AKASAKA-MITSUBISHI UE DIESEL ENGINE 6UEC37LA INSTRUCTION BOOK (MAINTENANCE MANUAL) AKASAKA DIESELS LIMITEDU ‘intenance Manual EC-L GROUP Contents ITEM Group-item General INTRODUCTION eo : 0010-01 MAINTENANCE FOR LENGTHY SHUTDOWN... 0020-02 ADJUSTMENT FOR ENGINE TIMING .... 7 0030-02 Maintenance schedule ..... oC 0040-01 Weight of main parts ..... Clearance of main parts Main bearing and thrust bearing ......... Exhaust valve and starting air valve .... Piston and piston ring ... Fiston rod stuffing box .. Connecting rod and crosshead Camshaft ariving gear. Camshaft bea: Exhaust vi ve Griving gear (Upper) +. +++++ jel injection pump driving gear, exhaust valve Griving gear (Lower) Starting air control valve ..... Tachometer and governor driving gear . Lubricator driving gear . htening values for mai pelts ..... enance orocedure for mein parts man ERRING Clearance measuring oving and fittine of bearing cap Femot and fitting of bearing metal ... ‘ightenine procedure for main bearing belt T BENRIN nepection and adjustment . Dismantling and of thrust rad .. 0080-02 0060-02 0060-03 0060-04 0060-05 1140-02 2140-02 2140-03 iido-o4 2260-01 1160-02 6-37LACRANK SHAFT Inspection ané deflection measurement CONNECTING ROD AND CROSSHEAD Inspection and foot liner adjustment .... Removing and Removing end fitting of connecting rod .. Removing and fitting of crosshead pi ‘Tightening proce PISTON AND PISTON ROD ire for crank pin bearing bolt Inspection and wear measuring Removing and fitting . Piston ring removing .. PISTON COOLING SYSTEM Inspection and adjustment... CAMSHAFT DRIVING GEAR Inspection and aéjustment ... HAUST VALVE DRIVING GEi Inspection and adjustment .. LUBRICATOR DRIVING GEAR Inspeétion and adjustment . Inspection of exhaust valve and rocker arm lubric: INJECTION PU Inpsection ené adjustment of inject Dismantling and assembling INJECTION PUMP DRIVING GEAR Inspection end adjustment . ng of lower crank pin bearing . Group-item 2220-02, 2350-62 2350-02 2460-01 2630-01 2820-01 2820-02Table of Contents BRR Maintenance Schedule RES ROR AMM OR Weights of Main Parts RREERBER Clearance of Main Parts ERBIOG EE Tightening Values for Main Bolts ERR bh ORR Maintenance Procedure for Main Parts ERRORS Sit 2hUEC-L GROUP | (Tem core This booklet is Volume II (Maintenance) of the Instruct: on Book for Mitsubishi UE Diesel Engine UEC-L type describing handling of Akasake~ necessary maintenance, inspection and adsuscment of main part: maintaining good condition of engine for lone time. Please refer to Vol I (Cperation end const: ion) for operation and Ané abou turbocharg , please x ger Instruction Book. people hand) ng this engine perform their maint: on the basis of this for no error. The republication of this instruction hook by reproducz. is pronibi:ye UEC-L Maintenance for Lengthy Shutdown GROUP 0020 ITEM ol Maintenance and inspection during lengthy shutdown Keeping all parts of the engine from rusting Greasing and draining various v Preventing from rain water Awning the engine Turning the engine and supplying oil every third day Draining the fuel oil service tank Maintenance and inspection after lengthy shutdown. When Starting the engine after len: and hy shutdown, extensive overhauling Minor repairs, clean and inspect the engine and ite systems throughly. The engine should not be started before it has been confirmed that the engine is ready for operation. Bolts Check the holding-down bolt, main bearing bolt, crosshead pin beari and crank pin bearing tightening bolts, piston cooling device bolts, etc. for tightness, and also ascerta: pin, dowel pin, etc, are secured in positi pin, tapered Bearings Make sure of the oil clearance of the main bearing, crosshead pin bearing and crank pin bearing. Various piping system Check various pipe coupling bolts for tightness, and inspect various valves for leakage. Inspect strainer for cleanliness. or replace them with new ones, if necessary. ‘lean then, (2) Cooling water system Examine the fresh water for the si ity of the anti corrosive agent contained in the water. Refer to the operation manual 062-01 for the anti corrosive agent. fied den: 2) Make sure that no oil or sea water is contained in the fresh water. (2) Lubricating oil system 1) Remove sediments from the lubricating oil tank. Keep the purifier in operation until foreign matters and water have been completely removed from lubricating oil. 2) Analyze the lubiricating oil, and make sure that the oil is identical with the brand specified. Refer to the operation manual 052-01 for the system lubricating oil. 3) Remove flushing oi} completely after flushing has been finished. 4) ‘Clean all the strainers paying attention for inside dusts, and remove air from them.a (6) Cylinder lubricating il system y) 2) 3 Fuel oil system » 2) 3) Starting air system v 2) Scavenging and exhaust system » 2) 5) 0020-01- 2/2 Make sure that the lubricating oil is identical with the brand specified. Refer to the operation manual 053-01 for the cylinder lubricating oil. When removing up the cylinder for inspection, turn lubricator by hand, and make sure that the cylinder lubricating oil is flowing out of the cylinder liner oil port. Clean the strainer of the oil feeding port located on the lubricator. Blow off the service tank Examine the fuel oil for property. Be sure to measure its viscosity at two different temperatures. Refer to the operation manual 041-01, 042-01, 043-01 for the fue oil Clean the strainer, and remove air from it Make sure that no water is in the air reservoir Drain the air reservoir, Open the valve fully by operating the sea water pump, and ascertain that no water leaks from the air cooler Look into the upper surface @ piston head cylinder jacket peep hole, and make sure there remai foreign matter on it, Open the valve of the moisture separator for draining. Look into the trunk inside through the scavenging trunk peep hole, and make sure there remains no foreign matter inside. 37LGROUP 0030 UEC-L Adjugement for Engine Timing RRA TOMER ITEM or Beginning of life es Shona: geg | Before te 14.3 Sook End of Lift ee | eae ges | after toc | 983 30g vaximun 2 | BRITE a 32 7 head Tapper clearance* 5 FR o bh DVT ELA Aa Beginning of cam lift 5 pelo tise des. | Before BoC 67 ee. End of cam lift . Parars) ges | after ape 76 x Besinning_of exh. valve opent # = éeg | Before Boc 59 eee Ené of exh. valve close? a * éeg | after BoC 69 Maximum 1ift RRVTS a | 36 $6 Beginning of valve open | BOTLEY YS ieee bd be After 45 Boy % eee |"ape epg) ae al agesiotpaiecion deg | Mlee te : rt * {et [te Note: * marks denote engine is in colé state. #oove mentioned table shown design value, after the comnissioning recorés of official shop trisi to be regarded as stenca =) -oeeRROmERT. ERCHDMECR+. REERARREMORG rEMKT SE. 37LAva on ce ring — GROUP c040 UEC-L Maintenance Schedule | | ITEM on Hours ] a] le figlelel8] js 5 }E/8]3/2\8]5) |: SlE/z)el ela] |e Parts work a8] gig yl 3 T TT system iub. | spot test lel ty dy * Chemical analysis [ | lel | jot Cooling fresh] Water analysis (density oF antivcorosve] TTI water pH, etc.) 7 i ° Retighten set bolts First rd Bed pla After second i o | Inspection of clearance and wear ile Main bearing | measuring nao | | Dismantling and inspection it | . Ly tt area Clearance measuring | ° bearing ho ata Inspection of thrust pad | e cylinder - peated Inspection of cooling water space Piston rod | Cleaning and inspection Stuffing box | Clearance measuring of ring and groove 1330 | | |] cylinder liner 37L cylinder liner inner dia. measuring Grind burr Smooth scavenging port Smooth lubricating hole Removing liner Replace O-ring0040-01-2/4 Hours . ale 8 Maintenance schedule of main parts s | oéelelels] je & [2182 /318| | 2 & VES) 8] |£ Parts Work 2) 518] 8/ 818) |e EBBBERee When removin ne Inspection of combustion chanber piston a Soamaesd 1dlo cover Cleaning of exhaust valve and fuel injection viave e then starting afte Priming lengthy shutdow: Fuel injec- | fuel injection test e See heatea Inspection of fuel injection nozzle an e Facing-up nozzle rity, | ry Te Inspection of tappet clearance i} | j Facing-up valve seat (at first le) ft | Exhaust vaive| Periodical dismantling, cleaning 5 and facina-up Laso | | | Clearance measuring lena | Je | Replace O-ring (valve stem guide | I | e | inspection of starting air pipe temp. ‘e 1] Starting | (check gas leakage) anal | ere! Cleaning, inspection and facine- { if necessary 1 1 | | Removing and inspection H eylinaer tase safty valve | vive opening pressure test ° Indicator | inspection Indie Inspee [1460 | | | 1 T | cleaning fin tube (air side) | ° Air cooler | 1620 | | | cleaning fin tube (cooling water side) | | | | an | Deflection measuring First crank shat aio After second Clearance rasuring of be . Connecting i | rod upper, | Dismantling, inspection and adjestnent | 2250 || lo lower bearing Hs: Dismantling and assembling of connecting e rod |0040-01-34 | Hours Maintenance schedule of main parts o dik gigi] | 2 & /F=le/sisig) {8 & lsloisj$i8is) 18 & [RBIEIS|S/2) | & sBleleleley [= Parts Work cle/s] sists lee] eerel | Clearance measuring of guide shoe e crosshead pin] Inspection of crosshead pin 2350 . Removing crosshead pin | ° | Trt Renoving piston le | | Dismantling and assembling of piston | le Pisto! Airtightness test 2850 | je Inspection of piston ané ring Inspection of piston head Clearance neasuring 2450 (Replace new ring if necessary) fice . piston inspection of slee cooling 2460 systen Inspection of inner pipe . cam | Inspection of surface - | inspection of surface - canchat | Inspection of gear contact surface | cae Backlash and clearance measuring ii ide Tt 1] : lel tt | cylineer napection of steel ball movenent of fe} | i] Exhaust vatvel SManing inlet fitter 2620 je Rocker arm | Discharge drain of lubricator . jtesteaxor | inspection of driving gear | . L2040-01-44 Maintenance schedule of rain pares els] [2 | gla] |e Parts Work ste| | elel | injece | D'Smantling, cleaning and inspection oe | ae a. | 2 ae Inspection of fuel injection timing | el |i — ie | | Starting air — f vate | Ii control viave| Dismantling and inspection of valve | . lubricating oi | | le Inspection of oil eo | Governor O11 exchanging | ossmantiing and inspection | | | Je! | | itt Dismantling and cleaning f- . T T T mantling and cleaning of blower side | | Cleaning of turbine (vegetal solid | 1 murbocharger | cleaning) | 400 Dismantling and cleaning of turbine side - Cleaning of suction filter cylind ta! | meal Inspection of lubricating condition - wing lubricate 2 ee | { el TT T Automatic | Afver starting starting air | Dismantling and inspection | iT | le stop valve Pett | pititi AuxiLiary 1 4, | Cleaning of impeller and casins 790 ° blower z " Heelea ella2 4 GROUP 0050 UEC-L Weight of Main Parts ITEM od Weight Part No Name of parts vnc} Weis 14 Main bearing cap 1 pe 57.5 Main bearing metal (upper) 1 pe 17 Main bearing metal (lower) 1 pe 8.0 116 ‘Thrust pad 1 pe Adjust ring 1 pe L pe 124 Tie rod complete 1 set Tie rod 1 pe Upper nut 1 pe Lower nut 1 pe 133 Piston rod stuffing box complete 1 set 50.4 134 cylinder Liner a pe 406 aal Cylinder cover (with valves and valve rset | a32 driving gear) cylinder cover 1 pc 341 Water guide jacket 1 pe 22.8 142 Fuel injection valve complete 1 set 2 Fuel injection valve complete (with Fuel 2 set 16.6 injection pressure control device) 143 Exhaust valve complete rset | 228 Exhaust valve stem dpc 19.12 Exhaust valve seat 1 pe 2.9 Exhaust valve housing 1 pc 40 144 Starting air valve complete 1 set 20 14s cylinder safety valve complete 1 set 2.8 146 Indicator valve complete 1 set 2.3 162 Air cooler complete (for4.5cylinder engine) | 1 set | 720 (for 6 cylinder engine) | 1 set | 750 r7,8cylinder engine) | 1 set | 2820 235 Connecting rod complete (with cross head pin| 1 set | 744 bearing, crank pin bearing) Crosshead pin bearing (upper) 1 pe Crosshead pin bearing (lower) 1 pe Crank pin bearing (upper) 1 pe Crank pin bearing (lower) 1 pe 63.4 Crank pin bearing metal (upper) 1 pe 7.0 Crank pin bearing metal (lower) 1 pe 6.5 Crosshead pin (with guide shoe holder, quide | 1 set | 218 shoe) connecting rod 1 pe 214 37L0050-01-2/2 Weight Part No. jame of part onit * Name of pa (eg) 245 | Piston complete (with piston rod stuffing 1 set 324, box) \ Piston head (with bolt) 1 set 64.3) Piston skirt 1 pe 15.5 Piston rod (with inner pipe) 1 set 270 Piston ring L pe 0.92 255 Cam shaft complete (for 4 cylinder engine) dset | 821 (for 5 cylinder engine) iset | 900 (for 6 cylinder engine) 1 set 979 (for 7 cylinder engine) dset | 1058 (for 8 cylinder Lset | 1137 Fuel cam 1 pe 24.8 Exhaust cam 1 pe 27.7 256 | Cam shaft driving gear: Crank shaft gear complete 1 ser 31s Idle gear complete 1 set 501.4 Camshaft gear complete 1 set 297.2 264 | Exhaust valve driving gear Push rod 1 pe 32 Driving piston complete 1 set 28.2 locker arm complete 1 set 54.6 Rocker arm 1 pe 16.2 Rocker arm 19 stand 1 pe 136.4 310 | Fuel injection pump complete 1 set 31 313. | Fuel injection pump driving gear Driving piston 1 set 32 342 | Governor (Woodword UG 8L) 1 set 20.4 400 | Turbocharger eT 33 sc 1 set 850 MET 42 SC 1set | 1400 723° | Auxiliary blower (for4,Scylinder engine} 1 set 472 (for 6 cylinder engine) 1 set 575 (for 7 cylinder engine) 1 set 575 (for 8 cylinder engine) 1 set 650 aeGROUP 0060 ITEM 01 UEC-L Clearence . Crankshaft 6 Thrust Bearing SRER BROAZSZbBS CRANKSHAFT BEARING BS PAX Laatt of clearance Note e& ARF J = 7 Refer to 1140-01 1140-018R 2 7 ~ | : TI cee | 0.6 10 L. i 5 ~ 15 = :UEC-L Clearance eer a RFRUOBME SF ITEM 02 ve HAUST VALVE STARTING AIR VALVE eee sHeme Note nd fi . 1 Waile engine is in-cold stage. RO RA OE ~ 2(_) shows permissible local wear value by corrosion. BENERDSORRONSHE RT. Stendaré clearance Limit of clearance | Note aes tt | e 8 ee a % | an avtar 0.214 ~ 022 05 bi+b: |¥ 0.20 ~ 0.25 05 bee ve _ € (oe) Mee #1 5 *2| outside diameter ~ ate 414 é 4 | 41-775 ~ 47-800 (46.5) ASE 72. ds 48.0 ~ 48.025 48.5 (49.3) | Angie, dtanecerUEC-L Clearance seeR Piston & Piston Ring GROUP 0060 EAbY RUE ARYL |ITEM 03 PISTON ERRY PISTON RING eR bUULe Top & 2nd Ring 3rd 6 4th Ring TBRO2 B77 SRRO ABE D7 UNIT sam T Standard clearance | Limit of clearance Note = 5 ae ptis eon ROR fe x a 0.18 ~ 0.25 os » o1s~o2s & | 0.6 e 24 ~27 b | c 2.8 ~32 ‘Total learance tieds 06 ~0.739 | nares New gia ~ | ar 4 ea 822 oo ; 1 New 12.85 ~ 4315 ui | T va 1 Lio New 8 | gm. 18 ~ 80 Wew D L_ ra 37LClearance FeER UEC-L GROUP 0060 ITEM Piston Rod Stuffing Box CARY By ee o4 STUFFING BOX ER but y to = : Tight ring Tight ring Tight ring O11 seraper ring lo #4bues 2 84byes 3 sth RM 4 thas — Standard clearance Limit of clearance Nore eres x, © ROOF * % 3 unit cotmpelearance on +943 aoe aaa : 37 mene et 3 unit coral clearance JORG ° STAMP Ee 5 Bundt total clearance ES LEAR “total clearanceT +. Clearance Connéceing Rod & Crosshead {GROUP 00 i : UEC-L ese ° 4 eER meekugozss lITEM\. os tf a, oy Can side 22 BE UNIT: mm | #eree & am OR ca x a 0.13 ~ 0.22 os | 1e ~ 026 04 east Cane ar ef 1g ~ 02 BDC eceta cites 0.16 ~ 0.26 as dtd 4° 0.15 ~ 0.20 0.4 Ata. te Be TDC 45°C RAYUEC-L Clearance _ Camshaft Driving Gear ROU) vesH ALBBHEE ITEM 06 Camshaft _gear. 2 seeE Backlash RyDF ava \ os 3 Crankshaft gear 2977 BE UsIT: om Standard clearance | Linit of clearance Note Beret mR Rm OF wR = 024~050 a6 a Total clearance 0.065 > 0.118 o2 aie water ~ é Backlash 0. 30~ 0. 46 0. eel I oveClearance | TeeR UEC-L Camshaft Bearing DABS GROUP 0060 ITEM 07 Ql: Free end and intermediate bearing sHaRe PMS +€2: Driving end bearing — ~~ Ha | Canchaft stopper | BAMA bye Camshaft Wo Te aL | a I SA A | QC | ) ; : - y | WH | | ) : con ot AZADA ~ | | \ pak. oor \puet cae | | ERAL MBA Camshaft bearing 2ARE Unit: mm Standard clearance | Limit of clearance Note | mares BARR it = 7 Total clearance ay 0.043 - 0.123 O35 Eare: : Total clearance a2 0.043 - 0,123 038 mater i b2 ~ BE ee dearence | { 37LAUEC-L Clearance TER OP litem ow _ Exhaust Valve Driving Gear [GROUP 00 60 BAR HS J Rocker arm Exhaust valve wR Standard clearance Limit of clearance Note meres fe A om OF tf % f 0684 ~oasr | O35 Total clearance — | were? by + be 02 es ia| Bauer Valve Delving Sepegeser| SOP 0060 HRY TS eS FB B= ep [TEM UEC-L fh rE 2 5 UNIT: mn var 2 0.10 | 018 Total clearance | b 0.030 ~ 0.090 025 eres Total clearance ¢ 6.030~0090 ets | ‘Total clearance rae 06 34~ 6.090 ; Total clearer ‘ 6.096~6090 ons Tora Total clearence Cane wereae Valve GROUP 0066 ITEM 1 > wl A p Ry P neo vert: es | | Standard clearance Limit of clearance Note emus t ‘ n 2 a | aers~a02 - a | 002~ 0.05 | >» | aozs~aose a2 Total slestence « | 0.1 ~0.15 Backlash ]Clearance Tachometer & Governor GROUP 0060 UEC-L Driving Ge PEER FRNA