 Winter refering to this pape, please quole Procedure 807-12 Eon 15 Dismanting Set th blocking device A on the main start ing valve in the BLOCKED poston, Engage the turning gear 8. Close the fuel ol inlet valve ©, (Close the cooting water Inlet valve D. Close the cooling water outlet valve E. (Open the cooling water drain cocks F anc s ‘Shut of he controlar and safety ar supply. Vent the manoeuvring system through the ball valve, ‘Also shut of the air supply on the eduction tnt for the hycraulcfpneumatle exhaust valve, and vont the system, MANAW abel VS Cylinder Cover Page 1 (0)901-42 Cylinder Cover ‘S50MC-C Dismanting 2. Remove the cooling water init and outlet pipes trom the exraust valve and eylnder Remove the drain pipe from the intormed ate pipe between the cylinder cover and the ‘exhaust vale, DDismount the fuel oll high-pressure pipes btween the fuel valves and pump. Dismount the contol air pipe from 1 Ing valve. Flomove the stating air pips, 3, Remove the screws which fasten the high- pressure pips to the oll cyindsr on the ex hhaust valve and the hydraulic activator, and lit the high-pressure pipe away DDismount the drain ol pipe between the ex- haust valve and the hycrauile activator, the ‘air pipe for the pneumatic exhaust vale, land the pipes for the sealing alt arrange: ment 4. Romove the protective jacket enclosing the intermaciate pipe between the exhaust re ccelver and the exhaust valve DDismount the scrows inthe flange between tie intermediate pipe and the exhaust re elven The four lowermost scree need net be dismantled, ust loosened. Remove the protective caps from the cylin: ‘oer cover nuts Page z When ralering to tis page please qvole Procedure 907-12 Eaibon 8 ‘MAN BAW Diet AS‘S50MC-C . Cylinder Cover Dismanting 901-12 55. Place eight spacer rings over the nuts, anc screw the eight hysraulle jacks onto the tude Connect the high-pressure pump to th jacks by means ofthe distributor block and the high-pressure hoses. Using the vent screws of the hydraulio nuts, vent the sysiom and increase the pressure ‘8 stated in Data. For operation of the bycraulle tools, see Procedure 912+ ‘Loosen the nuts by applying the tommy bar {through the slots in the spacer rings. Relieve the system of pressure. Disconnect the high-pressure hoses from the jacks. Finally, remove the hydraulic jacks and spacer rings, and unscrew the nuts. 6._ Hook the engine room crane on tothe titng attachment on top of the exhaust valve Lit away the cylinder cover complete, and land itn a couple of wooden planks. 7. Remove and discard the sealing ring be ‘ween cylinder cover and cylinder liner 6 Utter vetoing otis page please quote Procedure 507 12 Ebon 215 MAN EW Dial NS Pages 0)901-1.3 Cylinder Cover ‘ss0Me-C Overhaul 1. Dismount all valves and pipes on the eylin- der cover. DDismount all studs on the fp ofthe eyinder 2. Unserew the four sorews which secure the cooling jacket tothe cylinder cover. Ln the cylinder cover free of the cooing Jackel and land ion @ couple of planks. 11 tho cooling jacket sticks, use dismanting sores to force the jacketcover apart. 3, Remove and discard the O-rings from the cove, and carefuly clean the cooling jacket and the cyfinder cover. Provide the cylinder cover with new O- rings, wall lubricated with of, 4. Litthe cylinder cover and guide the jacket! cover into postion, using the guide pin as reterence (camshat sie} Mount and tighten the serews forthe cool ing jacket Tien rterting Yo is page,please quae Procedure 807-13 Eaton 275 THAN BAW Diesel A/SS5OMC-C. : Cylinder Cover 901-4.3 Overhaul 5. Recondtion the valve bores as fllows: 5. Fuel valve bore 6. The tool consists of @ common spindle with handle, and of a guide, a carbon cutter, & seating face cutter, and a grinding mancel CClean the fuel valve bores, using the car- on cutter. required, recondition the fuel valve seating wih the eppropriate cutter. Grind the seating withthe grinding mandrel land a. grinding compound (e.g. Carborun- ‘dum No. 200), ‘After the miling/grinding, clean the bore ‘and seating careluly, and check that the ‘seating is not damaged. 6 Exhaust valve bore 7. The tool consists of @ spindle with handle land a grinding dis. ‘tor cleaning the valve bore and seating, ‘grind the seating wih the grinding aise and 8 grinding compound (e.g. Carborundum No! 200), ‘After the grinding, clean the bore and seet- ing carefully, and check that the seating is not damaged. ‘hon refering to is page, ease quote Procedure SO1.1.3 Eaton BIB Page 5 0)901-43 Cylinder Cover SSOMC-C Overhaul Starting valve bore 8. The too! consiets of a guido, a cutter, and a grinding dis. Recondition the starting vale bore and ‘seating in the same way as described for the fuel valve bore, when roplacing valves on a cyinder cover that is mountod on tho engine, recondition the valve tores/seating In the same way as described here, but without dismounting the studs. 8. Clean the bores for safoty vavetindcator cock, Page 6 (0h Wha raoring otis page,please quote Procedire 01-1. Eon 216 THAN B&W Dies! NS‘S50M0-C Cylinder Cover a Overhaul 1 10. Lubricate the threads with ‘Never Selze' or Molybdenum Disutphide (MoS) and mount the valve studs. ‘Tighten up the studs in accordance withthe serewingin torque stated on the data sheet Fil up the grooves between the valve studs land the bores for tha valve studs with por- ‘matex to prevent water of oi from entering the bores during operation ofthe engine, Provide the water connection fanges with new gaskets, and keep the cyngor cover ready fr repiacement ‘Always fnew or overhauled valves before 8 cylinder cover Is mounted on the engine, 3 Ellon 5 Viper etoring tis age, late wt Poets | Man BW OeeeI NS1 gota Cylinder Cover SSOMC-C Mounting 41. Place a new sealing ring on top of the cy inder liner with the quide tabs inthe fore and aft diction, This fs to ensure that the tabs ft ito the {wo gas blow-out grooves miles In the cy inder cover guide recess. 2. Lit the eylinder cover by means of the crane and carefully wipe the contact sur- face which faces the cylinder ines. Provide the cooling water connecting pipes with new O-rings and lubricate theen with ‘eac0 oF Sof eoap. Mount @ new ‘kinger sealing ring in the groove of the flange of the Intermediate ioe. Lower the cover earetully Into postion fully check that tho cooling water connecting pipes engage cor- rectly withthe holes in the cooling Jacket. 3. Mount the cover nuts on the slués and sorew down, Place sight spacer rings, one around each rut, and mount the eight nydrauie jacks on the studs, Connect the high-pressure pump to the Jacks by means ofthe distbutor block and the high-pressure hoses. Use the vant sorawe ofthe hydraulic nuts to vent the system, and then increase the pressure as stated in Data For operation of the hyrraullc tools, see Procedure 919-1 “Tighten the nuts by applying the tommy bar through the eles in the epacerringe Roliove the systom of pressure, Finally, remove the hydraulic jacks and Fae 80) When rng oi ge, les quae Poco 07-4 Ein 376a a Cylinder Cover 901-44 Mounting 4. Mount the protective caps on the cylinder cover studs, ‘Align tho intermociate pipe so that the holes in the flange ofthe intermediate pipe are inline wth the threaded holes in the ex aust receiver, Mount the sorews of he lange between the Intermediate pipe and the exhaust receiver. Motel Lubricate the screws with ‘Never Seize" | ‘or Molybdenum Disulphide (MoS,) before ‘mounting. 5. Mount the insulating Jecket around the in- MAN BW Dieta AS termediate pipe, i | ie | | _———————— | When rearing 10 this page,please qvote Procedure BOT 14 Fon 216 Page 90, i901-14 Cylinder Cover ‘S5OMC-C Mounting 6. Mount the return ol pipe, the sealing alt pipe and the air pipe for pneumatic closing ofthe exaust vaive, Mount the high-pressure pipe for the hy. ‘raul valve gear Soe Procedure 908-144. 7. Mount the starting ai pipe and contol air poe for the starting valve. Mount the cooling water inlet and outlet pipes on the exhaust vale. Mount the dain pipe on the intermediate pipe between the exhausl valve and the oy Inder cover. Using a erowoot wrench and torque span- ‘er, mount tho fuel oil high-pressure pipes between the fuel pump and the tual aves (Checking thatthe pipes ft properly at the ate and that all pare are clean and pro: Video with new O-rings). See Procedure 909-144, Connect the outiet pipe trom the return oil Pipe on the fuel valves. ‘Shut the drain valves and open the cooing Water infet. After varting the cylinder seo: tion, shut the vent cocks and open the cool- ing water outet valve. (Open the fuel ol, ubrcatng ol and alr sup: Page To) piles to the alarm system. ‘Caution? ‘The alr supply 1 the extaust valve must aivays be connected before starting the ‘camshaft oll pumps. ‘This is very important, because other- wise the valve will open more than nor- ral4 | ey Cylinder Cover Panel Ban ‘ Plate 90151-184 o10 her eforing os pao, loos quis Pas BOVEY Ean To4 NAN BAW Diet AO" PO| | / i Plate 9o181-184.Cyli ler Cover Panel Tom Na Par Description tem No. Part Daserpton o10 oz 046 058 80 on 083 095 105 7 130 201 o10- 201 +) Too! panel Name pi Grincing toot Ning and gracing tool for fel valve Miling and grinding tool for starting valve seat Dismanting too for uel valve Handle {Grinding ring tor staring valve |Genging handie for staring valve Pressure test Ling chains| Handle "Too! panel, complete with fools 312690141, *) Optional exras(Sea) Cylinder Cover - Tools Plate 901614084 {2 ; ‘Wen referring to this page, please quote Plate 90161 Eaton 084 MAN'BBW vase! ASPlate 90161-88 Cylinder Cover - Tools item No. Part Doseription Part Description ons rg 039 40 052 064 O76 088 Hyeraute jack |Osrng with back-up rng, 80/80 mm | O-ring wth back-up cng, 00110 mm Stud seter M 4534.5 'Spacor ring for eylinder cover Spacer ring for crosshead bearing Hydraulic tools for cyiner cover and |crosshead boating Hydraulic tools for cylinder cover“7 Cylinder Cover - Tools Plate 90161-0096Plate 90161-96 Cylinder Gover - Tools hem item = na Part Doserption na Part Description 018 |Liting device (027 | Hose with unions (089 | Balancing ing, upper 040 | Spring balance 064 -| Suppor 086. | Balancing rng, ower 428 | Hyeralie jack, compiote 485. |Onrng with back-up ring, ©80!90mm : 147 | O-ring wits backup ring, Jet00/110mm 160 | Quick coupling, complete 72 | Gasket 196 | Sparepars,nycrao jacks 218 | Sorow 235 |Settlocking nt 255 |Hear-shaped thimple 267 | Wire tock 2280 | Ling bracket 282 | Distance pipe, L=15 i 302 | Screw | 325 | ScrewExtra Tools Plate o016215, (fags) vires on han kiussome | o10 022.Plate 90162-15 Cylinder Cover - Extra Tools tem MAN Baw. ry Part Description ean 010 | Grinding machine for cylinder covertiner 22 | Grinding whos!(aa ‘SAFETY PRECAUTIONS Ix] x] >EEEE Data 4 2 os ba os o7 9 40 Dat ps2 Daa pe os bar 48 baa Wien referring to his page, please quote Data Sh Man ‘Stopped engine Block he startiog mechanism Shut of stating ait supely Engage turing gear Shut of cooing water ‘Shut of oat of ‘Shut of ubiation ll Lock turbocharger rotors cia wah: ew piston rng wor piston ng Maxima verge eight = groove No. groove Nos. 2,9 end & Max. pemisuble bur sway: ~standas piston top Inconel piston op Hoight new ings: = plston cng No.4 ~ piston ing Noa 2,3. end-s simon tng 989 ston ing No.1 piston ring Nos. 2,3 and Minimum fee rng gap Vertical clearance, new parts Piston compte Paton crown Paton alin ton coolg pipe Picton od Tightening oque = coating a ips Tihtonng txque ston st “Tohtoning ore = piston reo “Tlohering ore = tting box Tigtening torus piston redoethead or —ianing angi Tightening ore ~eylince cover sacs "BAW Dieta NS Piston 1024 Data 102mm ‘8mm 34mm 24mm 28 mm 035-040 mm 880 1g 200 kg sig 253 58045 20Nm 20Nm 200 Nin or 20 Nn «90m “0° Standard Tools: See Section 919 ZS, —z, = 50-800, 200-700 8 Qa 102-1 Edtion 30 Paget 2Spare Parts 0201-00 086 | Smo 80201 0 047 90201-90167 020100 179 2010700 198 Page? @ eon Priston ing No. 264 Piston ig No. Looking wie ving Ding stot Piston ay asses wag When refering otis page,please quote Data Shoe! 102-1 Ealion 90 ‘MAN BAW Disa! ASi (aa Piston Checking s0t.1 Scavenge port inspection “To dotoct possible laakages from the piston of cylinder cover, Keep the cooling water and cool- Ing oll circulating during the seavenge port spection "Remove the inspection covers.on the cam- shaft side of the cylinder frame, “The scavenge por inspection can also be carried out from within the seavenge ar receiver. Clean the openings. Bagin the inspection atthe cylinder whose piston is nearest BDC. 2 Win the piston in BDC, inspect the piston ‘crown and the cyinder wal, Note down the resuts, ‘See Volume I, Operation, Chapter 707 3. Turn the engine. While the pieton is passing the scavenge sir ports, inspect the piston 198, the rlnglands and the piston skit. (Chock the movabilty and the tension ofthe Pleton ringe by proasing ageinat therm with ‘a wooden stick. [Note down the resus When refering otis pape, please quote Procodire S021 Eaton 228 NAN BAW Ola NS Paget 0)02-44 Piston Checking Baw 4. Alter turning the piston upwards, past the Sseavenge alr ports, inspect the piston rod and the lower part ofthe eytinder wall Note down the results 5, Re-mount the inspection covers on the cyt Inder ram, W necessary, replace the gas ete. Piston rings and piston crown 6. Remove the piston ftom the eylinder and place It on the piston support. ‘See Procedure 9021.2. Note! itis recommended to replace all the pi ton rings whenever a piston ls removed from the engine. Al the following measurements should be sed as a guideline for the running time of 2 sat of new piston rings. Depending on the extent of the wear, the running tine can be increased or de- txeased, For evaluation of the rings, see Volume J, Chapter 707. Page 20 Whar vor oe nage pase acl Procedre 602 7 Fon 228 " ” "HAN Be Diesel A(oes Piston 024.4 Bay e ‘Checking 7. Before dismanting the piston rings, meas- lure the fre ring gap of all the piston rings. Ifthe platon ring gop of one of the plston rings i loss than stated in Dat, the piston ring must be ceplaced, 8, "Take off the plston rings by means of the fing expander. cea nd inspect the rings. 8. Measure and record the radial wieth ofthe rings. Soe Volume |, Operation, Chaptor 707. j j —— New | D-1 ls Ee i ‘Worn | When refering oii page,please quote Procedure 2.1.1 Evan 26 Pages (3) i9021.4 Piston Checking ons 10 Min. mm 410. Piston rings with milled pressure reliot ‘ove must be replaced the radial depth (ofthe grooves has worn down to less than mm, 11. Clean the ring grooves and check them for burn marks or other deformation. Measure the ring grooves wih a caliper sauge. (Ceararice in piston ring grooves: 1" ‘The maximum vertical height In a ween ing groove must not exceed the velue stated in Data. 12, Clean the piston erown and check the burn- ‘away by moans of the template, For max mum permissible burr-away value, soe Da- ta Check the burn-away on the whole circum ference of the piston crown, Page a0ed Piston ‘Ben (Checking 18, Before mounting a new piston ring, meas- | 1. lure the piston ring gap and check the ring height ‘When measuring, insert the piston ring in either a new cylinder finer er Inthe bottom of used cylinder (below the ring travel * zone) For minimum ring gap, see Data, 14, Fit the piston rings (altemetely right-hand and lefsand cuts withthe ring gape stag: gered 180" and with the Tor mark up. Wards), by using the ring expander | When mounting the piston rings, use the ring expander to prevent unintended defor mation ofthe rings. Do not expand the rings more than neces: ‘sary. Tho upper ring (CPR fing) should not be expanded more than to te milled mark fon the ring expander 15, Check the vertical clesrance between the new piston ring and the new or recon lioned ring groove with a feeler gauge. See Data ‘When referring otis page, please quote Procedure 902-11 Editon 226 MAN B8W Daeel NS Pages (8)j | 1. Tun the crosshead down far enough to give ‘accoss to the piston rod stuffing box, the tightening screws for the piston red, and to the telescopic pie. 2 Release the stuffing box by removing the Jnnermost screws trom the stufing bax flange. Note! Do NOT remove the eutermast screws from the Nange. 