MAN 123/30H. Baw ENGINE DATA 0305 CHECKING OF MAIN BEARINGS (AUTOLOG) Tatas (a), ALIGNMENT OF MAIN BEARINGS The lower main bearing shells should be so positioned that they keep the main bearing journals of the crankshaft centered in a straight (ashore: horizontal) line. Deviations from this centre line cause the crankshaft to bend and in- crease the load on some main bearings. If two adjacent main bearings are placed too low, the crankshaft centre Tine will in this place be lowered to form an arc, causing the intermediate crank throw to bend in such a way that T "closes" when turned into bottom position and "opens" in top position. As the magnitude of such axial lenghtening and shortening during the turning of the throw increases in proportion to the dif- ference in the height of the bearing, it is measured as a check on the align- ment and condition of the bearing. As the crankshaft of medium-speed engines are very stiff, any great deviations in the alignment will result in clearance at the bottom shell the bearings. The cause of incorrect main bearing position may be wear of the bearings or misalignment of the engine. EFFECT THE DEFLECTION MEASUREMENT Prior to the deflection measurement it is necessary to check by means of a feeler gauge that the crankshaft beds down on the lower shells of all main bearings. If clearance is observed at the lower shell of one or more main bea- rings, the cause must be found and the fault rectified. The deflection measurement is effected by placing a spring-loaded dial gavae in the centre punch marks provided for this purpose; see the illustration.MAN 23/304 Baw ENGINE DATA 0205 CHECKING OF MAIN BEARINGS (AUTOLOG) fettton id “Closing” of the throw in top dead centre is regarded as negative (compression of the gauge). In the example above, the deflection reading is therefore posi_ tive. As, during the turning of the throw, the gauge and the connecting rod will meet near the bottom position of the throw, the measurement for the bot- tom position is to be replaced by the average of the nearby positions on eit- her side. The dial gauge is set to zero in the near-bottom position (X in fig. 7), and during the turning the throw is stopped in the positions horizontal - top - horizontal - near-bottom (P-T-S-Y in fig. 7) for reading of the gauge. CHECKING THE DEFLECTION MEASUREMENT The readings are entered in the table fig. 1. As "bottom" reading is used the mean value of the two “near-bottom" readings X and Y, fig. 2. The total de- flection (“Opening - Closing") of the throw during the turning from bottom to top position is entered in the table fig. 3. These figures are due to vertical misalignment of the main bearings. Similarly, horizontal misalignment proce- dures the figures in the table fig. 4. Besides misalignment of the main bea- rings, the readings can be influenced by ovality or eccentricity of the jour- nals. When taking deflection readings on engines equipped with turning gear, the turning gear should at each stoppage be turned a little backwards to ease off the tangential pressure on the teeth of the turning wheel. Other wise, this tangential pressure may falsify the readings especially for the aftmost crank throws. crec eRyL23/30H ENGINE DATA MAN Baw 0305 CHECKING OF MAIN BERAINGS (AUTOLOG) Edition 18H Data 4 (4) Deflection of crankshaft cyl. Crank position 1 2 3 6 Near bottom x 0 0 Oo Camshaft side P 2 0 2 Fig. 1] Top T 302 4 Rear side s 3 2 2 Near bottom (starboard) 2 -1 0 Fig. 2. | Bottom 4 (X+Y) = B 1 0 609 0 oO 4 Deflection from vertical misalignment Fig. 3 Top-Bottom or T- B= V 2.2 4 5 2 2 Deflection from Fig. 4 | horizontal misalignment 9 camshaft side - rear side _ or P-S= H 12 0 tt ——_ T+B= ¢ 4 405 ~ | Check on Mia. 8 | gauge readings Pas 0 S 2 4 § 4 3 € and D should be nearly the same. Readings for cyl. 4 to be repeated. Top ' oO Op} (camsh. = 1 © side) 1/100 = mam : « Fig. 6 Fig. 7 {Closing of the crankthrow Looking aft. Start in position x is considered negative Turn counterclockwise, HeleRy (CENERATING SETSMAN £23/30H Baw ENGINE DATA 0306 CYLINOER UNIT EDITION 12H Index New cylinder liner, inside diameter ... 225.000-225.046 mm “4 Worn cylinder liner should be replaced at «225.600 mm -2 Tightening of cylinder head nuts - 700 bar -3 Max. height of spindel above cylinderhead . 83,3 mm -4 Min. height of valve head ..........2.5 = 5.0 om -5 Valve seat ring to be scrapped when R = 0 -6 oe 22 Nm ~7 Tightening torque, screw for cooling jacket 0306 - 6 80% 45, W037MAN BSB: 1.23/30H ww ENGINE DATA 0307 Edition 26H PISTON AND CONNECTING ROD Data 1 (3) ws | —! R= 0,5 | R \ \ —H, AS? a 1g —>Fiston rings Oil scraper ring N PF R Normal heights Rings and grooves Tolerances New] Possible oversize | Rings Grooves “0, 010 40,14 Hy] 4] 445-5.0 os as =0, 010 40,11 H 4,5 - 5.0 , y 2| 4 -0, 025 40,09 7 ~0, 013 40, 10 ~0, 035 +0, 08 Note: All piston rings must be changed at normal piston overhaul, Hy = Upper piston ring, marked with’ ident. No. “top 881500-3" lig = Middle piston ring, marked with ident, No. “top 881501-5" Ho = Lower piston ring, marked with’ ident. No. “top 881502-7! see section 307 Hg = Scraper ring Ho(sag 123/30H Baw ENGINE OATA oa Edition 26H PISTON AND CONNECTING ROD Data 2 (3) . Minimum ring gap ( | Piston rings at Los Oi] scraper rings Test-tool oa Ring grooves must be renewed when test-tool can be pressed more than 2 mn into the groove. HS SEY GENERATING SE1S23/304 ENGINE OATA MAN Baw 0307 PISTON AND CONNECTING ROD Weight of piston and connecting rod assembly . seeeeceee 75 kg Clearance in big-end bearing .............2. 