REHEE ITEM ot ne 5 7 clearance | eter i bebe | ate Total clearance bitbe | 0.02 ¥ 0.05 Total cies - ——~ 0.02 v0.05 | s1 Slapranes a ° ate | 0.06% 0.18 © | aas Backiaan i [2 soe 2 | Gare ee | | ona 0.72 Sockiash i 37LClearance cylinder Lubricater Driving |GROUP 0060 UEC-L : Gear veeR VUYSEASR HSE ITEM 32 Camshaft Bae UNIT: mm Standard clearance Limit of clearance Note meres eR RE ® % 2 0025-0066 » 0.025~0066 2 Backlash ¢ ee By DD vm 4 02 ~ 03 Seen Tackiask « orgs | rr 37L143 Tightening Valves for Main Bolts GROUP 0070 i> EEK PAH ITEM 01 UEC-L 1, The following bolts should be tightened with a hydraulic tool. MERIC SEBAI F KOH vb ER REGA LTBI B. teen size | Meterial |iydraulic| Nut rev. Renarks be nt) | angle mie (oo kg/en®)] a0g2e Nane uss | ao honee | at lke ' a suestie| aera | a Le haem |B Tie ros | 0) a . masx6 | s4sc |{ 625 60 a4 ayK | a cylinder cover boll By “ | Y port sem43s | 640 >] 118 | DVT Adie } Rocker arm bearing , 2 stand bolt Masx3 | SCM4a5 C 640 135° | i NwESS Sse “1 the nut rev. angle, the degree obtained by the nut tightening rod at nt. HRT 4 iE 350 ka /od Seip eH B ICT REO ETS. F As for the standard of the nut rev. a handful tightening with m Foy bE fe, the degree obtained by the tighening rod shall be zero point. TE HMGATY RE OY ETB, 37LO1-2/4 x Other Nain Bolts - value in ( } shows informative EDWOEB AWS vs Co) PRE BERET = Size | materia | Fe | st (nm) Seq") | vane tobi | aera | ey bnea Jet ne : | Oo te Main bearing bolt 7 EMT Hw M36x3 scM435 35 (55) Crank pin bearing bolt 5 7 pee ean Ma5x3 Sema 35 125 (165) Exhaust valve bolt M363 scm435 106 (80) eRe IT . footer am shaft bolt ape || : eeu cant N36x3 | sema3s. | 55 » (75) ocala seen ees al ceee aE G0) Piston rod bolt 7 24x3 0 aaa M24 scma 35 20) (30) Piston head bolt : > ERY Ay RMT eek aaenaaes cos Piston inner piece bolt 7 cu : CARY RSME A HF a oo Fuel injection valve bolt al ee M16x2 ScMa35 (50) 5 Starting air valve bolt (35) | _ [emennanee cmd 35 as | 6 Gemshd: bearing bolt M20x2.5 | ScM435 Qs) 8.5 Fuel injection pump bolt 5 a Ra canes 20x2.5 | scm435 (20) L Canghaft housing bolt 7 D ees m20x2.5 | scma35 (60) 16 Camshaft housing bolt 77 wana encice a (40) A LAARIRE Hew» BD Crankshaft gear bolt waeu3 : | 5 IGcotanaecican 36x3 smc435 40 (95) Thrust beating upper cover bolt | wey ae ii aa mROO) 7 | RM TERIA 9 «Kaba CD) | M24x3 cecal ee oe | [Fuet injection pump stand bolt | yea 7 een cea ™20x2.5 | suca35 (25) 2 Metal chockd 10 |(60) Holding down bot 5b ay? ¥36x4 s45c SHE NAS A 7 a Epowy resin 10 {(40) chocks L GFN “Sas for the standard of the nut rev, angle, the degree obtained by the handful tightening with a 200 mm long spanner shail be zero point. HEA 200m OFM HOH TMM REO ET Be +6 The figure of tightening torque shows incase of Molycote paste coated on thread and bearing surface of nut. a MEME OMI 2— PERLE Fy Fillies 9 hie fet? Refer to the figure of next padi { HemCamshaft casing | er Toy ata Camshafi : pake i = Exhaust gas resssyni OTE 0070-01-337 GROUP 1000 UEC-L lotice using ‘the oil hydraulic jack ~ ITEM. ol 1, After releasing oil pressure, press the jack down until € to be zero. 2. Don't stretch C more than 7mm in any case. LANain Bearing GROUP 1140 UEC-L Clearance Measuring ITEM o1 Using tool: Name_of parts a. Depth gauge Main bearing housing 1 2. Upper main be 3. Lower 4. Bear Clearance measu When measuring the wear of the main bearing, leave the main bearing housing as installed. The tie bolt and the bearing tightening bolt shall be left as tightened when mea: See tothe st, main parts (0060-01). Clearance of main bearingUEC-L Main Bearing GROUP 1140 2 371 Removing end Fitting of Bearing Cep ITEM op Using tools: Name of parts a. Lifting piece —£, hire rope (short) 1, Crankshaft b. Lever g. Chain block 2. Main bearing cap c. Hanging piece —h. Chain block 3. stud bolt a. Shac) 4. Bye plate or e. Wire rope (long) j. Wire rope (short) Sea eee Removal of the main bearing cap ae 2 4a. os 6 View from artow Y S View from arow X Position the crankshaft pin at epproximately 15 dgrees downward in the camshaft side. Install the hanging pieces opening in the column as shown and (d) around the upper part of the in View Y, Install the lifting piece (a) and the lever ( ) on the main bearing cap (2), Attach the wire rope (e) on the lifting piece and hang the lever (b). Push down the lever (b) and lift up the main bearing cap (2) until at clears the stud bolts (3), (Refer to Fig. A.) Move the main bearing cap (2) sidewise with the lever (b) as far as the main bearing cap clears the arch in the column, (Refer to Fig. B.)1240-02-2/2 7. Install the shackle (i), the wire rope (3) and the chain block (g) on the hanging piece {c) and hook it on the lifting piece (a). Then, 1ift up the main bearing cap until it clears the threshold ef the opening in the colum. (Refer to Fig. C.) the chain block (h) on €. Hang the shackle (i), the wire rope (3) the eye plate on the scavenging trunk and the wire rope (£) on the lifing piece (a) respectively. Operate the chain blocks (g) and (h to move the main bearing cap outside, (Refer to Fig. D.) Reinstalletion of the main bearing cap Reinstall the main bearing cap in reverse order of removal. oeUEC-L Main Bearing GROUP ne | Removing and Fitting of Bearing Metal ITEM 03 Exh 37L Using tools: a. Lower metal drawing out pin Procedure for upper metal removing Procedure for lower metal removing a Turning 3. aust | _| side \ Name of parts 1. Crank shaft 2. Upper metal 3. Lower metal 4 Dowel pin 2. After taking out the main bearing cap, take out the upper bearing shell, Pay attention not to make scratch on the metal after taking out Fit again the upper metal n the counter order of the removing. 1. After having removed the upper metal, insert the lower metal taking out pin (a) into the crank shaft to turn the crank shaft in forward rotation direction (in the view fron the driving end). See A, 2. After the crank shafe is rotated 180 degrees and the lower metal cones up, take out the lower bearing shell from the crankcase door. 3. Fit again the lower metal in the counter order of theUEC-L Mein Bearing GROUP 1140 Tightening Procedure for Main Bearing Bolt | ITEM o4 Using tools a. Spanner 1. Main bearing housing b. Thickness gauge 2. Bed plate 3.0 Nut 4. Bearing tightening bolt Procedure for tightening 5 Clean the threaded area of bolt (4) and nut (3), and coat then with Tighten the nut (3) in orger ©, ©, @ ana handful with a 200 mm long spanner. As for the standard of the nut alternately by turning angle, the degree obtained by tightening shall be zero point. ghten the nut (3) in order @, ©, @ and @ alternately three Himes by 10° at a tine, Measure that the clearance Ay and Az between the main bearing housing (1) and the bed plate (2). ascertain that the clearance A is equal} to Ar. Tighten the nut in orger @, @@ ana G@ alternately two ames by 15° and 10° each, Refer to tichtening standard for main bolts (0070-01) for the nut turning angle. Measure the bearing clearance. Refer to the clearance measuring of main bearing mentioned in 1140-01 for the measuring procedure. Ascertain that the clearance of bearing is within specified limit, then set the locking washer. Refer to the clearance of main parts mentioned in 0060-01 for the clearance of main bearing.— UEC-L Thrust Bearing GROUP 1160 Inspection and Adjustment ITEM oL Using tools Name of parts a. Dial gauge 1, Thrust pad 4. Adjust ring b. Thickness gauge 2, Thrust bearing support 5. Inspection (Pree end side) eye 3, Thrust bearing support 6. Thrust collor (Driving end side) bearing support Inspection of thrust bearing clearance Push the crank shaft to the free end side or the driving end side so that the thrust collar (6) and the thrust pad (1) are adhered, and then push it again to counter side to measure the motion in that time by mean of the dial gauge (a). ‘The value is the clearance of thrust bearing. Ensure that the measured value is within the standard limit and there is no pronounced differ- ence comparing with that of newly built time. ‘The clearance between the thrust pad (1) and the thrust bearing support (2), (3) is not required to be measured daily. But it should be measured at every bearing overhaul or part replacement, and adjust it to be within the standard limit, if necessary, Refer to 0060-01 for the clearance of main parts, Lo 37k :Thrust Bearing GROUP 1160 UEC-L Dismantling and Assembling of Thrust Pad | yreRy 02 Using tools lame _of parts a. Thrust bearing 1. Thrust bearing 5. pad drawing piece cover 6. Byebolt 2, Thrust pad support 7. Crank shaft (ahead side) Thrust pad support (astern side) ‘Thrust pad Procedure for dismantling 1. Take out the upp 2. Take out the thrust , out (ahead side from where pad is to be drawn 2, de or asters both suppo: 3. Install the pad drawing p onto the screw hole on the thrust collar (6) outer surface. 