3, Remove the screws from the piston 10d Page 6 8 ‘When refering this page, pease Guoie Procedure 0021.2 Eaion 226 WAN BAW Diesel A'SPiston Dismanting 4. Mount the two distance places on tha piston fod foot to protect the lower scraper ring land to guide the stufing box, 5. Dismount the cylinder cover See Procedure 901-1.2 Carefully smocth out any wear ridges at the top of the cylinder tint by using & hand grinder. See Procedure 909-1.8 8, Turn the crosshead to TDC, while checking thatthe guide pins of the distance pieces lenier the holes inthe string box. hen refering otis page, please quote Procedure 802-12 Ean 226 MAN'BAW Dieta VS| scare Piston : Dsmaning (saa 7. The top ofthe pieton Is now tee of tho oy Ht necessary, remove one or two cylndor cover studs, using a stud setter ‘Clean te titing groove ofthe piston crown {and mount the liting too in such a manner that the two "xed" clawe of the too it into the fiting groove ofthe piston. FU the third, acjustable, caw ofthe tool to the liting gfoove and tighten t up against the stop ofthe tool. 8. Place the two halves of the support around ‘one ofthe openings inthe platform, Lif the piston out ofthe cylinder and tower the piston rod foot and sting bex through the opening in the platform. lace the two halves of the support around tho piston rod and secure the two halves va ‘serawa. 8. Place a cover over the opening fer th pis- ton fod stuffing box inthe bottom ofthe ey. Inder unt. ‘loan, measure and recondition the eylin- er inn. ‘See Procedure 905-2.1. age (9) When refering otis page,please quot Procedure 202-12 Eton 26 MAN BAW Dies ASPiston Dismanting 9024.2 10. Turn the crosshead down far enough to per mit mounting of the protective rubber cover fon the crosshead beating cap. “The protective rubber cover should remain In place to protect the crosshead bearing journal trom impurites unt te piston is re= ‘mounted. Low lifting height 1 the space conditions above the engine make ‘impossible to remove the piston inthe normal ‘way, the piston can be removed as follows: 11. Remove one or two cyfinder cover studs, ‘using the stud atte. LUft the piston high enough to give ample room over the cylinder cover studs Mount the clamp on the piston rod so that its cistance place les true against the pis: ton, 10. Whan rearing to tis page please quale Procedure 602 12 Fon 226 MAN BW Owe! VS Page 95)Piston Dismanting aaa 12, Place the supporting tools on the eytinder ‘cover studs and lower the piston untl th ‘lamp rests cn the tools, Femove the ling tol from the piston. Hook the transverse piece on tothe crane and attach Ifo the clamp for titing the pie- ton. 18, Lit the piston othe maximum erane height. Fun the erane athwartship and, atthe same {ime tit the piston, pep the piston rod clear of the cylinder tine fer and studs while carrying out the titing. men space conditions permit, straighten Up the piston and lead it aver tothe cutout In the platform for overhauling the piston, When the piston is at a sultable height ‘above the platform cutout, postion the pis- ton support around the ‘piston rod and clamp. ‘Now lower the piston while guiding the sup- port tothe platform cutout ‘ter landing the piston and ensuring that rests correcty on the support, remove the ‘iting too Wore! ‘On engines with extremely 1ow ting height, use the engine room double: crane instead ofthe traneverse piece. Page 1009) When rolering otis page please quote Procedure 3081-2 Edon 226 ‘MAN BW Diss ASPiston s021.3 Overhaul Position new O-rings on the platform ‘around the piston overhaul cut-out 2, Ease the piston down so that the stufing Doxcis Belew the floor. Lin the O-rings and assemble the Iwo halves ofthe piston support around the pis= ton rod Position tho O-rings on the piston support 8. Dismount the locking wire ard sorew up the support screws of the piston support 10 Position just Below the piston skit. Remove the piston skit screws, When referring otis page,please quote Procodare 219 Eaton 2 MANBEW Dist NS902-4.8 overou ey 4. Sorew the four sorews ofthe support down: ards unl the skirt rests on the support 1 tho ekit wil not budge, feo It by means cof two dismanting sores. 5. Dismount the locking wire and the in ‘most screws between the rod and the pe ten crown. Lut away the piston crown. 6. Diemount the bolts of the cooling ol pipe A tone. i Mount the ee bot and othe cotng ore. 5 ‘Aiter inspection of the cooling oil pipe, re- mmr ep i H ni A é Fa ay Tih rig Fie ara ls Pore BP Eon 8 "WAN BAW Drees NSPiston 9024.3 | maw Overhaul Alternatively, the piston can be dlemantied | 7 in the folowing way Note! “iting ofthe piston must only take place with the piston rod stufing box mounted [on the piston roa 7. While the complete piston is hanging trom i the iting tool, mount the collar round the piston rod go that the distana pieces of tne tollar bain contact withthe piston. Lowor the piston so that the collar rests on the platform Remove the lting tools trom the top ofthe piston crown, Hook the engine room erane on tothe lting | crossbar and hook the ehaine of the iting crossbar on to the shackles of the cola 8. Lift the piston tit it to the horizontal pos!- tion, and land it inthis postion on a couple | ‘of wooden blocks. Remove the liting erass- bar and cheins from the collar 8, Attach th iting tool to the bottom of the Piston rod foot. Hook the eran on to the Ht Ing toot Lift the foot of the piston rod clear of the ‘wooden block. Move the piston rod stung Box up the piston rod until itis In contact with the colar. Remove the two cietance laces from the piston fod foot f Note! During the tit, olow withthe crane to | keep the crane postioned vertically ‘above the feat ofthe piston rod. Kogp lting unl tho piston rod i in a verte «al positon. \Winen refering to this page. please quote Procedure 902.3 Eatin 226 Page 18 (18) MAN BAW Dial AS9024.3 ta Gad) 10. 10, Place the piston in an upright position wit the piston crown esting on wooden blocks. Dismount the focking wire ard the inner- ‘most serews between the rod and the ps {on crown, Lit the piston rod away and iand iin a Porizontal postion on a couple of wooden blocks. 11, Remove the locking wire and the screws in the skit and mount two eye bolts in the holes intended for dismanting screws. Lit the skit andi land i on a couple of planks. 12, Thoroughly clean and inspect all pats of the piston, FRlagarding check of the piston crown, see 1" Procedure 802-11, Replace all seating rings of the piston. All the new sealing rings must be coated with lubricating of before the piston is assem bie. Coat all screws with Molybdenum Disul- pide (M5) ‘Assemble the piston inthe reverse order to lsassemtly. Use the guide serew to ensure the correct positoning of the piston rod in relation tothe piston crown, ‘Tighten all he screws diagonally to the terque stated in Data.Piston 9024.3 | sah : vernal j 13, Lock al the screws with locking wire. 13. Mount the leking wie in such a way that the we le ghoned one ofthe stews works ose. See Procedure 218-7. 14: he piston and piston roe with lbreat ing oi ‘Mount the pessuretestng too around the base of the piston ro. Pressuretest the piston at the pressure Stated on the data Shoot E Check the contact surfaces ofthe pision land the sealing rings for ighiness. {Chock that there arene cracks in the piston For overhaul ofthe stuffing box, see Proce- ure 902-23. When eterna otis page, ease ete Provedire 02-13 Elian 2 Page 155) MAN BSW Dies ve902-14 Piston Ga Mounting () 1. Ceci piston ngs and piston crown a ‘sccordance with Procedure 902-1. CCoat the piston rings, piston rod and cin: er liner with lubricating o. 2. Mout the lifting tool on the piston crown. 3, Ensure that the stuting box 'scoxtectly po- siloned over the gulde pins Inthe elstence pieces maunted an the piston red foot ‘Coat the O-rings ofthe stutfing box wih ol 4, Remove tne protective rubber cover from the crosshead. Page 18 19) When rlarng to his page,please quote Procedure 9021.4 Fain 225 "WAN BAW Diesel AS| (oad) Piston 902-1.4 BR : Mounting '5, Remove tho cover trom the pston rod tuft: | 5 ing box opening in the bottom of the cylin, der unit. ©. Tum the crosshead to a postion 45° from ‘Toe. ‘Mount the guide rng for piston rings on the cylinder liner. 7. Lower the piston into the cylinder liner while guiding the piston rod foot through ‘cut-out inthe stuting box flange ~ until the piston ings are inside the ner, corre- | ‘sponding tothe ling to! lacking about 30 ‘mm in landing on the guide ring ao ‘When refering tots page,please quote Procedure S02 1.4 Eaton 226 ~~ Pee 7 0) MAN 3W Dito! NSana Viner Piston (ad) ‘Mounting Baw 8, Turn the crosshead to TDC wile checking ‘thatthe guide ring ofthe crosshead enters the eantra Role inthe piston rod. 8. After turning the piston fully to TDC, un- sctoW the adjustable claw of the ling too! and pull te titing tool free of the titing ‘r09Ve In the piston Remove tho liting tool and tho guide ring {or piston rings. “Turn the crosshead with the piston rod and the telescople pipe down far enough to per: mit mounting of the piston rod screws. 10, Remove the distance plecee trom the platon red foot, Mount and tighten the piston rod screws. Seo Data Look the serews with locking wie Mount the locking wire in such a way that the wice ts tightened ff one of the screws works loose. See Procedure 919-7. rng to Wis page,please quote Pracodure 902-14 Fdlion 228 WAN BW Dieea ASPiston Baw Mounting 11. Tighton down the piston rod stutfing box by | 11. means of the screws through the Inner holes inthe stuffing bax flange. Soe Data, 42. Carotuly clean the surtaces around the base ofthe studs and heck the O-rings on the studs Mount the eylnder cover studs with the stud seller. See Data, 18, Smear the piston rod with molybdenum di sulphide, and turn the crankshaft @ couple of revolutions. Mount the oyinder cover See Procedure O01-1.4. 14, Start the engine and keap it eunning for about 15 minutes at a umber of revolutions corresponding to very slow. ‘Then stop the engine and inspect the peton red and stuting box. ‘When referring to this page, please quote Procedure 9021-4 Eton 228 MAN BAW Disel AS(a\ Piston Rod Stuffing Box 102.2 ne Serr eeesmet Sern eee ee ee Zz bal cores cee pel ceertane a cee | Senate “Sucre a i scree ————- as ve tg vente laa eee a reer ie een mae ees warm ore ee reso am 4 ttt denne cares nea renee eo ee oo fer ea scam ae moses a eee Coa / ee a a eee arctee me Teese, eam When refering o his page,please quote Dala Sheet 102°? Falion 25 MAN BAW Dios: iS Pave itmee Piston Rod Stfing Box : Data (Ged) Spare Pans . Pate. eserton om. sozosvex 037 Scraper rings 3 8020500080 Oxing 1 90205200 183 Lamia for sraper ngs 16 | 9020500 167 Top serape ing a 20205%00 169 Pack sealing ing 8 | 50205000170 Gover seating ring 2 020500218 Spring 6 | $0205,00 228 Sing . a Pene2 ‘When reering to tis page,please quote Oata Shoot 103-2 Eaton 25 | MAN BAW Diesel NSi (= ___ Piston Rod Stutfing Box 902-2.1 Bay ‘Checking 1 1. After the piston rod stuffing box has bean ‘ismantied, check the following clearanc- See Procedure 902-2.2 uy sings ost sera ing and seat Vertical clesrance between sealing ring section and groove, (0-6) Clearance at rng ends (seraper tng) | “Total clearance (scraper ring). (D-8) Clearance at ring ends (sealing rings). “otal clearance (sealing rings) (0-8) Lome:most scraper rings, Vertical clearance betwaen scraper sing ‘and groove. (0-7) Clearance at rng ends, Total clearence. (0-9) ‘The ring clearances stated in Data apply 10 new ring. As a general guide, it is recommended — ‘depending on the overhauling tervals and ‘one's own experience ~ fo replace sealing ‘ings and seraper rings when the spectiea learance values D-8 and D-9 nas been halved. 2 Check the length ofthe springs at diferent loads. Adjust the loads to achieve the lengths stated in Data the loads necessary are outside the limits stated In Det, the springs must be discard od ki ‘Wen refering ois pape, please auote Procedure 902 21 Eton 4 Page MAN BW Oise! ASj 902.22 Piston Rod Stuffing Box Outside the engine Normally. overhaul ofthe piston ro stuffing box Is cartied out by routine methods in connection with cismanting (pling) ofthe pistons. See Procedure 9021.2. During such overhauls the piston reste on a suppor placed over one of the cut-outs in the top platform. ‘Work on the stuffing box is then carried out trom the platform below. 1. Mount two eye screws in the stung box flange, and hook on two tackles. “Them it the stuffing box a tle up the ps ton rod, and mount the worktabe round the piston fod at a sultable working height 2. Remove the O-ring ofthe stuffing box. the (ing Is intact and is to be used again, ‘move it up the piston rod and secure In this postion, for example with tape 1 the overhaul i carried out inside engine the O-ring has to be reused, Remove the nuts from the stufing box as sembling bots. ‘8, Take out the six bolts, and pull away one stuffing box hat. Mount two eye scrows in the stuting box hal and remave it from the workable. When refering to this page,please quot Procedure 02.2.2 Edin 274 THAN 88W Daa US(oad Piston Rod Stuffing Box ) : Diemanting 90222 Inside the engine 1 In the period betwoen piston overhauls, itbe- comes necessary to Inspect the piston rod stuffing box, proceed as follows: 1. Turn the erankthrow to about 90° from TOC. Mount the rubber hose around the piston fod to protect the crosshead bearing from Impurities. 2, Remove the dain ol pipe and al innermost ‘serene and all outer serews except fortwo ‘screws placed diametrically opposite in the Stung box fang, orginal tte en gine 8, Mount the worktable round the piston rod So that the two remaining screws can be loosened through the workteble holes ‘en refering to tis page please quot Procedure 80222 Eaton 214 MAN BAW Deel NS Panes)902.22 Piston Rod Stuffing Box i Dismantling Baw 4, Remove the two tong sorews from the workable Mount them in the stuffing box through the holes in the workable Flemove the remaining two screws fom the sutfing box. ‘5. Turn the piston to BOC, thereby withdraw: ing the stuffing box from the cylinder frame bottom. Remove the two tong dlsmantiing scrows ‘rom the sting box end mount them inthe workable, 6. By mearis of the four shor! screws in the ‘workable, press the stuting box out ofthe ttange. For overhauling the stufing box, see Pro codure 902-2.3 ing 10 this page, please quote Procedure 902-2.2 Edition 214 WAN B&W Diaai NSOverhaul (oa) Piston Rod Stuffing Box 90223 1. Remove the remaining stuffing box half ané press all sealing rings and scraper rings down agains the worktable, 2. Measure the vertical clearance (0-6, 0:9) between the ring segments to determine whether replacement is necessary. ‘See Procedure 9022.1. [ Rotel | p11 Dismantle and stack the rings in the CONWW Or} cy! od ‘when fitted in the stuffing . — ie u Carefully biean all the ring segments Inspect and assess the surlace quality of the sealing rings. I thelr siding surlaces f have scratches or marks, replace the rings i} 8. Cheok the lengths ofthe springs. See Procedure 9022.1. 4, Inspect the surface of the plston rod, it small longhudinal seatches have occurred (caused by poorly adapted stuffing box | rings), smooth the piston rod surface care fully witha tne grained carborundum stone. 