0.15 - 0.20 mm Clearance between connecting rod bush and piston pin . 0.15 - 0.20 mn TIGHTENING OF CONNECTING ROD SCREWS Colour code on the big-end to indicate correct éssembling position of the components. O® TIGHTENING oRvER For L@ @ CONNECTING ROD SCREWS TIGHTENING PROCEDURE Ist step saneasses 03 cee sess torque 250 Nn 2nd step ss... ++ repeat torque 250 tim 3rd Step eeeeeeeeeeeeeeeeeeeeeee @a 60° turning angle 4th step vee... turning check with 325 Nm Kote: Edition 264 Data 3 (3) Prior to assembly lubricate threads and contact faces of the screws with Copaslip or similar. After tightening ascertain that the big-end bearing moves easily on the journal. CENERATING SETS1.23/30H ENGINE DATA MAN Baw 0308 VALVE GEAR Edition 13H Data 1 (1) (cold engine) Index Inlet valve clearance ~ 0.5 mm 71 Exhaust valve clearance ... weseaee (0.9 -2 Tightening Torques: (Plate 30801) Nut for bracket rocker arm, Item No. 0791 ...... 150 Nm -3 (Plate 30802) Screws for valve gear housing, Item No. 1650... 50 Nm. -4 1989.11.14. eaee GENERATING SETS:MAN L23/30H Baw DATA D309 Edition 10H TURBOCHARGER Data 1 (1) Make: MAN Type: NR 15/R 180........ cyl Serial No. 1181655 for Engine No. 20786. HOLEBY1£23/30H ENGINE DATA FUEL INJECTION PUMP MAN Baw 0310 Edition 13H Data 1 (3) Index Maximum combustion pressure at full load ......... 130 3 bar <4 Max. difference between cylinders ..........s.se008 3 bar -3 A change of the height of the thrust piece spacer ring of 1/10 mm will change the max. pressure by .. 1 bar “4 1° turning of camshaft gear wheel changes maximum pressure by approx. ... stesees 3 bar -5 Tightening Torques: (Plate 31001) Connection piece, screw 2885 . seeeees 25 = 30 Nm -6 Barrel, screw 0916 ........ ++ 55 = 65 Nm -7 Plug screw 0372 -8 Cap screw 2974 ...., -9 (Plate 30802) Mounting fuel pump, screw 1927 ......0.., sees 150. Nim ~10 _ 90,35 GENERATING SETS:MAN 23/30H Baw ENGINE DATA 0310 FUEL INJECTION PUMP Edition 13H (ADJUSTMENT OF THE MAXIMUM COMBUSTION PRESSURE) Data 2 (3) If experienced to differ from testbed records, the maximum combustion pressure can be adjusted by alteration of the fuel injection timing. For each individual cylinder unit the injection timing is altered by adjustment of the fuel pump Teac. Increase of the lead will advance the fuel injection and increase the maximum combustion pressure. Reduction of the lead will delay the fuel injection and reduce the maximum com bustion pressure. Prior to any attempt to adjust the maximum combustion pressure by alteration of the fuel injection timing, it should be ascertained that the fuel injection valve, the engine piston, the inlet and exhaust valves, and the turbocharger with charge air cooler are working correctly and the compression pressure checked to be normal. The fuel pump lead can be adjusted by altering the number and/or thickness of the washers situated under the thrust piece in the thrust pin of the roller guide. The relationship between the height of the washer package, the maximum combu- stion pressure and other relavant parameters is shown in the scheme. ACTION RESULTS Total e height Distance tee Injection | Maximum of . fuel timing combust ion washer x! a pressure package oreasee f] Reduced {| increased {| Advances | Increased { reouceo || Increased {| resuces {| Delayed —_}| Reduced { Practically the fuel pump lead is expressed by the distance "Xx" measured be- tween the upper edge of the roller guide housing and the top of the thrust piece, when the roller is resting on the circular part of the fuel cam. The "X"-measurement should be checked and corrected, if required, whenever a fuel pump, ro'ler guide, roller guide housing or camshaft section is replaced. The distance sheet. "must be kept within the tolerance limit stated on the data The thrust piece is mounted to the thrust pin with a light press fit. The thrust piece is dismounted by the use of the special extractor and remounted by gentle use of a hammer with soft linings. 90.38 HeLEny CeneRATING SeTSMAN Bai 23/30H wr ENGINE DATA 03i0 FUEL INJECTION PUMP Edition 13H (ADJUSTMENT CF THE MAXIMUM COMBUSTION PRESSURE) Data 3 (3) The distance "x" is measured between the upper edge of the roller guide housing At and the top of the thrust piece, when the roller is resting At on the circular part of the fuel cam. —Thrust pin The thrust piece is mounted to the thrust pin with a Tight press fit. The thrust piece is dismounted by the use of the special extractor and remoun- ted by gentle use of a bench hammer with soft linings. 90.35MAN L23/30H Baw ENGINE DATA 311 FUEL INJECTION VALVE Edition 14H Data 1 (1) Index Fuel valve opening pressure to be set to ....... 320 bar “1 Tightening Torques: (Plate 31101) Union nut for nozzle, item No. 0509 ........ 100- 120 Nm -2 Nut for adjusting screw, item No. 0965 ... < 100 Nm -3 Cap nut, item No. 1122 22... cece eee 70 tim -4 Nuts for fuel valve studs, item No. 0230 ........ 30 Nm -5 Ey GENERATING SETS