4. Turn the crank shaft (7) counter clockwise from view of dri side, and push out pad (4) by means of the 5. When the pad (4) is pushed out about half body on the b the eyebolt (b) to pad (4), and take it ont - In case where the pad @ out de is required, it may be perform ording to same procedure as abo this operation, insert a wooden piece of equivalent thickness to that of pad and adjust ring drawn cut in the removed side so as to prevent the crank shaft displacement. fe, but & Procedure for assembling 1. Assemble parts in the counter order of dismantling. 2, Install surely all pads and adjust rings at the proper position as before dismantling.UEC-L Tie Rod Tightening Procedure GROUP 1240 37L ITEM on . Using tools me_of parts . a. Hydraulic jack Tie bolt b. Tension aut 2 jer nut ©. Foot piece 3. Lower nut Nut tighte Eyebe Fitting 1. Clean the threaded area and seat surfa coat it with sufficient Molykote. Screw the upper nut (2) with a certain reserve and lift it up by means of eyebolt (e) to insert it in the hole. 3. Drive the lower nut (3) > the specified 4. Lift up the tic rod wu © lower nut (3) | touches the bed plate, and tighten the upper | put (2) using the heening rod (é) | ghtening 1. Attach the foot piece (c) and hydraulic jack (a), and drive the tension nut (b) onto the bolt end threaded area by means of nut tight ning rod or this operation, after nut has been once tightened at maximum return it approx. 180° to facilitate the hydraulic jack removal. Refer to the tightening values for main bolts 0070-01 for the bolt tightening values, oil pressure, and nut turning angle. 3. By applying specified cil pressure, tighten the upper nut (2) at maximum by hand force using the nut tightening rod (a). Kenove the hydraulic tools. Lightening order Using two sets of hydraulic jack, Tightening Order Exhaust side 7222 tighten once every two bolts. a The taghtening order shall be 4003002 1 Ra direction from center to free ‘ end or to driving end a Free Driving end end 43 2021 5 6 7v2 - T UEC-L Piston Rod Stuffing Box jGROUP 1320 Dismant] ing and Assembling ITEM o1 Using tools a. Stuffing box holding table b, Positioning gauge Name of parts Stuffing Box Upper Stuffing Box Lower Support ring 041 scraper ring a Piston rod2330-01-2/2 Procedure for Dismantling when taking out only stuffing box (piston remains) (2) Keep the crank shaft at the positon of BDC. (2) Fit the sutffing box holding table (a) on the piston rod (8) by means of bolt and nut. (3) Turn the crankshaft unt: the top surface of the holding table (a) comes into contact with the bottom end of the lover suffing box (2). (Refer to Fig. A.) (4) Remove the support attaching bolt (7). (5) Turn the crankshaft at BDC. (6) Disassemble the stuffing boxes (1) engine. (Refer to Fig. B.) take them out of the When piston is to be taken out Attach the holding t: (a) on the piston rod (8). (2) Remove the stuffing box attaching bolt (6). in the state as the stuffing boxes (1) and (2) ston rod (8) Procedure for assembling 1. Fix the tight ring (4) and the oil scraper 5) to the piston rod with spring. 2. To match the rings to box croove, make the posit rings by means of the pes lower stuffing box (2) on (8) as the piston rod Further, assenble parts ir counter ordér a of the procedure for dismantling (1) to (6). v4 37LA— UEC-L Cylinder Liner GROUP 1340 spection and Adjustment ITEM Os Using tools Name of parts Meaning of Symbols a. Bore gauge 1. Cylinder liner F. Free end side b. Scale plate 2. Orring D. Driving end side c. Plate guage c. Cam side 4. Facing-up tool E, Exhaust side Inspection and adjustment 1. Measure the wear of the cylinder liner inner diameter by means of bore guage at every piston over- haul. Check if the wear is in the limit. The measurement shall be made at each position of the scale late (b) in the engine shaft direction (F-D) and the cylinder lateral direction (C-E) Prior to the measurement, deter- mine the standard value of the bore gauge (a) using the plate guage (C). Refer to 0060-03 for the limit of wear Bore gauge ‘The weesured value liner temp. and room tex measuring as well shall v¢ recoraed for the inforzation for following times. 2, Check if the inside face of the cylinder liner is smooth, The upper step area of cylinder liner, the cylinder lubricating hole and the scavenging air port shall be checked if they are free d from burr. Grind it if necessary 3. Inspect the packing surface of the cylinder liner (1) if it is no’ damaged. In case required, finish it to be smooth by mean of the facing-up tool (d). 4, Check the condition of the cylinder lubricating stud attaching seat and if there are pitchings on the cool- ing water contact surface of cylinder at every overhoul. a 5. The cylinder liner inside shall be 8 periodically inspected for no water . leak from upper area or that from “the cylinder lubricating stud area. When the liner port if fouled, clean it.12 “Cylinder Liner, GROUP 1340 UEC-L eatin TEM os i Using tools: Name of parts Bolt for drawing he Nut K. Bye bolt I. Wesher Process of Removing 1. Remove the y lubricating oil stua, 2. Attach the holder for drawing (a) and the support (c) to the cover bolt (2) Attach the bolt drawing (£), | the nut (h) and the wasser (1) to the holder for, drawing (a) Insert the holder for drawing (b) in the cylinder liner from the jacket scavenging room and t ne liner lower surface to tighten using the nut (h). Tighten the upper nut (h) until the cylinder liner (1) per surface touches the holder for @rawine (a) lower surface. 6. Fit the wire rove to the eye | bolt (k} and draw it out slowly.a Note Process of fitting 1340-02-2/2 Clean the cylinder liner ang cylinder jacket contact ané seal surface before the cylinder liner inserting O-rings shall be new ones of correct quality and dimension shall be used. Lubricate the O-ring area and the contact surf; of the cylinder liner and the cylinder jacket with grease. support (c) and 1 the chain block t insert the cylinder jacket in the state of Fis. The liner is norma the jacket are matched. After finishing the cylinder liner insertion, insert securely the cylinder lubricating stud.ua UEC-L -Cyinder Cover GROUP 1410 Inspection and Adjustment ITEM on Name of parts 2. cylinder cover 19. O-ring 2. Water guide jacket 20. O-ring Sleeve 21. O-ring 4. Cooling water feed pipe 23. Hexagon socket head cap screw 5. Stud bolt 24, Sleeve holder 6. Stud belt 25. Gas takeout jacket 9. Nut 26. Plug Hexagon nut 27. cover Hexagon socket head cap screw 28. Distance piece 13, Plug 29. Gasket Parallel pin 30. Bolt with wire hole 16. Parallel pin 31. Gasket Wire ce Inspection and adjustment When cylinder cover is dismantled, inspect carefully the next item And if necessary, facing-up.: mn \ Aarea: Fire contacting surtace Remove scale and carbon, and check for no crack in the v: holes or openings such air valve, cylinder safety valve or indicator valve. Barea: Cylinder liner facing surface Inspect the gascket urface if it is not damaged. C area: Exhaust valve seat packing surface Inspect if the packing seat face is deteriorated or not. If required, finish the ce smoothly using the facing tool. (See the following page.) Darea: Fuel e]_injection valve packing surface Inspect if the packing seat face is deteriorat or not If required, finish the face smoothly using the facing tool. See the following page E area: Starting air valve packing surface Inspect if the packing seat face is deteriorated or not If required » finish ne face smoothly using the facing tool (see the f¢ towing page.) O-ring and others: O-ring designated by the engine maker shal surely be used. as exhaust valve, fuel injection valve, starting 2410-01-2/3, injectionUsing tools a, Facing-up plate —b. “Guide Check the facing condition using the facing-up plate. Tf necessary, make facing with the facing-up plate (a), guide (b), and handle (c), 1410-01-3/3 c. Handle Procedure for facing-up of gascket area of startin: air valve, fuel injection valve, Fuel injection valve gascket area Starting air valve Using tools: £. Facing-up tool for starting air valve gascket area $- Facing-up tool for fuel injec~ tion valve gascket areaCylinder Cover GROUP 1410 Removing and Fitting ITEM 02 UEC-L cat Using tools: a. Cylinder cover lifting-up too) Procedure for removing cylinder cover ‘The cylinder cover is usually dismounted as a complete assembly with valves and the rocker arm. 1. Discharge the cylinder cooling water. 