5. Clean the halves of the etufing box hous: ing, ‘hen rearing to this page, please quote Procedure O02 23min oe ————~—~S~S~*~*«é MaN'BEW ieee AS9022.4 Piston Rod Stuffing Box Mounting 1. Lubricate the piston rod (in the area where all the ring units inthe stting bax wit be Positioned) with molybdenum disulphide (M052). Assemble all tne stuffing box sing units round the piston rod, on the workteble, In ‘the following way: + Place the fowermost scraper rng seg- ‘manison the worktable, + Place the spring rouné. the sog {nd Hook the spring ends togothor FRopeat this procedure for the remaining | scraper rings. f (On top of the scraper rings, assemble the cover sealing rings, te pack sealing ring and the top scraper ring uns (each con: sisting of a part and an B:part rng) ‘Assemble the 8-part sealing tg so thatthe two guide pins face upwards, place the Spring round the segments and hook the ‘pring ends together. } Assemble the 4-part cover sealing ring ‘above the B:part pack sealing rng. Push ‘the two rings together in euch @ manner ‘thatthe guide pins in the lower sealing ring engage with the two holes in the Upper sealing ring Finally, assomble the uppermost ring unit (consisting ofa 4-part seraper ring and an B:part pack sealing rng) 2. Use the stuffing box half on the worktable to adjust the height of all the assembled ring units on the piston rod unt the sing Units are opposite. the corresponcing {gr00ves inthe stuffing box housing. Subse quently, uh the stung bax half nto can ‘tact with the pston rod, round the ring unit. 9. Using a fesler gauge, measure the horizon. tal clearance ofthe rings, Seo Procedure $022.1. Wen referring to Wis page,please quote Procodre 002 2.4 Falion 274 'WAN BAW Dieeal A/SPiston Rod Stuffing Box 9022.8 Mounting 4. Than place the othor half ofthe stufing box: housing on the worktable, pushing i into place round the rings. Mount and tighten up the fit bots to the torque specited on the Data Sheet Outside the engine ‘ ‘5. Mount eye screws and wire ropes, and it the stuffing box a ite, Remove the workta- bie, ‘ 6. Lowor the stuffing box unt i rests againet | the distance piecas on the piston rod foot. i Mount & new O-ring in the stufing box aroove. Remove wie ropes and screws | For mounting of the stufing box and the | piston, see Procedure S02-1.4. When reering otis page please quote Procedure 0224 Faen21@—~——~S~S*~*~*« GT) MAN BW Diesel AS90224 Piston Rod Stuffing Box Mounting Inside the engine 1. After overhauling, support the stung box halves on top ofthe our screws. ‘Mount the two long screws from the workta- blo inthe stung box. LUnseron the short sevews Ing box lands on the flange. 0 that the stu 2. Turn the piston upwards until the stuiting box isn place In the eytindr kame. Note! “Make sure thatthe two gue pins in the ‘tange enter ine guide notes inthe bottom ‘ofthe oyinder frame. 3, Mount two secews in the flange through the holos inthe worktable When rtaring fo his page,please quote Procedure 902-24 Eien 214 "AN BAW Diesel A/SPiston Rod Stutfing Box 9022.4 Baw ‘Mounting 4. Remove the Jong screws frem the stuffing bor and mount them in the workable Remove the worktabe from the piston rod, 5. Mount and ti .serews for hten all the inner and ater 38 stuffing box, See Data 8. Remove the protecting rubber cover frm the piston rodiorossheas, ‘Smear the piston rod wih molybdenum di sulphide Them turn the crankshalt a couple of revo lution, Start up the engine and keop it running for approx. teen minutes at a number of re: lutions corresponding to vary slow or ile speed. ‘Then stop the engine and inspect the piston rod and stuffing box. ‘When rearing 1o this page, please quote Procodure 00224 Fain 214 ——~=~S*~*~*~*~« OO MAN Baw Diol NSPiston and Piston Rod Panel Plate 90251-237 > od 2 3 lOO ¢ ‘Wen refering to his page, please quote Pate 80261 Eaton 257 MAN BBW Diesel ASPlate 90251-237 Piston and Piston Rod Panel Tem No. Part Deserigtion Pan Deseiption ore 025 40 01 075 087 999 109 m0 ve 14 158 160 Panel fr tools Name pate Ling tool fo piston rod Litng tool for eyincer liner “Template for piston top Distance piece for stuffing box [Cover for stuffing box hole Hook for mounting of spring Pressure testing device Woekiae Piston rng expander Guide screw fr piston orown, Dismanting serewPiston and Piston Rod - Tools ‘iter refering to is page, pease quote Pate 0261 Elion 0700 Man ae Plate 90261-0100Plate 90261-0100 Piston and Piston Rod - Tools ee Tem i Par Deseriion Tee pat beearintion ‘is | Guide rng Tor piston (020 | Litng to! for piston (056 | Support for piston ier referring fo this page, please quale Plate 90261 Eaton 0100 | Won ering ois page ease ole Pal 26) Eon 0100(oe) Piston and Piston Rod - Extra Tools Plate 90264-002, 027 Then votaring tone page, pi MAN BW Olsat NSPlate 90264-02 Piston and Piston Rod - Extra Tools hem No. Part Descripion tem No. Part Description 015 oar Liting colar ‘Support for tting too!cylinder Liner 103-1 Data SAFETY PRECAUTIONS ‘Standard Tools: See Section 913 X] Stopped engine re] eececcaeereees Zz, Bees | Engage tunieg gar —r i eras rl eeres a [| Shut of kabsicating ot (aoa on Data At Oyler eameter, new 500 mm D2 Cynder ne, compote 1800 kg 3 Cooling jacket 18049 Dot Screwingsn torque 500.Nm cylinder cover ste DS Cylinder cover sud arg ‘ito referring to tis page, please quote Date 010307 Eaton 0030 Page 1) MAN BSW Diesel A'S109-1 Cylinder Liner —— Prate es: | ° i ils ‘Spare Parts | Pianta, ten oy 09020020 xing 8 9080200071 Oring 2 oso2cce 095 Oving 1 80802.00% 128 Gasket 4 1 808103000107 Gasket We refering ois page please quote Data 01030 Ean 6080 NaN BAW Dvece ASCylinder Liner 9031.1 | Baw (Checking 1. Dismount the eytinder cover and piston, See Procedure 901-1.2. See Procedure 902-1.2. CClean the cylinder liner and scavenge air ports 2. Position the cylinder liner measuring too Measure the cylinder inae with an inside micrometer atthe postions Indicated on tne ‘measuring tool. See Data, 8. Take measurements inthe fore-and-aft and | athwartship directions 4. Chock and evaluate the condition ofthe oy!- Inder liner according tothe desexption giv fen in Volume |, Chapter 707, Carefully ecxatch over any scores of marks | fon the cylinder liner running surface, by means of @ rough grindstone held in'the hand. = Using @ grinding machine, eemeva the wear ridges atthe top ang borom ofthe eyinger liner (where the piston rings reverse divec- tion), 80 that a emooth trneition fe formed Check the lubricating points of the cylinder by pumping cylinder oll to each Indlvioual lubricating point withthe Alpha lubricator. Clean any blocked lubricating duc. Mount the piston and eylindar cover See Procedure 902-14 Soe Procedure 901-1.4. ‘Wher referring to is page, lease quote Procedure 90301 Eaton 0226 i MAN BAW Dieal AS903-1.2 Cylinder Liner (oad) Dismantling saw 1. Dismount the cylinder cover ‘See Procadure 901-1.2 Discard the seating ring from the top of the onder liner. “Tur the piston down tar enough to make It possible to grind away the woar ridges at {he top of the liner wth a hand-grincer. Soe Procedure 908-13. Dismount the piston. See Provodure 902-1.2 Mount the two kiting serews lathe eylinder liner Note! Tighten the liting screws fo the torque } statec in Data | Check with a 0.05 mm feeler gauge that ‘theres no clearance between the screws and the eylinder lines. This must be done whenever the iting | too are mounted on the iner 2, Disconnect ~at the exhaust side ofthe oy- Inder ~ the ol pipes leading from the ey dor lubricator to the non-return valves, Dismount the four cooling water pipes - be tween the cooling jacket and eylinder cover “and clean them careful "Wen rearing to his page please quote Procedure M030) Eaion OP HAN BED Diesel A'S or)cylinder Liner Baw) Dismanting 8. Remove the screws of the cooling water in let pipe 4, Attach the orane to the tting crossbar Hook the chains from the ling crossbar on othe lting serews and It the cylinder liner with the coolng jacket out of the cylinder frame. Note! ‘Low iting height in the engine room may require the removal of one or more cylin or cover studs before dismartling the | cytinder tne. Land the cylinder liner vertically on, for In- stance, a couple of planks. CClean the cylinder frame internally, taking special care with the contact surfaces for the eylrder liner et the top of the cyinder frame. Discard the O-rings on the cooling water Pipes. Clean the pipes careful When rearing otis pape please quote Procedure MOOGOT Eien 0224 MAN BAW Diol NS 908-4.2| 90812 Cylinder Liner (oad) Dismantting Baw 5, The litng screws are also used for vans- Porting the cylinder liner. ‘The cyfinder ine isnot in balance, even withthe cooling jacket mounted. | To keep the liner in a horizontal poston during transportation, use 8.9. a wire rope connected from the scavenge ports to the traverse as shown onthe skote, Paaea@ Wha rterng to ie page,please quote Procedure MBO01 Eaton 0224 MAN BAW Dies ASCylinder Liner Overhaul 4. Ungorev the nuts on the non-return vaives. | 4 and remove the valves, CClean and Inspect the non-return valves. 2 Attach two tackles to the crossbar,..as shown, Mount two iting eye bolts in the cooling Jacket Hook the tackles on to the litng eye bolts fn the cooling jacket and haul tight. Femove the two liting serews from the cyl Inder liner. omove tho four clamps which fk the coo Ing Jacket to the eyinder tne. .__Littthe cooling jacket avay by means ofthe tackles, and land it on the wooden planks. When referring to this page, please quote Procedure M0301 Fattion 0228 MANBEW Diol AS Paes; Cylinder Liner Overhaul Baw) 4. Check and assess the contition ofthe cy Inder linge according to the description giv. ‘nin Volume I, Chapter 707 Carefully seratch over any scores or marks fn the cylinder finer running surface, by means of a rough grindstone held in the hand, Check nthe top of the tner for @ wear ridge {here the piston rings reverse direction). there Is any sign of @ wear ridge, itis nec: essary to create a groove by grinding. See ‘step 5. The groove serves tO prevent the bull-up of @ new wear ridge 5, Place an old piston ring on the top of the piston and turn to a. postion that enables the grinding dis to rest on the ol piston ring while removing the wear ridge. Use & grinding disc witha round edge. Check he distance C before grinding to as Certain thatthe wear ridge was caused by the fop ring st TOC, “The maximum depth ofthe groove is calou- 5 Srge = D x 0.0045, Note! Iti of the utmost importance thatthe ‘rove I mae with 3 reauar rounding Be crown inthe skateh, Winn retaring fo Wis page, lease quote Procedure MB0S01 Eaton 0234 MAN BEV Osea as| | i . Cylinder Liner 8. Replace the two uppermost O-rings on the cylinder liner. 7. Lower the cooling jacket on tothe cylinder liner, Note! Make sure thatthe serach marks inthe ‘camshaft side of the cylinder liner and cooling jacket coincide, '8. Mount the four clamps in the groove of the liner, and tighten the screws. Remove the tackles from the liting eross- bar and the cooling jacket iting eye Bots. 8% Mount the non-seturn valves for cylinder lu- brication. Tighten the nuts and connect the lubricating o pipes. 8 When refering ots pape, pease quale Procedure MOGBDI Elian Oza MAN BW Deal NS PasoCylinder Meth (aa 1. Loosen the water connections on the cool- Ing Jacket. | Mount the we ing rows inte ner Hook the chains from the liting crossbar on to the iting screws, and lM th Jackotainer | assembly. Mount the lowermost O-ring and spply@ It tle lubricating ol on the rng 2. Check tha the joint surfaces onthe cylinder frame and cylinder liner are completely clean, Coat the joint eurtaces with pormatex or a similar Fquid sealing compound Mount the cylinder finer in the cinder frame, Replace the O-rings on tho water Connections and mount the Water connec: tions on the cooling jacket Hf one or more cylinder cover studs have ‘been removed during the dismanting ofthe {ylinder cover, remount the studs using the slud setter and a torque wrench, see Data, Page @) ‘ihen raering to tis pape, please quote Procedure M3030) Flin 0224 ‘MAN @8W Dioss! VS8. Fita new gasket between the cooling water inlet pipe and the cooling jacket. Mount and tighten the screws. 44. Connect and tighten the olf plpes for the cylinder tuition Vent the cyfinder tubicsting system until oil, without alr bubbles, comes out from the non-return valves, Check that there fs no leakage fom the system. When this isin order, check that each ind vidual lubscating point functions corecty. 5. Lubricate the upper part inside ofthe cylin: or liner with eylinder Mbrieating oll and mount the piston. See Procedure 902-1.4, 6. Mount the sealing rng and the cylinder cov- Soe Procedure 801-1. “Tighten the upper water connections on the cooling jacket as soon as the cylinder cover Is correctly positioned, When refering otis page, pease quote Procedure i MAN BAW Dieta A/S Cylinder Liner Mounting PanesSAFETY PRECAUTIONS ‘Stopped engine Block he starting mechani ‘Shutoff staring alr supply Engage tuning gear 7 Shut off coating water ‘Shutoff wo of ‘Shut oft cating ot Lock turbocharger tors Cylinder Liner 1034 Data Standard Tools: See Section 913 Data et oxen vo nt Det Gnd ameter new sao mm | D-2. Cylinder tiner, complete: 1800 kg | 2 Oning hat wore | boyd cover tds ~ Seeing ous 00 Nn DS cinder cover stud a9 2-6 Ling ot = tghtenng que 200 Nn ‘When refering 0 Wis page,please quote Osta 1050) Eaton 0096 —~—~S~S~S~S~*« GT MAN BAW Diese! A'S| 09 Cylinder Liner ; Data ‘an i= 00« 582 Page? Cylinder Lubricators Data Bay omc oy ong 2 ving Feedback sensor (pick-up), complete 1 ving 1 ving 2 ving 1 When referring o this page, please quote Data 010902 Ealion 0975 MAN BAW Diese ASCylinder Lubricators 903.21 Baw) Checking Check of Ol Injection: ‘With stopped engine and normally when the system has been disassembled 1. Press the pRewus.-button on the HM con- rol panel, and check tha al ubricators are ‘operating correctly by watching the LEDS tn the intermediate boxes for each lubricae tor, placed net fo the lubvieators, 2. ifthe eylinder cover or the exhaust valve is removed, chock ineide the linet that all iu | bricating points are working property. Otherwise, remove the covers for scavenge. ort inspection, Tur the piston to BDC and check inside the liner with @ mirror and a powertl light source that al lubrication points are work: ing propery. | ‘With running engine: 8. Check that all ubricators are operating cor- i rectly by watching the LEDS on the interme Giate boxes for each lubricator. ‘The LEDS give signal when oll is injacte. CCheck the pressure shocks ‘rom the Injec- lion of the’ lubrieatore on each iubrcator Pipe by teeung win @ hand, Fin douts, disconnect the pipe at the cylin: or linge %6 observe the i! ow. L When reforing to his page, please quote Procedure WG0G02 Eaton @226————~—SCSCS~S~*SCS ag MAN BAW Bisel NS903-24 Cylinder Lubricators Checking zg Check of Aecumulators: 4. Measuring the nlrogen pre-prassure can only be done with stopped engine and pres: sure-fee lubrication system, Stop both oll pumps. Close the inlet valve and open the equalizing valve on the re ‘spective lubricator. ‘The nitrogen pressure inthe inlet aocumu- lator (0.7 Ire) can be checked wihout dis- ‘mounting the accumulator. For use of the pressure satting tool, see Step 6. 5, To measure the nitrogen pressure in the outlet accumulator (0.16 fre), the accuma- Istor oF the lubrleator with’ accumulator ‘must be dismounted. See Procedure 905-2.2, For ltrogen pressure in the accumulators, ‘ee Data, 6. Use of Pressure Setting Too! ‘Assemble the pressure setting tool as shown in Figure 5, and mount the reducing valve on the nittogen oylinde. necessary, Use a threaded adaptor. Mount 0-60 bar pressure gauge onthe fl- ing valve whon the inlet acourator (0.7 le fre) 1s to be checked, and a 0-10 bar bressure oauge when the outlet accumula {or (0.16 lire) Is to be checked Procedure M9002 Editon O26 Page? 00) MAN BAW Bess NSCylinder Lubricators 903.21 Checking 7, Before. mounting the filing valve on the ac cumulator, check that the accumulator top is clan, Mount the filing valve onthe relevant accu- Imulator with the union nut. Check that valves C and F are closed, Loosen the plug screw in the accumulator using a square drive handle in eocket E. It is now possibe to read the actual nitro {gen pressure inthe accumulator onthe da ‘gauge on the fling valve. | 8, Ifthe accumulator needs to be refiled with ritrogen, open valve A and increase the @ outlet pressure trom valve C on spindie {0 1-2 bar above the pressure stated in Da- Ps Open valve © until the accumulator I filed to the correct pressure. Close valve € and tighten the plug screw With socket E tothe torque stated In Data, Release the pressure in the filing valve at Bleed screw F. | Unscrew the filing valve trom the accumu lator. Retighten the plug screw to the torque stated in Data. Remount the accumulator. When referring to this page, please quote Procedure MQO302 Edition 0226 Page 8 (10) MAN BAW Die NS903.22 Cylinder Lubricators ; ‘isanting feos 1 a Dismanttng of lubricator ey ‘The engine must be stopped and blocked be- fore dismounting a lubriestor, Stop the cylinder ‘il pump station 4. Close the supply valve forthe lubricator and ‘pen the equalizing valve (tum both har- les to a horizontal postion), Disconnect the electrical plug onthe side of the lubricator. 