2. Fully close the root valve of the starting air reservoir and the inlet and outlet valves of the fuel injec A valve cooling water 3. Disconnect the joints of various pipes installed to the cylinder cover. 4. Remove the bolts of the joints between the exhaust ye and the cylinder 5. Stick adhesive tape to the connecting areas of the starti and the exhaust pipe to prevent admission of dir: air pipe 6. Clean the threaded area of cylinder cover bolts. 7. Loosen the nuts of cover bolts with the hydraulic tool. f. Attach the special lifting-up tool (a) to the cylinder cover. Lift up the cylinder cover slowly. Procedure for fitting cylinder cover. Clean well the jointing face between cylinder cover and cylinder liner, and replace the soft steel packing with new one. Apply grease to the cylinder liner receiving area in lower cylinder cover area. 3. Clean the threaded area of the cylinder cover bolt and apply "Molykote" there. 4. Hang the cylinder cover and lower it slowly to the cover bolts. \ 5. In that case, be careful for g~¢t matching with the guide pin without making mistake in direction— Cylinder Cover GROUP 1410 UEC-L Tightening Procedure for Cover Bolt ITEM a Using tools lame of parts a. Hydraulic jack wale Nut b. Hydraulic pump 2. Tightening bolt c. Foot piece 3. Cylinder cover d. Tension nut a e. Nut tightening rod Procedure for Tightening e 5 1. Using two sets of hydraulic jack, tighten once every two bolts. (Refer to Fig. below) ~ 2. Clean the threaded area of tie @ightening bolt (2) and nut M@), and coat them with Molykdéte ¢ eC 3, Tighten slightly the nut (4) by means of the nut tightening rod (e). As the nut is made to be térned easily, if it is hardly turned, check 3 the threaded area and repair it. ss 4. Install the hydraulic tools. First, attach the foot place the hydraulic jack (a) on it. Then, put the ten: onto end of threaded area of tightening bolt and tighten it ‘using tightening rod (e). After tightening up the tension nut (a), turn it back approx. 180° for facilitating removal of hydraulic jack (a). 5. Refer to the tightening values for main bolts (0070-1) for procedure of bolt tightening, tightening torque and nut turning angle 6. By applying specified hydraulic pressure, tighten at maximum the nut () by hand force using nut tightening rod (e). For tightening boltsignarked with *, tighten together the Rocker arm stand. Tightening order 2. No. 1 and No. § ¢ 2. No. 3 and No. 7? 1 3. No. 2 and No. 6 1 i 4. No. 4 and No. 8 Free end | After tightenfng according to above process, retighten them by applying specified hydraulic pressure.12 UEC-L Fuel Injection Valve GROUP 1420 Inspection and Removing ITEM on Using tools Namesof parts drawing: I> a8. Spanner y casing 7. Spring a " b. Click for drawing 2. Nozzle 8. Cap nut ©. ydraulic ran 3. Needle 9. Adjusting screw 4. Gasket 10, Lock nut L x i. 5S. O-ring 1i. Fuel injection £. fiydrautic pump 6. spindle pressure control gq. Pushing-up piece * oeeeee 4 inspection : As the fuel injection valve is apt to be 5 danaged by dirt in piping in the initial period of sailing, the injection test shall be made as soon as possible after the start (200% 400 Hr}. The test int lenghten gra ‘The criteria for rval may be y from the first test. he test interval is given in 0040-01 ‘The inspection and adjustment of the fuel injection valve shall be performed by making the maintenance chart for each cylinder on which thg voyage nunber, date, place, using on inje@tion test are to be recorded. This chart ig to be made as the reference for the next maintenance time 1. Make the injection test. (See 1420-02.) Clean nozzle (2) and (3) it injecting port is stopped. When the carbon flower is produced, make nozzle facing. (See 1420-04.) Inspect the gasket (4). If the gas leak is observed, make facing between the cylinder cover and seat surface. (See 1410-01.) 3. Check if the nozzle (2) top suffered the sulfuric corrosion. 4. Check if the pitching is produced on the casing (1) area to be inserted into the cylinder cover. 5. O-ring (5) shall be renewed for each overhaul. 6. Check if the facing between casing (1) and nozzle (2) is in good condition. Equally check for no discoloring or dowel pin hole expanded. 7. Inspect the spindle (6) for no bend or vertical scratch. When it is somewhat burned, it is to be rectified. 8. Inspect the spring (7) for no breakage. 9. Ascertain that the clearance H is not. showing any change since the preceeding inspection. (See 1420-02.)yo, SO Procedure for drawing out fuel-injection valve 0 D 1, Remove the fuel injection valve fixing nut after loosing it with the spanner (a). . 2. Set the pushing-up piece (g) and the click for drawin: 3; Connect the hydraulic pump hose (£) with the hydraulic ram (c). 4, Operate the hydraulic pump to remove the fuel injection valve slowly About operation of hydraulic pump, refer to the instruction manual supplied by the maker, 37L A 1420-01-2/2{GROUP 1420 UEC-L Fuel Injection valve Procedure for Fuel Injection Test ITEM 02 Using tools: Name of parts: a, Fuel valve testing device el injection valve b. Testing hose : 2. Adjusting screw c. Feeler gauge 3. Lock nut a. bye bolt 4. Nut (for clearance adjustment) e. valve holder 5. Lock nut > iy . / ree 2) and (3) are to be so set that the valve opi pressure a 2 Atomization test UW chee! is permitted. (in relation with the seat the atomization condition Procedure for fuel injection t Injection test: Fuel pressure is to be increased slowly, and its pressure measured when beginning to spout. Established valve opening pressure: 320 kg/cm? When the fuel pressure becomes high enough to open the valve, the handle is to be pushed hard two of three times to see if the fuel is atomized uniformly and is not dripping. Atomi zation tes Pressure test: the pressure is to be left at 320 kg/om?, and the tine . required for lowering the pressure to 220 kg/cm’shall be measured. (30 90 sec) Note: All joints of the fuel injection valve shall be surely tightened before use as it jets cut the pressurized diese) oil.—_— UEC-L Fuel Injection Valve aoe Dismantling and Assembling ITEM 03 Using tools: Name_of parts: a. Valve holder b. Ring wrench for cap nut c. Wrench So Process of taking apart i. Place the fuel injection valve (1) on the valve holder (a) with bolt (4)and nut (5). (See Fig. A.) 2. Loose the valve opening pressure adjusting screw unt turned by hand. the Remove bolt (6) and turn 180 cap nut (2) in up position. the fuel injection valve (1) 4, loose the cap nut (2) wit! taken out, the nozzle b special ring wrench. when the cap nut (2) is ‘The inside parts of nozzle can be taken out by taking out the adjusting screw (3). valve shall be placed rts dismounted from one fuel injectil t parts from other valves. togher to prevent eventual mixing with ¢! Procedure for assembly 1 parts shall be well cleaned with washi air blow, impressed pecially the fuel passing area in the o lly cleaned 3. Resembly the valve on the valve holder and o taking part process. we counter order of After the completion of assembly, make the inje test and the pressure test. In that case, make the priming by pushing the test Pump with the air vent valve of fuel injection valve opened, Kefer to 1420-02 for the injection test.UEC-L Procedire for Hozzle Facing-up ITEM Fust Injection Valve GROUP 1420 04 Us Pri ing tools ocess of facing-up nozzle Chuck ate ork, it is sdvisaple + Fe When the faee'u: fs te the powder for facing up, use to 600 ~ 800, and No 1000~No 1500 lastly. After finishing facing-up, the needie and the nozzle are to be cleaned by means of light oil,and their insides are to be made clean by means of air. Lastly, drip the nozzle and the needle valve in to lubricating ol}. The needle valve and the nozrle are faced together, and so they are not to be mixed up with other ones. 7 on test shall be performed after completion of facing-up. 37LUEC-L Fuel Injection Valve GROUP 1420 Inspection and Adjustment of Nozzle and Cap Nut | ITEM os- Using tools: Name of parts 2. Dial gause 1. Nozzle b. Surface plate 2. Needle c. Plier 3 4. Model gauge €. Surface plate Facing-up tool Cap nut surement of needle lift ‘ The needle lift increases due to repeated facing and so its 1! 5 to be measure: me, and replaced with a new one when me to the limit of use. oo cod zed use of nozzle hole Check the nogsle hole ty aeane of the Linit guume. L | "yellow marked gure ©)" can be Still usable, but shortly will reach using limit. k Already over using Limit, inserted. it should be condenned. Facino-up contact surface <8cing-up contact surface Be careful of discoloring around oil hole Be careful of expansion around dowel pin hole In case that the contact surface is dis- colored or that the dowel pin hole is expanded, facing-up is to be made for correction using surface plate. The valve body and the nozzle shall absolutely not be faced up together. eee Ne ore neeFuel Injection Valve GROUP 1420 UEC-L | sespectionof injecting Prassre control Device |rreay Name of parts Housing 7. O-ring 13, Adjusting cover 8. Valve body screw Upper piston 9. Bolt with hexagonal hole Wy oe Lower piston 10. Bolt with hexagonal hole Gascket 11. Spring pin o-ring 12. Grease nipple Inspection 1 2. 3. Check for no operation air leakage. Lubricate from grease nipple (12). When taking apart valve, check for no scratches on rubbing face of O-ring and piston. Bolts (9) shall be evenly Check if the clearance (H) between adjusting screw (13) and the nuc is the standard, and adjust it if necessary. Standard clearance #: 2.5mm ghtened when mounting on fuel valve body,v3 UEC-L “Exhaust Valve GROUP 1430 Removing and Dismantling ITEM a Removing Using tools: Name of parts a. Jacking bolt 1. Exhaust valve 5. Fixing plate b. Guide bolt housing 6. Bolt c. Disk ch 7. Exhaust valve a a htening bolt & e 4. Rubber cover 9. Lug piece rain off the exhaust valve cooling water according to (511-01). Take out the connecting bol Of the exhaust gas pipe (2) and remove the cooling water outlet tube (3), 3. Remove the rubber cover (4), the fixing plate (5), and the bolt (6). 4. Attach the retainer (d) with the bolt (e} using the bolt nole for ixing plete attechaent. 5. Take out the nut (8) of the exhaust vaive tightening bolt (7) following procedure of (1430-06). 6. Attach the disks (c), the guide bolts (b) and the jacking bolts (a) to two exhaust valve tightening bolts aiagonally facing of four, and Jack up it to draw out the exhaust valve. 7. Put the wire rope on the lug piece (9) of the exhaust valve housing to lift it up.1430-01-2/3, Fitting on rotary table Using tools Name of part a. Rotary table c. Shaft 1, Exhaust valve b. Exhaust valve Bolt 2. cover holder 1, Attach the exhaust valve holder (b) on the valve (1) with the bolt (d). attach the si 2, Place the exhaust valve (1) on the rotary table (a). Cotter removing Using tools Name of parts Valve seat holder 1. Exhaust valve body Valve seat fixing 2, Exhaust valve stem piece 3. cotter Hexagon socket bolt 4. Sp: Eye bolt Detail of valve seat holder 1, Attach the valve seat fixing piece (£) on the exhaust valve body (1) with the bolt (3) , 2, Attach €he valve seat holder (e) on the valve seat fixing piece with the bolt (a) to prevent fall of the exhaust valve stem (2)}. 3. Attachthe holding piece (a) n the exhaust valve body (2). | 4, "Turn the handle, then the cotter keeping screw (c) push downward and take the cotter (3) off.2430-01-3/3 Spring retainer removing b Using tools: Name of parts in : 4. spring retainer i! After the cotter removing, the spring i du | an retainer (4), and put the wire on it to draw out the spring retainer. xhaust valve stem removing Using tools a. Facing up handle b, Bolt Wire rope @. Exhaust valve ixing handle ‘Take out the stopper (2), turn the valve (d) upside down and fix it with ing handle [e). Attach the £ vp handle (a) to the exhaust valve stem (1) with the bolt (b) and put the wire rope on this handle to draw upware Valve stem quide removing and fitting Name of parts 1. Exhaust valve stem guide Using tools Retainer Removing Refer to Fig. A. Attach the tools as shown in Fig. and screw in upper nut (¢) to draw up the valve stem guide. Fitting Refer to Fig. B. Invert the exhaust valve housing by the rotary table. Screw uppeti‘nut (g) % to insert the valve stem guide. 37L :wa Exhaust Valve GROUP 1430 UEC-L Inspection Procedure ITEM o2 Using tools Name of parts a. Micrometer g. Measure 1, Valve seat b. Inside micrometer 2, Valve housing €. Dial guage 3. O-ring 2 V block 4, Valve stem guide e. Dye checking tool 5. valve stem f. Surface plate 6. Cotter Inspection of the cylinder cover and the valve seat surface apepection of the cylinder cover and the valve seat surface Inspect the cylinder seat (1), and if ne to 1430-03. Clean ai before facing up. ver and the seat surface of valve essary, face it up, For facing up, refer d take away dust from surroundings Valve seat O-ring 1, Material: Use "VITON" of material designated by the \aine make Renewal: Replace the "0" ring with a n Lithiui ing, and coat the new "0" ring with base grease. Fitting method If neces salve seat (1) face up together the valve housing (2) and the 2. Attach the O-ring (3) valve housing on it. he O-ring groove of valve seat (1) and place the Make the water tighteness leaks. For the water tighten A area: Facing up , oe B area: Facing up if necessary }Refer to 1430-03 for £ er maintenance to ensure that on water test, refer to 1430-02. ng up. Cooling chamber of the valve seat Scale ig apf £0 be accunolated inthe cooling chanber, This accumuiation of seaie hinders cooling and causes the exhaust valve co be danssca, amount of water is 10% less than the standard quantity, the scales in the chamber should be removed. Seale removal: Circulating scale renoval method 3 Cooling water using the chenicals is provides, Sopling wate Ask the engine maker for sta decaiie, Scale adhesion prevention: To prevent the scale adhesion, use yaaye Gistilied water when the distilling © Seat plant is provided or employ water softener, Precautions are to be paid for the water quality. oie Standard amount of water (cc) Seales are apt to accumulate at the cooling water inlet/ outlet.1430-02-2/4 Valve housing Check the following items and if necessary, perform repairs or maintanance work Gs Area A: Lubricating oil passage Check for no clogging, if necessary, B. clean it with wire Area B: Water chamber cover Check for no water leakage Area C: Cooling water passage Check for no scale adhesion. Area D: Facing surface with the valve seat Check for no gas leak or corrosion D Exhaust valve stem guide First, make visual check and then measure the inside meter at a few vertical points using the micrometer, When guide is worn or ~ corroded over using limit, renew it with new one. Refer to (0060-02) dismantling for using limit. Refer to (1430-01) for removing 4 area A: Check for no clogging of lubricating oil passage and ma \ Area B: This part may be corroded along water chamber of Area A Area B valve houding. Spring 1. Measurement of free lengt! When spring is used for long time, it may become softened. This spring softening amy cause hunting of the valve stem. Renew spring when its free length is reduced by 4%. 2. Check for no corrosion and inspect condition Cotter of the spring end contact. 1. Verification of facing Facing condition of the valve stem (5) and the cotter (6) is to be that cotter is contacted on Slarting surface of area A and C, and has clearance in area B, If it is contrary condition, it is contacted in area 8 6 | and has clearance in area A or C, the cotter shall \ not be used. 2. Pitting method: A (1) It is recommended not 10 change combination B of cotter, the spring retainer and the valve | WI steam as much ae practicable.‘ Cc (2) If the combination shall be changed or the new part is to be used, face parts up to check contacting condition. és 37L . - ne Te |1430-02-3/4 Valve stem Measurement of wear: First, make visual check, and then measure the outer diameter of the valve stem at a few point in four directions of sliding area using micrometer. Valve stem worn exceeding using limit shall be sent to the engine mak for builé up repair. Refer to 0060-02 for using limit. 