2. Unscrew the three serews in the bottom of the lubricator and disconnect the cover with pertaining pipes. ‘3. Unscrew the four screws on the side that secure te lubricate tothe hydraulic block, ‘and remove the lubricator ‘Special running 11s possible to change a lubricstor while the fengine Is running if a spare lubricator with O- rings and the necessary tools s avalabe. The change should be done ia. a maximum of 15, minutes. + Reduce the engine load to bslow 40% of wer + Lethe lubricator pump station run + Dismount the lubriestor ae described in oe steps 1-3 + Mount @ spare lubricator as described in Procedure £03-2.4, Page a (10) ‘When refering to this page, please quote Procedure M20802 Edition 0226 MAN BAW Dlenal WSay Cylinder Lubricators Baw Dismantiing Dismantling of accumulators 4 4. The engine must be before the accumulator is dismounted, Stop the onder ol pump station rt ‘lose the supply vale for the trator and open the equalizing valve Th 7 ee ip Teal pn ead (o ritrogen pre-pressure of 25-30 bat wil remain in the accumulator. topped and blocked - al Carefully unscrew the accumulator to re- lease the remaining ol pressure in the sye- tem. Remove the accumulator trom the hydraulic block When refering to is pape, pease quote Procedure MBG808 Eaion 0226 a5 MAN G8W Disa! A'S909-23 Cylinder Lubricators Overhaul 1. Place the lubriestor In @ bench vice with sot ‘awe Remove the adjusting serew with bushings Unserew the ell accumulator. Discard the Oxing from the adjusting 2. Romove the serews trom the cylinder block. 3. Pull up the eylinder block, Remove the spring and actuator piston wth plungers. Remove and discard the O-ing from the oylinder bok. Femove the cover for the non-eturn valves. “Take out springs and balls, Remove and diseard the O-rings | Page 6 (10) ‘Winen referring to this page, please quote Procedure M0302 Ealtion 0226 AN BBW Diesel ASCylinder Lubricators Baw Overhaul 4, Remove the cover from the terminal box, | 4 o> land disconnect the wires for the feedback (pick-up) sensor, Remove the terminal box ‘Carefully, unscrew the feedback sensor and remove and dlecard the O-ring Clean the housing with di ene and dry with @ nonsily cloth, coll or Kero: 5, Inspect the plungers, actuator piston and B cylinder block for Weer, using a magniying —=———= slase [s Chock that the balls from the non-retuin valves are in good conaiton (Check the seats for the non-etuen valves, 8. Belore mounting the feedback sensor, ‘check thatthe sensor is flush with the sen” s0F housing Mount the feedback sensor of anew ane, if = necessary, with a new O-ring CCheck with an object with a straight edge (€.g. the end of e caliper) that the end of the feedback sensor does net protrude into the actustor piston eyincer Mount tha tarminal oe, Connect the wires and mount the caver on the terminal box oO iter refering to tis page, ploase quote Frocadure WS0S02 Elion 0226 MAN BAW Diseel A ~ Page 7 0)9032.3 Cylinder Lubricators Overhaul Bay 7. Fitthe cylinder block with new O-rings ‘Assemble the non-return valves In the ey! Ind block. Mount the cover with the three inner Check with small screwdriver that the springs are correctly centered 8. Fi the oyinder block with @ new O-ring Pre-assomble the eyiincer block with the actuator piston and plungers to ensure the correct guidance of the plunger, before nally assembling the cylnder block unt Mount the spring and press down the actu: ator piston with plungers. Mount an NB x 60 Ssorew with a washer to keep the spring compressed 9. Mount the eylinder block assembly in the cylinder housing Mount the serows and tighten the block to the housing, Femove the MG x 60 screw with washer, When referring to this page, please quote Procedure MB0302 Ecition 0226 MANAW Diesel VSCylinder Lubricators Baw) Overhaul Mount the adjusting sorew fitted with a new | 10. (O-ring and the distance busting ‘Mount the cil accumulator. 1. Ifthe lubricator s not tobe mounted on the engine immediately after overhauling, cover | all openings with plastic to prevent dr from fontering the lubrcstor during storage. Coat all surtaces with thin layer of ol i When refering otis pape, pease quote Procedure Monat® Editon G28 MAN BAW Distal A'S903-24 Cylinder Lubricators Mounting Baw) 1. Before mounting the accumulator, check the nitrogen pressure, see Data, Mount the accum 2, Mount new O-rings on the hydraulic block land on the cover with pipes. Mount the lubriestor and tighten the sexows fn the hyeraulic black. Tighten the screws inthe bottom of the Iu ator tothe pipe connection 3. Close the equalizing valve and open the supply valve (handles to bein a vertical po sion Mount the electrical plug. Check the injec- tion of cylinder oll onthe feedback LED on the intermeciate box forthe specie lube calor cee yi an i tering iis page, please quote Procedure MS0S02 Ealion 0226 MAN B&W Diocal vsCylinder Lubricators 103-2 Ban Data ‘SAFETY PRECAUTIONS Standard Toole: See Section 913 ae semne oe ‘Shutoff fuel ol ‘Shut of beatin ot Look ubochargr rotors | LL Data at Dati ve At Oyindercilfeed rate: 0.7-1.1 fbhoh 0.9515 gK0m When refering (otis page,please quote Data D70802 Eaton 0078 Paget NAN GAW Disal AS103-2 Cylinder Lubricators fone fans ‘Spare Parts tet aston oy ‘Page 2 2) ‘When referring to this page, please quote Data 010302 Edition 0016 MAN BRW Diace ASCylinder Lubricators Checking 1. Further information concerning other than nominal feed rates, feed rates forrunning- In and for part foad operation, and recom- mended oil types, is given in instruction ‘book Volume , OPERATION. 2. The oylinderlubricators are mounted on the ‘ont end of the engine, For lubricator number. See the sketch. 3. Each oylinder has six Injection point. (Check that the pumps for al injetion points are activated during one revolution of the gine in AHEAD dlrecton untl the mark on No. 1 lubricator housing is in line with the mark on the scale at the lead shaft. This indicates thatthe pump stroke is ‘completed for lubricating point NO. 1 ‘8. Check thatthe erankthrow for cylinder No. ‘is positioned between 103" and 114" past BoC. Use the numbers on the turning wheel to determine the exact postion ofthe crank throws, Vinon retin to tis page, ploase quote Procedure MO080® Eaton 0227 MAN BW Diesel A'S Marks PagetCylinder Lubricators Checking Baw 6. Turn the engine further in AHEAD direction until the mark on the second lubricator ‘housing isin ine withthe markon the seal atthe lead-in shat. This Iaicates tat the pump stroke is completed for lubricating Point No. 21 on No. 2 lubricator. 7. Check that the crankthrow for the aftmost ‘ylinder is positioned between 103° and 114" past BDC. 8, tone of the erankthrows Is not in the eor- rect position, adjust the lbricatrs ‘Soe Procedire 909-23. f ‘tmost ylinder Page 2 a When retering to this page. please quote Procedure Me0302 Edin 0227 MAN 88W Diesel AS(ge8) Cylinder Lubricators 903-2.3, ‘Adjustment | | i Note! ‘Any adjustment of tubvicator No.1 will ater the seting of lubricator No.2. ‘Therefore, any adjustment of lubricator No. 1 must be followed by @re-adjust- ‘mont of lubricator No. 2. 1. Remove the guards over the couplings. Loosen the sot screws inthe couplings ang pull the coupling wheels out of contact with the planet wheels. For adjustment of ubricator No.1, turn t Grankshalt in. anE«D lection unt ‘rankthrow for oyinder No. tis 108" past | 2 BDC for lubricator No, WW necessary, turn the lubricator shaft in AHEAD direction, shh coupling wets into contact win | ‘epi whe! fr hbator Not a sun one For adjustment of ubreator No. 2, turn the crankshaft in ANEAD rection ntl the crankthrow forthe aftmast cylinder is 108° past BDC. Uso the numbers on the turing wheel to termine the exact poston of the eranke throws, | i eR 4 } When referring to this page, please quate Procedure M90302 Edition 0227 Pages (4) MAN BAW Dial A'S903-23 Cylinder Lubricators Adjusiment Baw 3. Turn the pum shaft slowly in ANEAD drec- Pape ate) Wen roaring to tis page,please quote Procedure tion until the mark on the scale atthe load- in shaft ein tine with the mark on the lubri- ‘ator housing Re-engage the coupling wheel and tighten the set screw, Fo-chotk the setting See Procedure 903-2.1. ‘Mount the guard over the coupling 106802 Eston 0227 MAN BAW Dea ASCylinder Liner - ToolsPlate 90361-81 Cylinder Liner - Tools = Part Destin ‘em a Descapion 012 | Crossbar for eyinder ner ‘028 | Cylinder gauge, complete(oa) Cylinder Liner - Extra Tools ‘When referring fo tis page, please quote Plate 90962 Eaton 02 MAN GEW Diss AS Plate 9036202Plate o0362-02 Cylinder Liner - Extra Toot hem tom i Part Desorption a Part Description 018 | Wear ridge ming machine| (oa ‘Test Equipment for Alpha-Lubricator _—_—~Plate 90364-001 Item Ne.| Alternetive Thesed Type New | [Fase | ea7aieo oe 1 as ser ors TD [Fose: Woaat a SSS SOC O14 LAP) 135: ‘55/8-180 28 555991011 (G8) | 127 W2d.5x1 71d" 535 291" 012 (USAT 139, Wasa 71a 1535 391015 (KOR) | 152 weet .exi/ide 4 555 S91 010 (6) —] Luts 093 127 Then veforing to ie page, pease quote Pla NAN BAW Oieal NSPlate 9064-01 Test Equipment for Alpha-Lubricator hem No. Part Description tom No. Pas Description o19 032 one 056 068 088 15 vr 139 182 164 178 “Tool box Adaptor Pressure gauge cla ype, 0-60 bar Pressure gauge dal type, 0-10 bar Adaptor Rroducing vave Adaptor Adaptor ‘Adaptor ‘Adaptor Hose-stoet wih 2 union Fling and tasting valveey SAFETY PRECAUTIONS [| stopped engine X | Block the stating mechanism 2 | Shut of staring se supply X | Engage tuning ear | Shut of coating water % | Shut of fue of X | Shut of ucating oi Lock wxbocharger tre Data a oesion D1 Top clearance In crosshead bearing: ax, Min. 2 Ol wedgetengih, L= DS Hycraue pressure = diemanting tightening D-#_Crosshead bearing cap DS Connecing red complete 2.6 Beating shot ower 0-7 Crosshead, compete DB Piston = tightening torque or tightening angio ‘hon refering otis page, pease auc Data D140" Cation 0026 MAN BAW Daas AS Crosshead Bearing 0.58 mm 020mm 201mm 1500-1680 bar 1600 bar 170k9 1400 49 309 19009 4308 100Nms40 ° Data 108-1 Standard Tools: See Section 913 ZY, | ed @ 50900 Nin, 280-760 Ne 22400 kg, 2 800 ig =o @ EME 1 1.5m, 4x9m E— Qo xm, 2x20 & 21000 22000 kg, | | a t Page i1041 Crosshead Bearing | | | Plate 90451 7 k 120 | Spare Parts: rtm bia » | Pegeze ‘When referring to this page, please quote Data 010401 Edition 0026. MAN BAW Daas NSCrosshead Bearing 904-14 Checking ‘The top clearance between the journal and a = ‘new bearing shel isthe result of a summation of the production tolerances of the bearing components, For the top clearance ofa specie bearing, see the. measurement in the Adjustment Sheet In Volume J, OPERATION. 41. Open'the crankease door at the relevant oylinder. 2. Turn the crankthrow concerned to 90° be- i fore EDC on the exhaust side 3. Measure the clearance in the crosshead beating by inserting feeler gauge be- ‘ween the bearing cap and the crosshead journal, exactly next to the landing surface for the piston fod foot. See Data i 4, The citference betwoen the actual meas: urement and the measurement recorded in ‘he Aglustment Sheet (or the clearance not- od for a new bearing installed later) must Not exceed 0.1 mm. if s0, the crosshead bearing must be disassembled for inspoc- See Procedure 904-1.2 5. The woar limit ora crosshead bearing shell, 1S confined to a 50% recuction of the il wedge length (L). See Data, 6. For further extemal inspection of the cross: head bearing, see Chapter 708, “Bearings” in the instruction book, Volume 1, OPERA { 5, TION. (oieage)| ‘Wen refering to is page, pease quote Procedure MB0A01 Eaton OS TT) MAN BBW Oma! NS| soe Crosshead Bearing i : See (ea) ‘This procedure has boen divided into the fol. lowing, two dismanting tuations: + wih piston mounted + with piston removed ‘With piston mounted: 4. Turn the crankshaft down far enough to five access to the nuts and sorens on the Piston rod. 2. Mount two chains in the inner serew hates Inthe top ofthe crankcase In te athwarth- ship direction, for suspending the piston rea. 2 3. Loosen and remove the locking wite fom the screws on the piston od foot. Remove / the screws, | i U Page2 (1 ‘When refering to his page, please quote Procedure MOO40% Elin 0225 MAN BAW Diesel AS(oa) Crosshead Bearing Baw : Dismantling 9081.2 4. Mount a iting eye bot on each side of the | 4 piston rag. 5. Tumn the crosshead to TOC. Hook the chains to the liting eye bolts in he piston red “Turn the crosshead downward, and the pis ton rod will then remain suspended trom the two chains With piston removed: 6. Tum to BOC, 7. Place the spacer rings arcund the nuts and ‘serew the Mydraulc jacks on tothe studs Loosen the crosshead bearing cap nuts For operation of the hydraulle jacks, 806 Procedure 913-5. Remove the hydraulic jacks and the spacer Fings, and unserew the nuts. Page (1)904-1.2 Crosshead Bearing eng (aa 8, Mount the lifting attachments on the head of the connecting fod. 9. Suspend two tackles trom the iting brack- fs, in the athwarthship cretion. 10, Mount two eye bolts inthe top ofthe eross- head bearing ea. Hook the tacles on to the eye bolts, and remove the bearing cap from the engine ‘Check tne upper part of tho journal Page TO) When tring i page, ase ast Prete WGDAG] Eon 228le Crosshead Bearing 900-1.2 Baw . Dismantling 11, Place the bearing cap on one side on a couple of wooden planks, 12, Fasten tackles to the thed iting brackets fn the frame box wall 18, Tur the crosshead upwards unil the piston Tod lands on the crosshead, Eneure thatthe uide ring in the crosshead fis corecty in the centre hole of the piston rod, Do not remove the chains or titing eye bots. ‘ier refering to is page, lease quale Procedure MGO&D) Eaton @225———~—~SCS~S~*«é GT MAN 2W Dita! NS9001.2 Crosshead Bearing Dismanting E) 14 14, Turn to-TDG and attach the tackle hooks to the iting attachments. Haul the tackles tight 15, Mount the four supports for guide shoes on the crosshead guides, Carefully turn the eranke down towards the exhaust sid, uni the guide shoes rest on ‘the supports: ‘Adjust the support brackets to the guide ‘shoes 50 thatthe weight of the crosshead | is eventy distibuted on the tour supports Haul the tackles tight 16. Tun the eranithrow carefully towerde BDC hile following’ wih the tackles, thus con- tinuously supporting the connecting rod. 17. With the erosshead resting onthe supports, chock the lower part of the crosshead jour- ‘al and the lower beating shal, Regarding checking ofjoural and bearing ‘sells, sea Volume I, OPERATION, Chap- ter 708, ‘Bearings: Pageot Wen rterng fo is page, lease quota Procedure NG0401 Eaton 0225, NAN BRAD NSCrosshead Bearing Dismanting 18. tn cases where It fs necessary to remove the lower bearing shel, tit the connecting rod towards the doorway on the camshaft sid, using the tackles, Dismount the focking soraws, and turn the bearing shell so far up that an eye batt can bbe mourted Lit the bearing sellout ofthe engine. Win rfarng Yo spa MAN BAW Dasel AS jaase qucle Procedure WeDAD1 Edin 225 9084.2 Page? 00)1 soste Crosshead Bearing ; Mounting fsa ‘With piston mounted ‘With piston removed: 1. Mount and secure the bearing shell in the bearing housing “The excess height X isto onsure the cor- rect tightoning-down of the bearing ehell ‘and must not be eliminated. 