2. Dye check of the valve seat Since crack may be produced in build up area, the valve stem seat area is recommended to be dye checked. Inspecti of the cotter contacting area visually for no scratch, and Deflection measurement of the valve stem Measure deflection of the valve stem by rotating accor: following method. Grinding mac! A as base poi: Deflection at B poi shall not exceed 0.1 Deflection at ¢ point shall not exceed 0.2 mm Inspe on of stem iower surface Crater by burn! ay be produced, When the depth of crater exceeds using Limit, the valve stem is to be sent to the engine maker for build up welding repair. | | snes J \ BLA 7 | ore ee i fl S2LA 8 7 T 60LA 10 Vaive stem lubrication The valve stem lubrication is v important factor for wear of the valve stem and the valve stem guide, Precautions shall be paid. Refer to the section for lubrication of operation manual (054-01).1430-02-4/4 Water tightness testing procedure Using tools a b. c. a. Exhaust valve holder e, Bolt Plug with O-ring £. Valve seat fixing piece Flange g. Bolt Gasket h. Valve seat fixing plate Valve seat holder After maintenance work, the exhaust valve shall be tested for water tightness. but Insert plug with O-ring (b) in to the cooling water inlet holes at two pgsition on the valve housing and fix them with the valve seat fixing piece (£) and the bolt (g). Attach the testing flange (c) and the gasket (d) to the cooling water outlet port of the valve housing using the bolt (e), Check for no air leak from the valve seat O-ring area or the valve housing cover by ordinary use air at 4V 7 kg/m’. Tf the test is required to be made when the valve stem is not attached for some reasons, tighten the valve seat and the valve housing as shown below before test. In case where no valve stem is attached. Put the old gasket under the valve seat to prevent seratel i— Exhaust Valve GROUP 1430 UEC-L Facing up Procedure ' ITEM 03 Using tools Name of parts a. Facing up hanéle b. Spring 1. Exhaust valve housing ©. Valve seat fixing plate 2, Valve seat @. valve seat fixing piece 3. Valve stem , ©. Hexagon socket bolt 4. Old gasket to be rejected £. Bolt g. Facing up piece Facing up handle Exhaust valve stem and valve seat valve seat (2) with the valve seat fixing piece (e), the fixing plate (4) and the bolt (£) Put the old gasket (4) under the valve seat to prevent scrate! Place the spring (c) as shown in Fig., and insert the valve stem (3). Attach the facing up tool (b) and the bolt (g). Put the facing agent on the valve seat area, rotate right and left the facing up tool with both hands and move it vertically tapping to face up Use actual valve stem and valve seat to be combined when facing up. Check rubbing condition by marking the valve stem and the valve seat with red paint. When rubbing condition is not adequate, change the combination of valve stemand valve seat or recrind valve stem and/or valve seat. After facing up, recheck rvbbing condition by marking with red paint. Criteria for judgement are as follows. (1) Contact shall be overall surface contact of (do) along all the seat width. (about 60% contact is allowed as well.) (2) r£ contact is i only at the inner surface, it is b not allowed, | Valve seat area, valve seat cS — and valve Fousing ] a Yalve seat ares fucing up (Ares A) i | Gveriey the faciny uy piece (i) om the valve west (2) for fecing w | 2. Facing up the valve veat and the valve a housing (Ares 2) Foce up the vive sent (2) and tue valve > 1 housing (1) wits the facing up piece(i). [~~ | le42 GROUP 1420 UEC-L Exhaust valve Grinding Procedure - {ITEM 04 Using tools Name of parts a. Gauge for valve stem using limit 1. Valve stem b. Gauge for valve seat using limit 2. Valve seat Judgement whether grinding is allowed or not whickness measuring of built-up material: jeasure thickness of built-up material of seat area by means of limit gauges (a), and if the valve stem or the valve seat worn over limit, it should ee (se WF we seen stea (1) is over 1 ) 2 line of tne gauge (a). epair repair of valve stem and the ste 7 ing up © stem and ve seat shall be securely sent t: engine maker Grinding ‘inding machine @ grinding machine designated by the engine maker is to be used. @ machine shoul@ be installed in P ch undergoes as slight vibration as possible. Vibrations are, in some eases, to produce wavy forms on the ground Necessity of grinding The grinding is to be performed only when grinding is necessary. In case where there are no dents on the valve valve seat, and where there are some which do not require grinding, facing-up should be carried out instead of grinding, to make the valve stem Z valve seat more durable. Cr. as follows. (Same criteria f Area A: The relatively large dents should be ground ~ till they are reduced to the ones diameter. Area Bz The defective parts which are about 2 mm in diameter and distance 2 = 10 mm or more may be left as they are. Area C: The defects on the outer sides should be ground off as much as possible,1430-04-2/2 Method of grinding For the handling of the grinding machine, refer to the instruction book. In general, cares shall be directed to the following matters. (1) To avoid vibration, grinding should be carried out while in port, if possible, (2) case that the grinding speed is too high and where the part ground at a time is too much, hair crackings are apt to arise in the ground part. (3) The deflection at the time of centering the valve stem and valve Seat on the grinding machine should not exceed 0.1 mm. (4) Grinding should be directed in the direction from valve seat je to outside. Grinding direction is to be as shown by the "ARROW" mark. (Same instruction is applicable for valve stem as well.) rinding angle: (1) The grinding angle should be formed as same angle for the valve stem and the valve seat. (2) The valve stem is to be rounded off on all the outer side. Aree A: Grinding tool stall be conta! ed at all width of seat + Area B: The valve stem shall be rounded as specified R. 37LA | SLA |Ne@ia [Neos Rimm)| 6 e Boy (3) The flat section of the outer side of the valve seat is reduced an area every time it is machined. (As Ty —-T2) | When Tz is less than value shown in following table, the surface C is to be ground to become Le more than the value in tabli i [atta Nea [eet ST tC? ALA nT (ta imm| 3 ry Facing-up Facing-up is to be carried out after grinding. For the facing-up procedure, refer to 1430-03,UEC-L Exhaust Valve |aroup 1430 37L Assembly and Fitting |'e 05 Using tools Name of part: Rotary table 1. Valve housing hetainer Valve seat - Valve seat guard table Valve seat guard Handle + Cotter dismantling tool Valve stem guide drawing tool Procedure for assempling Each part to be assembled should be reconditioned accordance w: spection procedure (1430 ocedure (1430-03) dure (1430. he assembling shall be 30-01) dismantling re for fitting event exhaust valve from fixing, apply the follow: ents.. However, nothing should be pplied to the gasket and the gasket surface, A care should be exercise: may not be stained with the preventive age t when the exhaust valve inserted into the cylinder cover. Area A: Side of valve housing Neverseize Emocon {Aluminun-based) Area B: Side of valve seat Boron spray (Boron-based) Area C: Valve seat gasket surface Nothing is to be applied . Fit the exhaust valve to the cylinder cover in counter order of removing in (1430-01).Exhaust Valve GROUP 1430 UEC-L Tightening Procedure for Exhaust Valve 8olt ITEM 06 Using tools Name of parts spanner 1, Exhaust valve tightening bolt 2. wut Procedure for Tightening 1 Clean the threaded area of the tightening b coat then with Molykote. Tighten the not (2) in order ©, ®, @ ane © alternately handful with 2 200mm long spanner. ‘The degree obt ed by tightenii shall be zero point, and put a match-mark to the (2) and nut,(2). Tighten diagonal two bolts at a time, Refer to tightening standard for main bolts (0070-01) for the nut turning angle. ‘ After tightening up the bolt put a match-mark them by the paint etc. 5. It is recommended to re-tightening the bolt after several days Tightening order 1. No.1 and No.4 2, No.2 and No.3 3. No.1 and No.4GROUP 1430 UEC-L . Exhaust Valve Adjustment of Tappet Clearance ITEM 07 | Using tools Name of parts a. Thickness gauge - Rocker arm 2. Adjusting screw 3. Lock nut | 4, Exhaust valve housing | { ; | | | Adjustment | . Adjust the tappet clearence surely in the c ste ~ The system lubricating oil pressure. shall be kept within the specified limits. ‘The piston of the cylinder to be subjected to adjustment should be turned until the piston comes to the position of the top dead center. 