2, Ralse the connecting rod to an upright po- sition. “Tr to TOC while “otowing’ wih the tack: los, for assembling the crosshoad and the connecting ro, “Take care that the guide shoes do not dam- ‘age the bearing shel. ‘8. Remove the supports from the crosshead guides, Remove the tackles from the crosshead, “Turn the erank throw to BDC. 1 the piston is mounted, slomty turn down ‘nll is fully suspended trom the chains. Pages (io) When ateag to this page,please quote Procedore MOO407 Eifion 0225 MAN BAW Oana} 0SCrosshead Bearing 9001.4 Baw) Mounting 4. Lif the bearing cap inte the engine. Lower the bering cap onto the crosshead and re move the tacties. Remove the ting st tachments from the connecting od. Note! “Take care thatthe boating studs do not damage the crosshead, 5. Tighton al tour crosshead bearing cap nuts simultanoously. See Data For operation of hyaraulc jacks, see Proc: ure 919-1, 6. Mount the piston, ‘See Procedure 902-1.4 With piston mountes 7. Turn the crosshead upwards uni the piston rod lands an the crosshead. Eneure thatthe {guide ring in the crosshead Nts correctly in the centre hole ofthe piston rod. When referring to this page, please quote Procedure MB0407 Ealtion 0225 Page 9 (10) MAN BAW Diol AS0014 Crosshead Bearing 8. Unhaok the ebains trom the liting eye bolts In the piston rod. Femove.the chains and ye bolts from the top of the crankcase, ‘rom the piston rod and from the crosshead bearing cap, 9. Turn down to BDC, tighten the serewe in the piston rod, and lock with locking wire Soe Data. Mount the locking wite in such’a way that the witeis tightened ia screw works lose. Soe Procedure 913-7. } | PapeT0(i) Wan rtaning'e tis page,please quot Procedure MAO(01 Elion 0235 ‘MAN BAW Dleeal AIS(oe) Crosshead 1042 Bay Data ‘SAFETY PRECAUTIONS | Standard Tools: See Section 913 ote ao [5] Enea ug pour —=0 oot A] sector oo a tommee 2 = pe At = dismantling 1800-1650 bar 2x 1000 kg Dt omimavangcy to ae b+ tomate ‘wom | er = os oxtstamine at | Cone ee Bardi om ae ee e linen refering tis page, pease quot Data ‘Di0402 Edition ooze —SSCS*~*~S«é‘When refering to this page. please quote Data D 10402 Ealion 0028 MAN BAW Diesel NS1 Diemount the piston, Soe Procedure 902-1.2 Dismount the main bearing lubricating oll pipes. . Dismaunt the cooling oll outst pipe from the guide shoe and the orain ol! slotted Pipe. Loosen and remave the screws which se- ‘ure the telescope pipe to the guide shoe. Inorder to reach the screw inthe corner be hind the telescopic pipe, use the offset too! along with 2 socket wrench Mount the retaining tol for the telescopic pipe on the stating box housing fr the tel fescopie pipe. “Turn the crosshead to TOC, Suspend the telescopic pipe by means of ‘ho tool. ‘Turn the crosshead to gain access to the nuts on the crosshead bearing studs. ‘Mount to eye bots inthe top ofthe crank: cease in the ore-and-attdcestion. Mount the spacer rings and the ydraulie Tacks for loosening the aus on the crass: head bearing studs, For operation of the hydraulic to0!s, see Procedure 915-1. Loosen the nuts, remove the hydraule jacks ‘and unserew the rut, Crosshead Dismanting When refering to tis page,please quote Procedure Mo0%02 Ealion (226 MAN BAW Dee NS904.22 Crosshead Dismanting 5. Mount eye bolts in the crosshead bearing cap and hook the tackles on tothe iting brackets inthe top ofthe crankcase. Dismount the beating cap and Ht it out of the engine 66. Mount the special iting too! and a shackle fon the crosshead, Mount the iting attachments fr fixing the connecting red, onthe head ofthe connect- ing ro. Faston tackles tothe iting brackets on the frame box wall and attach the tackle hooks {o the liting attachments. Haul the tackles tight ‘Altach the flatplated wire strap to the en- ‘ine room crane. Hook the engine room exane on to the iting teal on the crosshead, and it the crose ead. 7. Using the tackles, tt he connecting rod to- wards the exhaust side, walle turing the ranianraw towards the camshaft sie. “Tanstor the tackos from one liting attach: rant fo another as necessary when the crankthrow is 80° after BDC, ston turning. By aternate use ofthe tackles it the con. necting rod unt it rests against a couple of ‘wooden planks in the bottom of the bed: plate. Pagea ‘Wien referring to tis page, please quote Procedure M90402 Ecition 0228 MAN BE Dice ASGao Crosshead Dismanting 9042.2 8. Lower the crosshead to @ postion just ‘above the main bearing caps. Romove the guide stips and both guide plates from the guide shoes. Mount a ting eye bolt in one of the guide " shoes, and hook on a tackle, ‘Squeeze Ina plank between the guide shoes. 8. Suspond two tackles from the eye bol in the top of the rankcase In the foreand-aft direction, ‘Mount an eye bot in the top of each guide shoe. Mount the guide shee extractor too! on the aude shoo. Hook the tackles on tothe eye bolts in the {uide shoes, haul fight and, at the same time, using the guide shoe extractor tool, pull the crosshead towards the extractor tool unt itis free of the opposite guide shoo, Follow the movemert ofthe crosshead with the engine room erane. Lit up the tree guide shoe, 40. Using the guice oh the crosshead fom the remaining guide shoe, unt the crosshead is tree of the guide shoe. Follow the movement ofthe crosshead with the engine room erane, Dsmount the guide shoe extractor too, Lift up the guide shoe. 17)90022 . Crosshead Dismanting 414. Turn the crosshead 90°, 42. Mount the wire guide tool inthe framebox door opening. ‘By means of wire rope and tackles, remove ‘he crosshead from the engine. Protect the eroschead withthe rubber cov- ‘18 provided, and land I outside the engine. IM necessary, remove the guide shoes from the engine Pages) When refering fo tis page,please uote Procedure HO0402 Eon 0226 MAN BAW Diaao NSlee Crosshead 042.4 Baw . Mounting 1. Attach the lat pated wire strap tothe en= sine room crane Lift the crosshead into the engine, using wie rope, tackles, and the engine room “Turn the crosshead 90° Loner one guide shoe and mount the guide shoe extractor tool, Use the guide shoe extractor tooo pullthe crosshead 90 far trough the guide shoe |= thatthe other guide shoe can be lowered, Follow the movement ofthe crosshead with the engine room crane. Lower the other guise shoe. Use the guide shos extractor too! to push the crosshead towards the second guide shoe, Follow the movement ofthe crosshead with the engine room crane, When rotering to tis pape, please quote Procedure WOOAO2 Eden 0225 Pages 7) Mas aw Oree AlsCrosshead Mounting fae 5. Mount the guide plates on the side of the ‘guide shoes, Tighton the secews and lock them with lock ing wire. Soe Procedure 919-7. Using the engine room crane, it the ross head to a working postion and mount the {guide strips on the side ofthe guide shoes ‘Tighten the serews and lock them wthiock- Ing wire. See Procedure 913-7, 6. Using the tackles, it the connecting rod to vertical position while turing the crank throw to BDC. 7. When the connecting rd is Ina vertical po-~ sition, lower the crosshead and land i en ‘connecting rod. Femove the iting attachments from the connecting rod head. Remove the ling tol from the crosshoas, When aang Wo his page,please ute Procedure MOG4G2 Eaton 0225 MAN BEW olen ASCrosshead 9042.4 Mounting 8. Mount the spacer rings and the hydraulle Jacks for tightening tne ruts on the cross head bearing studs. For operation of th hydraulic toole, soe Procedure 919-1 Mount the drain oll slotted pipe and the ‘cooling oll outet pipe on the guide shoe. “Turn the crankshaft to TOC, ‘Land the telescope pipe on the guide shoo. 10. For tightening the bolt in the comer bebind the telescopic pipe, use the offset tool along with the torgus wrench. 11. Mount the lubricating el pipes on the main bearing caps. 42, Mount the piston. ‘See Procedure 902-1.4 ‘Winen refering ois page, please quote Procedure WO0402 Ein 226 Paso MAN Saw Owwel NS‘SAFETY PRECAUTIONS Stepped engine [=] P=] =] 1 Block he stating mechani Shut of stating ar supply Engage turing goar Shut of cooing water ‘Shut of flo Shut of bicating of Lock turbocharger rotors z ‘Acceptance era with Piston in canie (A crecton) eas. points PEIPA. Nw we f ZAZA. Ona N: Now and cold engine wih staybots tightened (loss than 100 runing hour). (0: Engine in servic, When referring to this page, please quote Data D10408 Edition 0023 NaN BaW Dias AS Reciprocating Parts Data | Standard Tools: See Section 919, Value 05mm a5mm 02mm oamm 9mm osm tm | 40mm 1043 Page 12)Reciprocating Parts Data Spare Parts Page "Wen ein page plese qi Data DTS Fn 0| Reciprocating Parts 9048.41 Baw Checking In order to achieve uniform measuring condi- ‘ions on board, the ships vim must be as close as possibe to 0°. 1. Mount @ transparent plastic tube along the length of the Beaplate. Bend each end approx. 250 mm up along the fremebox side. See T. _ FF the tube with water (possibly coloured) ntl the water level is apprex. 100 mm from the end of the tube “Tim the ship unt the atference between the water love § fora and aft is loss than 1.5 mm per 1000 mm. Measurements are o be taken witha ruler, 2. Turn the engine in asrenn direction to 45° aftar BDC fthe guide shoe must rest against the crosshead guide). 3. Mount the tool between the guide shoa/ guide strip. For this purpose, use the third Leal threaded bole trom bottom of guide shoe | {this hole Is normally used fer fastening the {guide trp to the shoe) Al “g ‘By means ofthe two sorews in the mice Of the too), pull the guide shoes unt they | rest lightly against the end face of cross. head. Notel ‘When the tool Is mounted, i isnot possi bie to urn past TDC and BDC. ‘Viner refering to is page, pease quote Provedire MGO%09 Eaton 3 ~~~) MON Saw Buea NSi 9043.1 _ Reciprocating Parts Checking Baw oe ae 4. Check the centering ofthe piston in the ey- Inder liner by measuring the clearance (rom the scavenge air space with a long feeler gauge) between the piston skirt and the eylinder finer in the Fore and At posi- tions (PF-PA). ‘Make sure thatthe pistons clear ofthe cy Inder ne Inthe fore-and- loo} 2 —___ O76 29) 015 4 090 ‘Win refering to is pag, please quco Pate S05Si Fain 207 MAN BBW Oso VSPlate 90561-207 Crankshaft, Thrust Shaft, Main Bearing, Ete. Panel item No. Pas Description Tem No. Part Description ors, cer 40 078 038 090 10 m 13 135 we 184 “Too! pane! Name pate Polly for wire Ling to! or main bearing cap Dismanfing tool for main bearing chet ‘Mounting tool or hin bearing shell Tool for turning out segments Ling atachipent Fetaining tools for main bearing shells Liting 00! fo elit valve Mounting toot fo thin bearing shot Liting too! or main Bearing shePlate 90861-068 Main Bearing - Tools 3 2g ij Plate 90561-68 Main Bearing - Tools item No. Part Description Tom No. Prt Desccption cet 033 085 057 069 | 070 082 098 18 128 1a (O-ring with back-up ing, 75185 mm ‘O-ring with back-up ing, 6070 mam Ling toot Nat Hyéeaute jack, upper Exinsion stud Supporting bok Stud ster O-ring with backup ing, 65778 mm Hydrate jack, ower Hiydrause tot for main bearing, completo| ay Crankshatt - Tools ( : nen referring to this page,please quote Plate 90552 Eation 0115 Page 1) MAN BW Diet ASPlato. Crankshaft - Tools 90562-0115 (aes) item item ; ree Item Description ie Item Description 015 | Measuring too! for main bearing clear- 027 | Lifting tool for thrust shaft | 039 | Liting tool for crankshaft 40 | Scrow 052 | Crosspiece | | Page 2 (2) When referring to this page, pleaso quote Plate 90562 Evition 0115 MAN B&W Dist AISTuning Wheel - Tools Plate 90563-012 Ki Demerrnnnis LER ee When rearing otis pape, Peace quota Plate G0563 Elion 12 MAN BAW Dial NSPlate 90563-12 Turning Wheel - Tools Part Description brad Part Description Hycrauic jack (O-ring with back-up ing, 758 mm ‘O-ring with back-up rng, 55185 mm _| Spacer ring Hyrule tol for taning wheel bots, [complete $8882 |F5(oa) Main Bearing - Tools Plato (aes) : 90565-0013 {ion ering otis page pleas quote Plato Pass Eton 0013 Page 1@) MAN BAW OrelPate Main Bearing - Tools Pitlescos : ing- Too (oe) Mem | tom Deserinton Him | om desertion 11 | Utng et er ma beer cap cos. | Puy re £82. | Nowe war min bat cee | | ar Ven oe 1 te page, place une Pate PEGS Eaton 0018 MAN BAW Diesel ASPlate 90570-0002 Page (2) . 8 i § g 3 3 : i : i 8 i ti 33Plate Thrust Shaft - Tools Ptr ana (oad) = ion We] tm Desciption Rem] nam bosopton al | een ae Se ‘MAN BAW Disa ASGao ‘SAFETY PRECAUTIONS Stopped engine Bock he tating mechanism ‘Shut of starting air supply Engage tuning goar ‘Shut of cooking water ‘Shut off fel it % | Shut off tabreating oi Lock turbocharger rotors Ot Max, wear of tooth on chain wheel D2 Original ong (chain pitch x 10 rks) DS 101inks measurements 11% of onsionee chain crapping of chain When referring to tis pa MAN BAW Diabet NS Chains Data 3.0mm 835.0 mm 243.46 mm Standard Tools: See Section 913, ZY please guste Data D100" Eton 0026 106-1106-1 . Chains Data i > 5 i rap Plate 90651 bea i ° | (©, | os . if os | spererans | eet Som ow Wen rearing to this page,please quote Data 010801 Eon 002s ;o™e ‘er pees MAN BLW Diesel AS i‘S50MC-C Chains Checking 906-14 Carry out the inspection as follows: 1. Make a general inspection for loose bolts and screws 2. Inspect tube cil pipes for damage, and check jet nazzles for possible stoppages or ‘deformations. 8. Examine the rubber track ofthe guideways for eracks or ether damage. Roplace the guideway i bits have started to be “plucked out" of the rubber track. 4. Chock the testh ofthe chain wheels, If ab- Formal wear is found, take a measurement (00 Data), Measurements are best taken by placing a or straightedge avor points A and B anc then measuring the distance D-1. 5, If abnormal wear is obsorved at the bottom of the teeth, make a drawing in seala 1:1 of the teeth and wear profile. Measure the geometry of the bottom and note down all avalable measurements n= ‘luding D-A and D-B on the drawing, O-8 is best found by placing a short straightedge between the tp of the two teeth For assessing the measurement results, contact MAN BSW Diesel In mast cases, scratches caused by the ide plates ofthe chain willbe found on the ‘sides of th tooth. Such scratches can gen erally be considered normal When rearing 1 is page, please quote Procedure 06.7 Elon 208 NAN B&W Diet A'S Page| 906-14 ‘S50MC-C. Papez@ 6. The chains tor the camshatt dtive are matched together to ensure an even load ‘istrbution. ‘Tokeep such matching chains in thelr pars, the side plates ofthe outer link nearest 10 ‘tho assembled link have been marked with year, month, day and chain number. Example: No. 1 order, 340520 1A 1340520 18. {(@40520 10, possible 3 chain) No. 2 order, 1840820 28 1340520 28. (@40520 20, possible 3 chain) (On the same links there is an arrow (->) which indicates the rounting direction. Check the chains for eracks on possibly de- fective rollers and side plates. (Chock that the chain rollers can run trealy and thatthe chain links can freely move on {the pin and bushing (that they are. not “seized” between the pin and the bushing) tis normal, however, that the rollers get Hight, circumferential scratches during the runningsin petiod. These fine scratches are ‘of no importance and need not be consid- red. It fe recommended that each single lnk i checked. 7. 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 Soo Procedure 908-23. ‘When refering tis page,please quote Procedure 806-17 Edin 203 MAN BW Disa] AS‘SB0MC-C Chains 906-4.2 : Dismanting Ik may become necessary to disassemble [ 4, the chain if, for instance, cracked rollers of seizures between pin and bushing nave boon discovered during the inspection Procedure 806-1.) Note! ‘ime a chainlink is cisassembled, ink must always bo fied as the link pn press-ftis destroyed when breaking the chain, ‘When a new links fitted in one chain, the corresponding link nthe other ehain ‘must also be renewed. 1. Remove the tension on the chain by loos [2, ting the chain tightener. (See Procedure 906-2.) ‘Turn the engine until the slack part of the ‘chain, with the chainlink that Isto be dis- assembled, isin a favourable postion for tne work 2. Mount a wire round the link rors a short distance from the disassembly polnt, and tighton the wire lightly wih @ tackle Protect the link rollers over which the wire 's wrappad. Note! the chain is to be completly removes, | | * contact MAN B&W Diesel for further information. ‘The fyoting of the pins that are to be pressed out Is to be chisoled or ground ‘vay. 8, Place the chain bursting too! over the outer chain link, and diemanti the link by ater- nately tightening the screws on the foo ‘Won refering to is pape, please quale Procedure SOB 2Edw@N a ~*~ OS) MAN BaW Diet A'S| Papeete) Chains ‘S5OMO-C Mounting Bofore assembling the inner and outer Inks, clean the pins and bushings. 41. Combine the inner chainlink with the outer chainlink and mount the compression toc, Force the loose side plate of the outer link into place by alternately tightening the ‘screws on the comprossion tol 2. When the link has been assembled, remove the compression tool and lack the pin ends by riveting Ropeat thie procedure until the chain has been assembled FRamove the tackle and wire and adjust the chaln tension, (See Data and Procedure 906-2.) WAN 84 Dees AISChains Checking Baw) 906-14 Carty out the inspection as follows: 41, Make a general inspection for loose bolts ‘and sorews, 2. Inspect lube oll pipes for damage, and ‘check jt nozzles for possible sioppages or deformations 3. Examine the rubber track ofthe guideways for cracks er ether damage. Replace the guideway if bits have started to be “plucked out of the eubber track. 4. Check the teeth ofthe chain wheels. If ab- ‘normal wear is found, take a measurement, Measurements are best token by placing a short sraight-edge over poinie A ang B and then measuring the distance D-. 5. If abnormal wear Is observed atthe bottom of the teeth, make a drawing in scale 1:1 of ‘the teotn and wear prof. For assessing the wear proflle, contact MAN BAW Diesel, In mast cases, scratches caused by the ‘side plates ofthe chain willbe found an the sides ofthe teeth. Such seraiches can gon craly be considered normal, When refering to is page, pase quote Procedure M9801 Ean 0227 MANBAW Die! NS Fae906-141 : Chains Checking (Ga) - 8. The chains for the camshat drive are matched together io ensure an even load distribution. ‘To keep such matching chalns in thei pairs, the side plates of the outer link nearest to | the assembled link have been marked with year, month, day and chain number. b2—— Example: No.1 order, 1840820 18 == 840820 18 (640520 1C, possible 3 chain) } No. 2 order, 840520 28 1840520 28 (240820 26, possible ard chain) (On the samo links there ie an arrow (->) which indicates the mounting drection Check the chains for cracks on possibly de- ‘ective rollers and sie plates. CCheck thet the chain rollers can run treoly ‘and that the chain inks can freely move on | the pin and bushing (that they are not “seized” between the pin and the bushing), i It is normal, however, that the roles get light, ‘circumferential scratches during the runningsin period. These tine seraiches are of no importance and need net be consid- red Its recommended that each single fink is checked. 7. Check chain wear by measuring the length ff 10 chain links and comparing the result withthe value given in Data. Hf necessary, adjust the chain tightener See Procedure 906-2.3 | Peer When refering to tis page, pease quota Procedure Ma0G01 Eton O22]. | ‘MAN Baw Diesel VSChains Dismanting It may become necessary to clsassemble the chain if, fr instance, cracked rollers or selzutes between pin and bushing have been discovered during the inspection. ‘See Procedure 906-1.1, Note! Every time a chain inks disassembled, anew link must always be fited as the link pin press-t ie destroyed when breaking the chain When a new linkisfted in one chain, the corresponding link in the other chain must also be renewed. 1. Remove the tension on the chain by loos- ‘ening the chain tghtoner. (See Procedure 906-2.3) ‘um the engine unt the slack part of the chain, with he chain tink that Ie to be ois- assembled, is in & favourable postion for the work 2, Mount a wire round the link roles a short distance from the disassembly point, and ‘ighion the wicelighty witha tackle, Protect the lnk roles: over which the wire Js wrapped, Notel Ifthe chain to be completely removed, contact MAN B&W Diese! for further information. The rioting of the pins that are to be pressed cut Is to be chiseled of ground vay. 8. Place the chain bursting tol over the outer chain link, and dlsmantis the link by ater- nately tightening the sorewe on the tool. When relering to his pge, please guote Procedure MOODY Fain O27 NAN BAW Dice! A'S Paseoi | S014 : Chains | Mounting (a Before assembling the inner and outer links, clean the pins and bushings. 1. Combine the inner chain ink withthe outer ‘hain ink and mount the compression too, Force the loose side plate ofthe outer link into place. by alternately tightening. the ‘Screws on the compression tool, 2. When the link hes been assembled, remove the compression tool and lock the pin ends by rhting. Repeat this procedure until the chaln has been assembied. Remove the tackle and wie, and adjust the chain tension, (Bee Data and Procedure 9062.3). i Fagea()__ Whan eforing foi page, please quote Procedure MG06D) Eaton 0281 ‘MAN BAW Diwel AS‘S50MC-C Chain Tightener 106-2 (Ferd ges oy ‘SAFETY PRECAUTIONS ‘Standard Tools: See Section 213 eee araaeantomasin Zz ehoteareyer rey Engg pe =e fates gees ‘Shut off fuel of —et ecoaeaeen aaa i Data ot Oeetptan yo +t Ciearance 04 mm D2 Tightening angle 720 (= 12 hexagons) 3 Reduced tightening angle 00" (10 hexagons) j D4 Max distance 265 mm When rearing otis page, please quote Dala Sheet 106-2 Editon O7 Pope 1 MAN B&W Dawa! A'S106-2 Chain Tightener ‘S50MC-C (For 4.6 0yL engines ony) Data Spare Parts Preteen Deion oy Page2 2) ‘When refering o Wis page,please quote Data Sheet 106-2 Edlion OT MAN a8 Dns) ASSBOMC-C Chain Tightener ‘Adjusting 1. To retighton the chaine, loosen nuts A, B, © and D to tree the chain tightaner bol 2. Turn the engin caine fe on the wheel thatthe stack part of the 1 side asthe tightonar if balancoweights are mounted, continue the turning unt thoy are hanging vertically downwards. 3. With the balancowsights in this position, tighten nut B on the chain tightener bolt un: Al there is a clearance between the shaft {and the nut as stated in D-t Then tighten nut B as stated In D-2 (eee Data). ‘When refering te his page, please quote Procedure G02 Eaion 208 Pease MAN BAW Oise! AS906-2.3 (Fortsoy.enginos ony) Chain Tightener ‘s50MC-C. Adjusting Pager When refering tie page, plbaze gua Fre 4. Tighten nut © hard against the contact face ofthe shaft. Tighten nut D. Lock nuts © and D with the tab washer, 5. Tighlon nut A Lock nuts A and B withthe tab washer. 6. Measure distance X. 7. tthe chain is worn (X>165 mm), repeat the procedure from step 1, but lighten nut bly to the reduced tightoning angie, so Dat, It distance X exceeds the max. distance (see Data, find and eliminate the cause of the abnormal chain elongation, 0g. a de- fective chain, damaged chain’ whee's of bearings, ete. Repeat the procedure trom stop 1 ore 9062.9 Eaton 266 VAN BE Diesel AS‘s50M0-C SAFETY PRECAUTIONS ‘Stopped engine ‘Block the stating mechanism ‘Shutoff staring ar supply Engage turing goar ‘Shut of cooing water Shutoff fue ‘Shutoff bricating 08 Lock turbocharger rotors Data et oxen DA Clearance 1-2 Tightening angio (7 hroxagocs) Chain Tightener 1062 Data (For 7-8. engees oy Standard Tools: See Section 913 ZY c=E 4 mm When efaring fis page,please quot Data Shoot 105-2 Edion 04 Paget 2 MAN BAW Diesel A'S| i 106-2 Chain Tightener ‘SSOMC-C (For? engines ony) Data ‘Spare Parts Pau, eit or Page2 ‘When erring t this page,please avoto Data Shoot 106-2 Eaton 04 "MAN BAW Disa) AS‘SS0MC-C Chain Tightener 906.23 Adjusting (For7-8 oy ergs ony 1. To rtighten the chains, toosen nuts A, B, | * C and D to tree the chain ightener bo, 2. Turn the engine so thatthe slack part ofthe chains is on the same sido as the tghlener whee 8." Tighten nut B on the chain tightensr bolt ntl there is a clearance between the shaft ‘and the nut ae stated in D-1 Then tighten nut B as stated in D2 (soe Data). For chain wear, see Procedure 906-1.1. When eferig t tis pape, pease quote Procedore 0062.3 Eaton 200 Pose 1 2) MANBEW Owes WS906-23 Chain Tightener ‘S50MC-C. For78.y1 engines ontp Adjusting _ - > Page?) When roaring to tis page please quale 4. Tighten nut € hard against the contac face ‘ofthe shat. Tighten nut Lock nuts © and D withthe tab washer 5, Tighten nut A. Lock nuts A. and B with the tab washer. ‘The numberof times that etightening can be carried out depends on when the i for ‘scrapping the chaln has been reached. Seo Data page 106-1. THAN BAW Diesel AS‘S50MC-C Camshaft 106-3 Data SAFETY PRECAUTIONS ‘Stopped engine Block the staring mechanism ‘Shut off staring ar supply Engage tuning gaar Shutoff cooling water ‘Shutoff fut ot Shut offlubicaing cit, Lock turbocharger rotors Data a, cect Det Pin gauge fortop dead centre fenton No.1 (Gheck measurement 0-2 Fin gauge foreamshatt (Check measurement 0-3 Max. permissible change in ead angie ‘corresponding to 641 om p 35mm Standard Tools: See Section 913 or Vien rearing otis page, lease quote Data Sheet 106-9 Eaton 02 Page 1@) MAN GaW Dizol A'S106-3 Camshaft ‘S5ONIC-C. — Data, | Spare Parts tem aeton or Page 212) ~ ‘Wher refering to this page, please quote Data Sheet 106-3 Eaton 02 MAN GRW Oise! AS‘SAFETY PRECAUTIONS ‘Stopped engine Block he eating mechanism ‘Shutoff starting a supply Engage tring gear ‘Shut off cooling water ‘Sha off fel ol ‘Shutoff viating of Lock turbocharger rotors EERE x)=] Data fe Onan D1 Pin gauge ortop dead entre of eanitvow No. (Check measurement D2 Pin gauge forcamahat (Check messurement D8 Max. permissible change in load angle corresporsing to Camshaft Data 23mm 40 mem ea 8mm Standard Tools: See Section 913, Bx When refering to this page, please quote Data 010603 Eton 0020 MAN BAW Dial NS 106-3 Pae1®1083 | Feee Camshaft Data once o ‘When referring to tis page, please quote Data 10603 Edition 0020 MAN BAW Dies ASSSOMC-C. Camshaft a Checking 1. Tur the eranktheow for cylinder 1 to TOC. “Tum In the AeAo direction to ensure that {he tension ofthe chain on the chain drive Js correct. It necessary, adjust the chain tension. _ See Procedure 906-2. Chock the TOC of eylinder 1 against the ‘mark on the turning whe. 2, Check the TOC position with the pin gauge: | 2. fn the erankthrow, Dt. i When rearing to tis page, pleese quote Procedure 60637 Eon 23 MAN BAW Disa A/S PagetPage?) Camshaft ‘s50M0-C Checking 8. Postion the camshaft pin gauge inthe een- ‘re punch mark, and measure the deviation, i any, in lead angle For max. permissible change, see D-9. 4. Check and adjust the cylinder lubricate. ‘See Procedure 903-2.1. Check the setting ofthe starting alr dieib- Wor. See Procedure 907-1.1 '5. When cheoking the camshatt position, also check the running surface of the cams. [As the inspection must Include the entre ‘surface of the cam, the cam should be turned the whole way round during the In ‘specion ‘The running surface of the cam must be completely smooth and bright 6. I light scratches are ascertained, remove ‘them by carefully polshing the cam in the lesion of rotation with a tine earborun- dum stone. Such light soraiches can appear ifthe roller guide and the cam are notcor- rectly algned. Inthe event of heavier sratches i direct taking ofthe material on the running path, MAN B&W Diesel should be contacted for Father stations Vien rearing to his page,please quot Procedure 0637 Eaion 03 MAN BRW OAS| | | ‘S50MC-C Camshaft Adjustment 9063.3 41. I the chains prove to be so heavily worn that the deviation between the measuring Points and the pin gauge hes reached the ‘maximum value stat 3.1, MAN BBW Diesel should be contacted ‘or further instructions. in Procedure 906- page please avoieProvodire S053 Eon 208(ees) Camshaft Bearings 106-4 mae Data | SAFETY PRECAUTIONS Standard Tools: See Section 918 7] serve eae [2c] Socket mechani ZY % x Shut of stating air supply | Engage tuning oar == ‘Shut off cooling water Sto lot oe ‘ [3] snort ot tector te @ Data — ne once nw Ds eit of bean cap ‘810 2 Toning owe bet ap 15h 28. Cenranoettreenca! sears wang 2.08 nm 24 Max weartteuing shel 001m | — eserves, pose gost Das botea Eaten oie SSS MaNBaW Dial AS106-4 Camshaft Bearings Data i. Plate 90651 bag °°) (© © oO 5 oss or Spare Parts Ft ean ov Page 2@ len elering t this page, rease quote Dala 070804 Eaton 0078 MAN BAW Dlocel NSCamshaft Bearing 906-41 a hocking 1. As the upper shell of the camshaft beering ‘sssombly has bean dispensed with on thle tengine, itis no longar necessary to meas: Ure the top clearance of the camshaft bear ing, DDismount the inspection covers trom the front of the camshart housing. Check for wiped-out metal at the bearing fends, and for fragments of metal in the ‘camshaft housing, In the event of any signs of anomaliee, the i Dearing shell must be dismantled for closor Investigation and, if necessary, the beating shell must be replaced, It no anomalies are found during the visual inspection, diemanting need nat be eartied out. ‘When checking the camsnan bearings, is recommended falso to check the condition of the fusl ane exhauet came, See Procedures 908-8 and 209-9 liter ralaring tots page,please qucle Procedure M0G5D4 Eahion 21S Page 18) MANBAW Oa NS906-4.2 Page 216) Camshaft Bearing Disaring (Gaa\ ‘Before iemantting any camshat bear- | Ing, the main chain must be reloved of tension by loosening the chain ightener to avotd damaging engine pars. See Procedure 906-23. 1. Rornove the inspection cover rom the eam- shaft housing Dismount the lubricating ot! connecting pipe and the plug secews trom the baseplate ver the Bearing in question. Lt the roller guide ofthe exhaust valve hy ‘raulle pump. See Procedure 908-7. 2. Loosen the bearing cap screws through the holes In the baseplate. Remove the screws from the bearing cap. Mount two 10 mm eyo bolts in the pertain- Ing threads on top ofthe bearing cap. 3. Side the bearing cap carefully towards the exhaust cam dso. “Turn tho boaring cap and pull out through the inspection opening ‘When eeving otis page,please quate Procedire HG0B04 Eon 021 MAN BBY Diese ASCamshaft Bearing 906-42 man Dismanting 4. Place the hydraulic jack in the camshaft housing underneath the circular part ofthe exnaust cam. Pace a dial gauge on the camshatt, and it the camshaft 0.30 mm. 5. "Press lghty onthe upper edge ofthe shell to turn the shel up over the camshatt, Remove the shell from the camshaft hous: ing When referring to this pape, please quote Procedure MGO6D4 Edin G215 Paes 6 MAN BaW Oreo! NS906-43 Pages Camshaft Bearing Overhaul mane For assessment of the bearing condtion, see Volume | OPERATION, Chapter 708 "Bearings Inspect the entire surface of the bearing Journal for seizures, UW seizures are found on the bearing journal surface (on ascount of bearing Bresktown). polish the surlace with a fine carborundum Stone to re-establish a bright and emooth ‘surface, By closely oxamining the sliding surface of ‘the bearing shell visual, an impression ‘can be formed of whether tho lubrication of the bearing surface hes been inuficiont oF centiraly mssing. Normally, cmshatt bear ing damage only occurs due to faulty lube catlon, Measure the thickness ofthe beating shell with a micrometer to check the amount of ‘When rfering to this page lease quote Procedure MOO6O4 Eaton 0216fd _ Camshaft Bearing 906-44 | =) Mounting 1. Clean tho bearing journal, the bearing sup- port and the bearing shel, 2. Coat the bearing shell with ol, mount the sholion the camshaft, and turn tint place. ‘8 Place the bearing cap on the camshatt next "fo the exhaust cam. Notet ‘Be careful nolo seratch the exhaust cam roller surface, Tun the bearing cap to an upright position and slide tcaretlly onto the bearing shel Remove the aye bolts and mount the outer- ‘most bearing cap screw. ‘Tighten the outermost sorew ightly unl the | clearance given in 0-3 Is reached, Then ‘mount and tighten th innermost serow with ‘a forque spanner. Seo Data D-2. This pro- cedure ensures that the outermost seraw vill obtain the correct torque. Check the torque on the outermost screw i ih a torque spanner. hen refering to his page. pease quote Procedire MO0GD4 Eaon zis ————~Page 5 @) ‘ieee A'S906-44 Camshaft Bearing : owning (ay 5, Check the clearance D-3. Then mount the lubricating of pipe and the plug sorew in the baseplate. ‘6 Lower the camstiat into positon, Remove the hydraulic Jack from the camshat hous- ing. 7. Clean the camshatt housing and mount the Inspection covers. en referring Wo hls page, please quote Procedure NGOGI Edition 0215 THAN BEW Oieea VS‘S50MC-C Moment Compensator 106-5 - Data SAFETY PRECAUTIONS ‘Standard Tools: See Section 913 [X] stoned eine [DC] sock estan mechan ZX, be al ‘Shut off staring a supply Engage tuming oar ‘Shutoff coating water ‘Shutoff to ‘Shut off bain cit Lock turbocharger rotors Data | ‘Wien referring to this page, please quote Daa Sheet 106-8 Eaton O2 Page 12) MAN Gaw Diseal A'S1065 Spare Parts 20) oman Moment Compensator Data ‘S50MC-C. When rearing otis pape, please quote Data Shoot 106-6 Eaton 2 WAN BkW Basel NS‘s50M0-C Moment Compensator Checking IW dismanting has been necessary, the ty: \welghts must be assembled in the correct po- sition in relation to the engine crankshaft. Incorrectly mounted tlyweights can cause (heavy) vibrations of the engine, ote! ‘The following applies 1o a elockwiee- rotating engine [Aftmost 2nd Order Moment Compensator ‘Turn the crankthrow of cylinder No. 1 In the ‘aneA0 dlreetion tothe position shown inthe fig ures for 4, 5, 6-cyinder engines, respectively ‘Check that the fyweights point vertically down wards (max. deviaton’ one-half. chalnwhe tooth pitch). ‘Turn the camshaft relative tothe crankshaft in accordance with the ‘valve opening diagram, {and then mount the chain, Tighien the chain In accordance with the in- suction ‘See Procedure 906-2.3. Tum the crankthrow of eylinder No. 1 in the ‘nueAo direction to TDC and carry out fine justment of the camshaft Foremost 2nd Order Moment Compensator “Turn the crankthrow of cylinder No. 1 in the ‘ate40 direction to the positon shown inthe fig Utes for 4,8, G-ylinder engines, respectively. ‘Check thatthe lyweights point vertically down wards (max. deviation one-half chalnwheet tooth piteh) and then mount the chain, Tighten the chain in accordance with the in- struction See Procedure 906-6.2. Note! For an anticlockwise-rotating engine, tho dogrees mentionad in the respective figures must be before Toc, not after the. When refering to ts page, pease quote Procedure 60657 Evan 207 MAN BAW Dieal AS| 9065.3 ‘Moment Compensator S50MC-C. i a Adjustment 1. When tightening the chain, bring the tw ‘lyweights to a vertical downward position. 2, Release the lock washers and loosen nuts At, A2 and B2. 3. Tighten nut B1 untl he spring s completely ‘compressed. Then loosen nut Bt unth the length ofthe spring matches the number of ‘mm indicated on the dataplate mounted on the spring, (F=14000 ma Page 213) ~ Wien refering to his page,please quote Procedure 806-59 Edion 207 | ‘WAN B&W Baad NS‘S50MC-C Moment Compensator 9065.3 Adjustment 4. Tighton nut At light Make sure that this does not compress the spring further. Tighten nut A2 white holding nut AA with a spanner. Lock botn nuts withthe lock washer. ‘Tighten nut B1 until the thrust ange of the spring les hard against the distance tube, Tighten nut B2, and lock both nuts withthe Jock washer. ‘When referring to fs page, please quote Procedure 8066.3 Eaton 207 aN BAW Diet AS Pages)| ‘s50M0-0 Replacement of Cams on Camshaft 106-6 ta | sarery precautions |-Standerd Tools: Se Seton 918 [><] stopped engine LX | Block the starting mechanism 18, 24mm 7] stot sang at wpe = X | Engage turing gear Wz2am Shut cl cosig water X | Shut off fuel oi! 1xam i | Shitting ct 140760 a onl ° —— = 750.2000 Nm Lock utethage Data ri) D4 Waning sah tuscan 8S D2 Fueam mialmovinet 145mm 8 “Thtring me orecows 6808 meereah D4 Mang sro oximstean 5 nm 05 haustcam sta movement 220mm | D6 Tightening torque for screws 560 Nm | Paton 7 Ttteing me ersewwa Nn Rhone | ‘When eforing fo tis page, please quote Data Shoot 106-6 Eaion OT Paget) Meee106-6 Spare Parts 90871-115 158 9061-115 165 9ostt-115 191 ooett-115 201, Page2@) Replacement of Cams on Camshaft ‘S50MC-C Data meton o Seren 2 Repacam fue 1 Screw 2 Repair cam, exhaust 1 When refering to his page, please quote Data Shoat 105-8 Edion Of NAN BAW Diol A'SMo-c Replacement of Cams on Camshaft Fuel Cam 4, Remove the front cover of the camshaft housing, 2, Lit the roller guide from the cam in ques tion, See Procedures 908-5 or 90946, 3. Tum the camshaft eo that the marking seratch can be seen, : 4. Extend the marking scratch on the shatt by D-t. See Data, Whe. ry MANBEW Dies A'S 2 Eaton 207 Paget)Replacement of Cams on Camshaft Dismantling i Pesoa Moc Remove the plug trom the cam and mount gaskets and snap-on connectors instead, Connect the snap-on connectors tothe hy- raulc high-pressure pump. ‘Apply oll pressure to the cam, using the high-pressure pump. When oll seeps out along the cam, press the cam sideways, in the direction towards the forward end ofthe engine, Tho cam should be moved as stated In D-2 tobe sure that it gets tree ofthe liner fr the roller guide, In case the cam cannot be moved as de- scribed in tem 6, MAN B&W should be con- {acted for further instructions. When refring to tis page, pease quote Procedure 906 62 Eaton 201 MAN BEW Disa ASmoc Replacement of Cams on Camshaft 086.2 Dismanting | Exhaust Cam a 8. Remove the front cover of the camshaft housing, 410. Litt the roller guise trom the cam in ques: tion. See Procedure 908-6. 11. Extend the marking scratch onthe indicator drive cam onto the camshatt Extend the marking scratch on the exhaust ‘cam onto the camshaft by D-8. See Data, hen refering fo is page, please quote Procedure 8-62 Eatin 207 Pas i MANBAW Diet A'S906-6.2 Replacement of Cams on Camshaft oc Dismanting Panes 12, 18. 14 Dismamtia and remove the Indicator drive cam from the camshaft, Femove the plug trom the cam and mount (g8skets and snap-on connectors instead, Connect the snap-on connectors tothe by- rac high-prossure pump. ‘Apply oll pressure to the cam, using the high-pressure pump. \Wnen ol! seeps out along the cam, press the cam sideways, in the direction towards the aft ond of the engine When rolering to this page,please quote Procedure 06-62 Ealion 201 MAN BaW 0} asoc Replacement of Cams on Camshaft Dismanting 18. The cam should be moved as stated in 0-5. | 15. fa tobe sure that t gets tree ofthe liner forthe roller guide, 16. In the event that the cam cannot be moved as described in item 14, MAN B&W should 906-6.2 bo contacted for futher Instructions. ‘When rearing othe page, please quote Proc MAN BaW Diesel A'S ~ Pages)906-64 Replacement of Cams on Camshaft Mo. Mounting Fuel Cam 1. Before mounting the two-part spare cam, the bore and the area on the shat must be degreased. Place the two:part spare cam on the shaft, ‘mount the four screws, and ghten slighty, 0 that the gap between the two parte is equal at both sides. 2. Make sure that the marking scratches on the cam and the camshaft coincide, and that the runing surfece of the cam is op- posite the role. Tighten the screws just hard enough to avoid that the cam slips when the roller tuide is lowered onto the cam. Measure the tuel cam lead (see Procedures 908-1 and 908-2) and adjust It necessary. Tighten the screws to -9 and check that the gap is stil equal at both sides. | __ lek the cereus with Loctite, type 242 2 (EN2498). CE) [=] | & men cv ne tr ean | 5a Price SO Eon Bi I idaiaati Sosa NScc Replacement of Cams on Camshaft Mounting Exhaust Cam i. 4. Mount the indicator drive cam and adust ‘according to Chapter 706 in the Operation ‘manual. Tighten the soltlocking nuts 9s stated in Der. 5, Before mounting the two-part spare cam, the bore and the area on the shaft must be degreased. Place the two-part spare cam on the shatt, ‘mount the four screws, and Sghten slightly, so that the gap betwoen the two parts is equal at both sides. 6. Make sure that the marking scratches on | 5. ‘the cam and the eamshaft coincide, and ‘hat the running surface of the cam is op- posite the roll. Tighton the screws just hard enough to avoid that the cam slips when the toler ‘ulde is lowered onto the cam. Measure the fuel cam lead (see Procedure 1908-7) and adjust I necessary. Tighten the sorews to D-6 and check that the gap is stil equal at bot sides, Lock the screws with Loctite. type 242 (EN2438). 7. Mount the cover on the front of the cam [6 | shaft housing When refering (otis page, please quote Procedure 664 Eaton 01 Fae NAN B&W Dizol ASChain Drive and Camshaft Panel Plate 90651-173 019 fh | ‘Whar tering ios page,please quota Pate OO651 Eaton 173 NAN BBW Deal NSPlate 90651-173. Chain Drive and Camshaft Panel Tem a Part Description a Part Description 019 |) Toot panel (020 | Name plate ‘044 | Pin wrench for fue cam 086 | Chain assombting toot (068 "| Chain disassembling tol 182 | Hyerauic jack fort of camshaft 019. |» Too panel, complete 152 | "with ools *) Optional extrasPlate 90561-62 Camshaft - Tools | wen hem na Pat Description fa Part Descspton 25 | Pin gauge for camshatt (060 | Pin gauge for cranishat(Gas Camshatt - Tools Plate 90662-040 8 hen rete ots page, pease quote Pina 90682 Eaton #0 MAN BEW Dieet NS “Pilate 90562-40 Camshaft “Tools Pert Description a Part Description Hysraulc jack ‘Osring with back-up rng, 65-75 mm |O-ing wit back-up rng, 50-60 mm ‘Spacer ng Hydraulic tools for camshaft bearing, complete Stud setter MSan3.5 @ 82883 |F¥Starting Air Distributor SAFETY PRECAUTIONS S00 Section 918 ‘Stopped engine bx] [3] Block the staring mechanism [3C] shut of starting airsupply x Engage tuning gear Shut of cooling water ‘Shut of flo === ss00Km ‘Shut of lubricating ol | Lock tzbecharger tors ret Deron va ua 1-1 Clearance between gear ‘wheel and bushing win, 0.9mm Max 16mm 1-2 Clearance wa rte outermost pasion: Min. tmm Max 3mm 1-3 Clearance with rater in innermost postion vi 1mm Max 2am Dot Tightening torque ‘gee whos on carat one Winer refering to his page,please quote Data Sheet 107-7 Elion 2 MAN BAW Oizeal IS 1074 Paget)sora Starting Air Distributor Data Spare Parts Pate, besenton oy Page 2 (2) ‘When referring to this page, please quote Data Sheet 107-1 Edition 02 MAN B&W Dies A'SStarting Air Distributor 1. Turn the engine in axxo direction te bring the piston of cylinder No, + 9 TOC, Check withthe pin gauge. 2 Remove the plug screw and gasket from the side of the distributor housing, and insert chook pin K in slat . 3. Ifthe cheek pin cannot enter the sot, ie. if the slot is not aligned withthe hole in the distributor housing, the ar distrbutor must be adjusted, See Procedure 807-1.3. Checking A ' hen refering to his page please quote Procadire 6071.1 Eton 204 MAN BAW Die AIS Paget 8)074.3 Starting Air Distributor Adjustment Bay 1. Turn the engine in axeAo diroction to bring the piston of cylinder 1 to TDC. (Check with the pin gauge. 2 Dismount the end cover of the camshatt housing, along with the stating air est Lor, fom the engine, omove the plug serew and gasket fom th side of the Gistributor housing, and insert ‘chock pin K in sot 8. “Tu the shaft together withthe distributer ise until check pin K enters slot Sin the ‘isc and keep it there, 3. Check and, 1 necessary, adjust clearance D-t between the gear wheel and the bush- ing, Pee) Wie tering ta is a ‘Please quale Procedure 907-13 Filion 704 ‘MAN BAW Diesel ASStarting Air Distributor Bay Adjustment 4, Remove the lower half of the gearwheel drive cover. Mount the upper half of the geerwheol drive cover with tho complete Starting alr distributor after loosening the gear wheel on the camshit, and then en- ‘gage the two gear wheels by turning the ‘Wheel on the camshat Tighten snd lock the gear wheel screws on the camshatt, s00 Data, D-4 Mount the lower half of the gearwhee! drive 5, Remove check pin K from the gistibulor housing and mount the gasket end plig 6. Check the clearance between the roller and the two interlocking valves wh the roller in lis innermost and outermost postions, 1e- spectively (ASTERN and AHEAD). 071.3 ier roaring tis page, pease quote Prosodure GO? 13 Eton 204 MAN Baw Dito NS D-2 Pages 8)‘ss0Mc-c Starting Air Distributor 107-4 Data ‘SAFETY PRECAUTIONS ‘Standard Tools: See Section 913 X] stped ene [3] ec tno sarin carn Zz x Ff Shuto sarng aie spoiy Engage turning gear —=0 Shuto coting water j Shite et == 19001 Shut of ubctng ot Lock wostarger tre Data +t Clearance between gear ‘wheel ane bushing Min 0.0mm Max temm D2 Tightening torque — ‘ear whoa on camshaft 90Nm | When retaring otis page,please quote Oata Sheet 107-1 Eaton 0 Pages @) MAN BAW Dial 4S1074 Spare Parts Page 2 @) etn Starting Air Distributor ‘S50MO-C Data ‘When rtaring hs page please quote Data Shea 107-1 Eaton 08 MAN BRW Diaes NS‘S50MC-C Starting Air Distributor Checking ‘+ Tum te ngine in anes drocion bing | the piston of eylinder No. 1 10 TOC. (Check with the pin gauge. 2. Flemove the plug screw and gasket from the side of the distrbutor housing, and insert “check pin Kin slot 8. 8, If the check pin cannot enter the slot, if the slot isnot aligned with the hole in the istibutor housing, the alr istrbutor must be acjuste, S00 Procedure 907-1.3. Viner etorsing fis page, please quate Procedure 807.1 Caton 207 MAN GaW Oita! AS Pago)Starting Air Distributor ss0Me-c Adjustment 1. Turn the engine in AHEAD direction to bring the piston of cylinder 1 to TDC. Chock with the pin gauge 2. Dismount the end cover of the camshaft Pousing, along with the starting al dst or, from the engine Femove the plug screw and gasket from the side of the distributor housing, and insert ‘check pin K in slot “Tur the shaft together with tie distributor ‘isc until check pin K enters slot § In the disc and keep It there. 8. Check and, f necessary, adjust clearance 1D-1 between the gear wheel anc the bush ing. i Page 2) ‘When rearing to tis page, pase quote Procedure 9071.9 Eailon 207 WAN B&W Desel AS |‘S50MC-C. Starting Air Distributor Adjustment 9074.3 4. Remove the lower halt of the gearwhee! ‘rive cover. Mount the upper half of the (earwheol drive cover with the complete Starting air dstibutor after loosening the gear wheel on the camshaft, and thon of age the two gear wheels by turning the ‘whee! on the camshat Tighten and lock the gear wheel screws on the camshatt, see Data, 0-2 Mount the lower half ofthe gearwhee! drive 5. Remove check pin K trom the distibutor housing and mount the gasket and plug screw. 2 Viner efaring to mis page, please quot Procedure 07°13 Eaion 207 MAN BAW Oletat AS Pape 3)Starting Air Valve 1072 aa SAFETY PRECAUTIONS Stun Tot: sen Suen Fee . 7 beak te wary mara ZB, aero Peres — aoa see amet eee rs ae — Ot Wartomsrgarvawe rok 02 TeHetncep ae on pasos zim : ise ‘When referring to this page, please quote Data D10702 Edition 0022 Page 1 (2) MAN BAW Diesel AS1072 Starting Air Valve Data Spare Parts| Starting Air Valve 907-22 7) Dismanting 1. Shut he starting ai and contol aint. Dismount the contrat alr pipes. Unscrew the fixing nuts ofthe starting valve flange. 2, Pull the starting er valve out ofthe eylinger ‘cover and remove it rom the engine, 7 When referring to this page, please quote Procedure G07-22 Edition 217 Page 16) MAN SEW Dete! NS907-23 Starting Air Valve ka : Overraul 1a 1. Remove the top cover fing screws and re- ‘move the cover, Remove and discard the gasket 2. Serew off the valve spindle nut and remove the valve spindle trom the valve housing, ‘Teke out the piston, distance pipe, valve spring, andthe liner. Remove and discard the O-ring Page2() When refering otis page,please quote Procedure 907-23 Ealion 211 eer) ° bans MAN B&W Diese AS(oad) Starting Air Valve Baw . Overhaul 3. Grind the valve housing seating with the ‘grinding ring etter applying grinding paste. Carborundum No, 200, Grind the seatings of the spindle and haus- ing to match, using the face weench to ro- tate the vale spin .Carborundum Ne, 506, 4. Thoroughly clean all parts before reassem- bling the valve Lubricate ail intecnal paris (slicing suriac- 8) with, for instance, Molybdenum Disul- hide, MoS, '. First mount the liner io the valve housing, then the valve spindle, the distance pipe ‘the spring ane the piston, When refaing 0 te page,please quote Provodire 607-23 Editon B11 MAN BAW Dial NS 07-23 Sse t fd a | “t Se aed — E ea E ; i are| 907-28 Starting Air Valve | {6 Mount the nut on the valve spindle and tighten the nut, see 0-2, 7. Place a now gasket on the valve housing. Mount and tighten the top cover. Replace the O-ring on the valve housing, tthe starting air valve ls not to be mounted in the engine immediately after the over- haul, all openings of the valve should be ‘covered with plastic to prevent dit from ene tering the valve during storage. ‘Wher refering to is page,please guote Procedre 07.2.9 Eaton 371 ° WwaN Baw Desa NsStarting Air Valve 907-24 Mounting 1. Carefully clean the starting valve bore in | 1 = the cylinder cover ang, it necessary, recon dition the seat for the starting valve in the bore a See Procedure 901-1.3. If not already done, repiace the O-ring on the overhauied valve and lubricate. with Neverseize or Molybdenum Dsuiphide, Mes, For overhaul, see Procedure 907-2. 2, Mount the vale in he eyinder cover. il ( il 8. Mount the nuts and tighten-up aternaely, In at least three stop. Loosen the nuts again and repeat the pro- ‘cedure to reach the ful tightening angle or torque, 0-3 Mount the control air pipes and turn on starting air and contol ai. on relaing fo his pape, pease aucie Procedure 072d Eon BV Page 56) MAN Bai DalHigh-Pressure Pipe 1084 Data ‘SAFETY PRECAUTIONS ‘Standard Tools: See Section 913 ‘Shut off starting air supply 7 re See Seon == 10-120 et onen ve ut DA. Weightothighpressue pine 4g 2 Tightening torque High-pressure pipe 36Nm When ralaring otis page,please quote Data D10901 Eton O17 Poet @) MAN BAW Dae! NS108-1 Spare Parts | Page 2 High-Pressure Pipe Pala (Gee When rearing to this page,please quote Data D1080" alton 0017 MAN BAW Diesel ASS5OMC-C _ High-Pressure Pipe 908-12 Dismanting 1. When replacing the hycraulle high-pressure plpe, exhaust valve or hydreule actuator, heck the high-pressure pipe sealing sur: ‘aces, 2 Before dsmounting the high-pressure pipe, stop the camshaft oll pump. Loosen the serews for the high-pressure pipe and lit the pipe slightly away trom the ‘actuator to let the oil in the pipe drain Through the drain holes in the actuator 3. Remove the screws in both ends of the | high-pressure pipe. Lit the high-pressure pipe away from the engine. When reforing to is page, please quote Procedure 008.12 Eaton 272 Page 8) MAN BW Diet A'S908-1.3 _ High-Pressure Pipe Ss0MC-0. Overhaul The two ends of the pipe are identical and should Both be overhauled as follows: 1. Remove the thrust piece from the actuator! exhaust valve. Remove and discard the O-rings from the ‘thrust piece and the trust flange. i <> ‘Clean and inspect the conical seats of the high-pressure pipe and the thrust piece. “The seats cannot be reconditioned. la seats damaged, the thrust piace! high-pressure pipe must be replaced : 2. Taare be ml Oa end bor aoe pti atom he ea ba | 2. Repo to tat fg fon th pe os fener tn feo nr! Osh i See oer scene ena eere | fe coreare tse! When relering tie page, please quote Procedure 906-1. Ealion 212 MAN BW Deal NSS50MC-C _ High-Pressure Pipe Mounting 908-1.4 1. Mount new O-ings, lubrleated with a litle camshaft lubricating oll, on the trust pioe- 9 and thrust flanges. Mount the thrust pisces on the actuatorfex- haust valve. iount the high-pressure pipe on the en- sine. Note! ‘when mounting the high-pressure pip take care not to damage the conical Seats of tho siperthrust pisces. 2. Air fiting the pipe to the exhaust valve and actuator, tighten up the screws of the pressure flanges diagonally, see Data. ‘3. Check the system for tightness. When efaring otis page,please quote Procedure 08-14 Eaion 212 MAN BBW Diao AS Pages 6)‘SAFETY PRECAUTIONS FE] sree none [oe] sexe staring mean [ac] it tain say [Be] ene tig gar FE] shat in we % Shut of fue of X | Shuto lubrestng ot X | Lock turbocharger toe Data Fel. Decoition ©-1 Exhaust vale, compete 0-2 Exhaust vale housing D3 Ofoyinder Det Ar oyinder DS. Spine D6 Botom pace D7 Oteyinder, inside ameter max 8 Pision rns, min. thickness 1.9. Win dance psn 10 Max atone option D-41 Min. lamer of spine stm D.t2 Tightening trque ol finder 0-18 Tightonng trae, srewe for sing bot 0-14 Tieng torque, safety vane D415 Opening pressure, safety vale 1-18 Grinirg angle, vale spine 1417 Grinding angle, botiom piace 18 Max. grinding of sot, D9 Gap ofbotom piece 1.20 Max. burro of spindle D.2t Max ginding of spine 22 Hydra pressure = Gsmanting 23 Hydra pressure = mounting 1-24 Max. damoter, top 0-25 Max. ameter, botiom 0-28 Measuring ata = spindle stem Wher rofring tots pag, please quote Data 010802 Caio G026 MAN BAW Deal NS Exhaust Valve Data Standard Tools: See Secon 913 ZY rt === ean 2x M0, 2xm16 Valve Unit 2o0kg 3005 75h 20kg a5k9 55k3 712mm 26mm 470mm S12mm 70No s0Nm 50.80Nm attr wos" sao 23mm | tom | DL comm 20mm 11900-1650 bar 0.6mm 2.0mm 235.945 mm 108.2108.2 Spare Parts 080-255 688 Gast sosotsene 743 Oring sosotsccec B14 —- Gasket Exhaust Valve Data Baw Plate em No. Dasergtion ay ‘060% %0onc O49 Gasket 4 S060" oon O62 Gasket 1 060% oan 185 Leck washer 2 ‘osorooc 182 Gasket 1 So80r ese 312 Oring 4 S060t eon 398 Sealing rag 4 eosorecc 573 Guida ring 1 oe0r2cocc 385 Sealing rg : sosorsocn 387 Gasket 1 080reon 107 Oring 1 2080teor 44 Leck washer 2 sosor2enc 481 Sealing rg + So8oreoo 64 Oring + Soeorsece 576 Oring + Sosorseen 53 Sealing Fog 2 1 1 1 1 s0o0t-oe 28 Oring soot 887 Oring age) ‘Wen refering to this pag, please quote Date 010802 Eton 0025 MAN BAW Diocs NS(oes Exhaust Valve 908.21 ae (Checking 4. Before mounting an overhauled exhaust valva in the engin, itis recommended that the valve be checked as follows: + Lift up the valve with the engine room ‘rane (which makes the valve open), Connect compressed ai to the pneu matic piston. The valve should” now slose. Check that a 1.0 mm fester gauge can be inserted about 15 mm Into gap Gs, to ensure that there is a clearance between the outer parts of the seating faces of valve housing and the spindle, Soe Procedure 908-23. G3 Ater_shutting-off the compressed” sir supply and releasing the vent plug screw located just above the ball cock onthe ait cylinder, the exhaust valve should open, + After doing this a couple of times, leave the valve closed and ehut-off the com pressed lr. The valve should remain Closed for atleast 15 minutes. 2. When the exhaust valve is mounted in the cylinder cover, and the eoeling water inlet to the eylinder tover and exhaust valve ls ‘open, check the tightness of the sealing fing between the bottom piece and the oy Indor cover by ensuring that watar dove nat flow tom the two small bores on the top side ofthe batiom piece. Ut water does flow from one ot both of ese bores, the exraust valve must be dlemount 19d and the sealing rings replaced. Liner refering to tis page,please quote Prosedure MGOBD2 Eaton 0227 pane) MAN Baw Dose JSDismanting | | 9082.2 . Exhaust Valve | 1. Close the cooting water init and outlet, and Grain the exaust valve, Dismount the high-pressure pipe forthe hy- ‘raule valve actuation. ‘See Procedure 908-12 Disconnect the cooing water outlet plpe ‘rom the exhaust valve. Dismount the return olf pipe from the ex: aust valve. 2 Dismount the air pipes forthe seating alr ar- rangement and’ the pneumatic exhaust valve. ‘Remove the screws ofthe cooing watorin- let flange at the side of the exhaust valve. Remove the plate jacket with insulation ‘rom the intermediate pipe and remove the screws which attach the intermediate pipe to the Inlet pipe of the exhaust receiver. Page2(i) Wan refaving fo is paga, please quote Procedure MGO8O8 Ealion 237 HAN BEV Dios ASExhaust Valve Dismanting 4, Romove the protective cape from the ex aust valve studs, and mount the four hy- Sraule jacks. Connect the high-pressure pump to the jacks by means of the distributor Bloc. and four high-pressure hoses, Blood the hycraulc system and raise the pressure as slated in Data. Then loosen land remove the nus, ‘See Procedure 943-1, Attach the crane to the eye bal fitted on top ofthe valve and it he exhaust vaive away, Carefully cloan the exhaust valve bore in the eyliner cover and recondition the seat ing and sealing surlaces of the bore, fre quire. See Procedure 901-1.3. ‘Viner rearing otis page, please que Procedure MO08D2 Calon 0227 MaNaaW Ouse AS Page (16)9082.8 . Exhaust Valve vt Ga) 1. Place the exhaust valve on @ wooden sup- port on the platform. | | | ; Remove the eight nuts and the safety ‘zap from the oll cylinder. 2 Lit away and place the oll onder on a ‘wooden support Dismount and inspect the O-rings and_ the ‘Hvust place of the hydraulic high-pressure Pipe for marks. Replace the O-ings and thrust piece, i necessary. ‘Check the functioning ofthe exhaust valve ‘eiaton indicator. 3. Loosen the screws and remove the ling ‘eyo from the oll cylinder to gain accoss to the onifiee plug. Unscrew and clean 2 tice plug. Chock and cioan the bore for the eriice plugin the top ofthe oll eyinder, MAN 28W Dieeal AVS | age s(18) Won refoving otis page,please quote Procedure MS0803 Ediion 2719082.3 (ad Exhaust Valve mew Overhaul 44, Place the oll cyindor in a horizontal posts | 4 ton, Remove and discard the sealing ring. Flemove the flange and take out the piston, Inspect the bore ofthe oll eylinder for seor- Ing and check its measurements. It the diameter ofthe bore excoeds the val- Ue stated in Data, send the ol oylinder to fan MAN B&W authorized workshop for r= pair. 5. Release the vent plug screw located just above tho bal cack on the alr lind to et the alr escape fom below the piston. Flemove the four sews from the flange on top of the air piston and dmount the flange. Loosen the ai piston from the conical lok: ing ting by means of a tin hammer, and re ‘move the tonical locking ring. 6, Pass lifting straps through the four bores of the valve housing and it the valve housing Clear of the valve spindle, “Take care ~ when the internal O-ring in the air piston and the inernal rings forthe seal ing arrangement at the botam ofthe aienyt- [6 Inder pass the groove for tne conical ting at | the top of te spindle. ian refering to his page,please gta Procedure MOOSG2 Eaton 0221 MAN BAW Oaeel NS Pages 08)9082.3 Exhaust Valve 7. Unsorew and remove the look serewe which rotaln the bottom piocs. Lif the valve hous Ing approx. 10 mm, I the bottom piece has become stuck, use 2 tin hammer to release f. Lif the valve Rousing away and land ft on a couple of wooden pans. Bottom piece: {8 Inspect the seating of the botiom piece carefully for damage and check with the bottom piece template. Note! ] Before using the botiom piece template, | ‘horoughiy clean the contact faces an the | | [vane nousing seat witha stoe! brush. | ‘Almeasurements should be taken atfour | tiametrically opposite points on the cr- ‘umiarance of the bottom piace seating ‘Take measurements G and Gs, using @ a fooler gauge. Compare the result vith the - figures stated in Data D-18 and 0-19, 9. IF burn marks aro visible on the bottom ploce seating OF Gy does not equal O-18, oe THEN the valve housing seat must be Stour JF the template rests on the lower surace inthe groove, ie. Gp = 0, THEN the bottom place must be discarded and replaced with ‘new bottom plece. Further grinding 0° =~ Conaitioning Is net recommended. When refering to is page,please quote Procedure NS0a02 Fallon 0271 MAN BEV Diese ASExhaust Valve Ban Overhaul 10.1 Ris necessary to grind the seating, pro- | 10. 200d a8 fliows: Before placing the botiom piece on the grinding machine, turn the grinding head away from the grinding table. Mount and secure the bottom plooe in the grinding machine. Using a dlal gauge, chook that the bottom ploce le covrectly centered ‘Adjust the grinding head to achieve the cor- rect grinding angle as stated in Data Note! ‘As the grinding angle is very important for the correct operation of the exhaust valve, make absolutely sure that the ‘grinding head fs correctly adjusted. Regarding ihe use ofthe grinding machine, ‘ee separate Instructions from the grinding ‘machine manufacturer. During the grinding, use the bottom piece template frequently to ensure that maxi- mum grinding isnot exceeded, 908 step 10. ‘After grinding, inspect’ the bottom piece ‘seating again, using a Teeler gauge and the Bottom pose tempat, to measure, how ‘much materat has been ground awe, Grind the recess so that gap G, equals 1-19 as stated on the Data sheet 11 the grinding tool forthe outside seating Is avaliable, grind the outside seating using Carporundum Ne, 200 and tne special Drinding too! (eng), operate it by hand (20. ‘hot use the power of the grinding machine {e rotate the bottom piece). Grind until a smooth sure is achieved Clean the soat of grinding paste When referring fo this page, please quote Procedure MBOBO2 Eaton G221 MAN GaWDieol NS Pane 7)a Exhaust Valve GA | Overhaul Baw Valve spindle 42. Clean the head of the valve spindle with steel brush. Inspect the seating o! the valve spindle for burn marks. Check the burnoff Ft of the vale spindle by measuring along the spindle template {tom point A to point D and in point, Botore using the spindle template, thor ‘oughly lean the contact faces on the ‘valve sping witha stl brush. ‘All measurements shouldbe taken at fou | Giametrcally opposite pois an the oe cumferenee ofthe vee spindle. Take tare that the most burned-ot point is | measured. ‘Small dant mak inthe valve spindle seating are acceptable and need not be ‘round away, provided thatthe dent marks do no allow blow-by of exhaust {28 from the combustion chamber tothe exhaust gas recelver, For further evaluation ofthe valve spindle ‘seating, sea also Chapter 707 In tho Instruction book, Volume 1, Operation. 18. Measure the gap Gy between the spindle ‘template and the seating ofthe spindle IF burn marks are visible on the seating, ‘the spindle must be ground. IF gap G, exceeds the max. valve D-21, ‘ee Data, OR the burn-off Fy exceeds the max. burn-offD-20, the spindle must not be round. Instead the spindle must be recon dioned, Contact MAN BAW Diesel for advice on re conditioning. Parana When refering fo tis paga, please quote Procedure MG0802 Falten 0221 MON BAW Diesel A'SExhaust Valve Overhaul 14, Mount and secure the spindle inthe gtind- Ing machine. Using a dal gauge, check that the spindle is corectly centered. ‘Adjust the grinding head to achieve the cor rect grinding angle as stated in Data. Note! 'As the grinding angles very important to ‘the operation of he exhaust valve, make absolutely sure to adjust the grinding head corcvet. Regarding the use ofthe grinding machine, 00 coparate instructions from the grinding ‘machine manufacturer During grinding, measure gap G, frequent ly. The max. gincing of the spindle, see Data, must net be exceedee, IW the max. grnaing tnt is reached, anc bburn marks are stl visible on the seating of tho spindle, contact MAN B&W Diesel for ‘advice on reconaltioning. 15. Check the spindle stom for weat in the area D-26 measured trom the top ofthe spindle, 1" the stem clameter i lees than stated in Data, or the hara facing layer is worn away, contact MAN BBW Diete! for advicn, NaN awe her ceria eis oe, lease quo Procedure Wie Eton 0221Exhaust Valve Orta ey 16, Dismount the air piston trom the air eyin der. Remove and discard the teflon guide fing and teflon sealing rng Notel When cutting the rings, take care not to | damage the edges of th ring grooves in the air piston Dismaunt the seating alr contol box. fom the air cylinderivalve housing Mount two eyo bolts in the alr cylinder and dismount the ai eylinder. 17. Clean the alr cylinder and check the run: ning surface for wear or possibie scores, FRomove the four screws in the bottom of Page 10) the air eyinder. Dismount and check the flanges and the sealing rings of the sealing air arrange ment Fit new O-ings and sealing rings when ‘mounting the flanges in the bottom of the alr cylinder. Make sure to mount the sealing rings cor- rectly, 528 the sketch, “Tighten the four screws. 418. Replace the sealing ring in the groove at the very bottom of the air cylinder. Remove the protective cap from the eafety| valve, dismount the valve rom the ar eine der, and repiace the gasket and sealing ring. Wher refering fo tis page, pleas 7a Procedure HO080® Ea O22 MAN Be Disa ASExhaust Valve Overhaul 18, Place the valve inthe pressure testing de- Vee. Connect the testing device with the high: Pressure pump by means of @ hose. Check the opening pressure, see Data, 1 he opening pressure isnot correct, fcos- fen the lock nut and, using a serewaiver, adjust the safety valve untl the corcect pressure is indicated Tighten the lock nut and test the opening pressure onee more. When mounting the satay valve in the air {B cylinder, use only te machined faces:on the valve housing and tghten, see Date Finally, mount the protective cap. 20, Inspect the bushing in the spindle guide for woar. See Data Itt proves necessary to replace the bush ing, pull it clear by means of four gisman- tung serews, 21. Mount the bottom piece (with new O-rings) fon the valve housing and secure with the Mount the vabe spinal inthe vane hous- ne ‘ g Ue volarng tas page, please gute Procedure MOOGD2 Eaton 727 MAN BAW Dees NS oC)908-23 2A. . cz oo Celli. KKK ESC Page Toc) Exhaust Valve Overhaul 22. After overhauling and remounting the valve ‘spindle and bottom piece info the valve housing, guide the air cylinder with the sealing air arrangement down over the valve spin Caution! To avoid damage, take great care when internal rings (well-coated with ord nary lube oi pass the groove forthe con: eal locking ing 28, Remove the fiter plug screw trom the soal- Ing air control unit CGlean and check the fer plug serew, and replace the O-ring. ‘After checking, re-mount the filer plug Loosen and remove the screms and cover the sealing ar valve spindle in the control unit. Fomove the valve spindle and check the sealing rings and tha spring. If necessary, replace them. [Ator checking, mount the valve spince and ‘pring, and lighten the cover. 28, Unscrew the seating tr orice pipe Coan the orice in the end ofthe pe. Femount the orice pie. Oe MAN BEW Bess AS