4, Loose the lock nut (3) and the adljusting screw (2). Push down the rocker arm (1) on the push-rod side to eliminate the push-rod clearance. 6. Insert the thickness gauge {a) into the measuring position, and tighten it with the adjusting screw (2) and fix it with the lock nut (3). 7. The clearance should be adjusted every time the exhaust valve is replaced with a new one. 8. For the tappet clearance, refer to (0030-01). 9» + op a 37L 45L°Vz] Starting Air Valve GROUP 1440 UEC-L y Inspection and Removing ITEM oO Using tools a. Jack bolt a. rust b. Nut c. Washer Name of parts, 1, Housing 2. cover 3. valve stem 4. Piston 5. Spring 6 7 8 . Bolt 9. Nut 10. O-ring ou. Oring 12. Grease nipple 13, Set screw 14. Set screw 5. Hexagon socket bolt 16. Hexagon socket bolt 17. Orvis of 18, Oring 19. Washer with clickes spection L The periodical overhaul shall be performed in accordance with the maintenance schedule (0040-01). Check the contact surfaces between the valve stem (3) and the valve housing (1). I£ necessary, face it up. See the tightening values for main bolts (0070-01) for the starting air valve tightening bolts (15) and (16). (ay an eh meretore, fron the contact surface between the valve housi fe valve stem (3), the starting air bran a check it from time to time by hand tou ch pipe is he ch. iubricate periodically the starting air valve inside from the grease nipple (12). O-rings (10), (11), (17) and (18) shall be replaced with new ones at every overhaul.1440-01-2/2 7. Check “spring (5) for no. breakage. ay 8. Tighten securely the ni clickes ( x 8. The gasket Removing 1, Install the jack bolt (a) on to the cover (2) and lock it with the lower nut (b). Tighten the upper nu! b) to jack up the starting air valve.UEC-L | Cylinder Safety Valve Inspection and Adjustment |GRoup 1ss0 [Tem or Using tools for overhaul fc. Hose joi Cylinger safety val testing device on valve holder lame_of parts Valve guide Spring support Valve support Spring Lock aut ie 3 4 4 Inspection and adjustment the fuel injection valve Valve opening pressure he valve opening pres above is our of standare (6) and sere in lor Q a (7) and 7, valve seat 8. Gasckec 9. valve 0. Gasckee testing device. 170 33 kg/en? loose the Lock draw out) djustment valve (2) and ne sul fi ved5 Indicator Valve GROUP 1450 UEC-L Inspection and Seat Surface Facing Procedure | ITEM 02 Name of parts . 1. Valve housing Using tools: 2, Valve stem guide 3, Valve seat holder @- Valve seat holder drawing tool 4. Handle b. Valve seat drawing tool 27 Bangle disk 6. Washer ©. Facing tool 7. Joint _ 18 8. cap nut 9, Ring 10, Union nut Ll. Gasket 12. Gasket 13. Gasket 2 15. valve sten 2 «16. Valve seat 7. Lock nut 5 18. Chai 20. Spring washer 21. Cross recessed flat head small screw 22. Hexagonal nut 24. Gasket Inspection and adjustment 1. The indicator valve is subject to the periodical inspection. See 0030-01. Check the facing condition of seat surface and for no sulphuric corrosion, and make facing-up if necessary. (See Fig. C) For drawing out the valve seat, first draw out the valve seat holder (3) using the valve seat holder Grawing toll (a), then take out the valve seat (16) by means of the valve seat drawing tool (b). (See ae Fig. A and B) Check for no clogging of gas way or su: When reassenbling the valve seat, coat with Molykote before screwing lSeat_surface facing procedure phuric corrosion. the threaded area Face up the valve seat (16) of indicator by means of the facing tool (c), thenfinish| lit by co-facing of the valve stem (15) and the valve seat (16). (See Fig. C) 5 Fig. AUEC-L Air Cooler GROUP 1620 37L Inspection and Adjustment ITEM 0 Name of parts 1. Air cooler casing 7. Inspection eye cover 2. Outlet/inlet side water chanber 8. Inspection eye 3. Return side water chanber 9. Inspection eye 4. Tube plate 10. Manoneter 5. Air vent cock LL. Air duct 6. Drain cock Scavenging air \ spection and adjustment Check the foul condition of fin tubes from the inspection eyes (8 (9) on the air duct (11). Make cleaning, if necessary. For the cleaning procedure, refer to 1620-02. 2. Read the differential pressure of the scavenging air inlet and outlet by means of the manometer (10) to determine the foul degree of the air side. Clean it, if necessary. See 022-01 for the limited values for operation of operation manual 3. Open the water chambers (2) (3) of sea water side to check the fouling of chamber, cloyging of fin tube, and wear condition of the anti-corrosive plate. Clean it, if necessary. 4. When the fin tube is failed, open the chambers (2), (3) and drive wooden plugs into both failed tube ends.UEC-L Air Cooler, GROUP 1620 Chemica] Cleaning of Fin Tubes ITEM 02 Using tools Name of parts a. Steam inlet tube 1. Air cooler b. Drain cock attachment 2. Air charge duct ¢. Drain cock 3. Inspection eye d. Marine bronze hose valve 4, Inspection eye e. Vinyl hose 5. Fresh water inlet tube f£. Hose band g- Cleaning cover h. Cleaning cover Process of cleaning Remove the inspection eye (3) and install the cleani bottom of the air cooler (1), 9 covers (g)(h) on the Attach the drain cock attachment (b), the drain cock (c), the vinyl hose (e) and the hose band (f) to the cleaning cover (g). : Remove the inspection eye (4) with the air charge duct atcached. Supply fresh water until the fine tube are submerged. Add chemical to the water. Boil the water by feeding steam. Throttle the steam supply when the water starts boiling and continue to heat for cleaning 3 V5 hours. Perform the cleaning carefully with the water level rise due to steam. Open the drain cock (c) to eliminate the contaminated water while pouring fresh water. In this work, be careful for that the fin tubes are not exposed to air. When temperature of the contaminated water lowers to a iivel close to normal temperature by pouring and draining, drain the entire contaminated water. Check the fin tubes if they are cleaned, set the device again as before, 37L2110 Crank Shaft Ce Inspection and Deflection Measurement ITEM oe Using tool: a. Dial guage for deflection measuring Inspection When overhauling the main bearing metal an pay Grind it by mean of oil stone and make its surface smooth, if required. Mea: a rement of crank shaft deflection 1¢ crank pin bearing meta: attention to the rough surface of the crank shaft bearing area ‘The measurement of the crank shaft deflection shall be made for determining the eccentricity of the crank journal due to the wear of the main bearing metal When the main bearing metal is replaced with new one, the measurement of deflection shall be surely made. When any abnormality is observed in the main bear: the crank shaft deflection shall be measured. g metal as well, Use the dial gavge (a) for the measurement of the crank sha: deflection. The dial guage shall be attached to the crank web marked position. ‘The measuring position is to be where the crank pin is at TDC, the position nearly BDC is not obstructed by the connecting rod and the other moving ports and the crank pin of camshaft side and exh side are horizontal. 1 jalue to be recorde le flection = Deflection (B)} « st= Value to be recorded = {Defi (1) - Deflection (ay) x x4 Method of writing down the mea are The empty, the drat. position and the crank case temperature shall be simultaneously recorded. 1/100 mm i Date T Standard difference [ Fore Ceeeeaeeeeneens Drafe }— } | ae Normal value: + 0.08 - Limit value: + 0.16 If the déflection measured value exceeds the limit, investigage the causes a cnénd J ots py ‘The above recorded values to be plotted. engine condition, the condition in state of ship fully loaded and Crank case temp. Cylinder No. 123456 take proper me:12 Connecting Rod and Cross Head GROUP 2350 UEC-L Inspection and Foot Liner Adjustment ITEM ei Using tools: Name of parts 4. Thickness gauge 1. Crank pin bearing tight b. Supporting plate 2. Connecting rod ©. Pin 3. Crank pin upper bearing 4. Crank pin lower bearing €. Wire rope 5. Bolt f. Tie belt 6. Guide shoe $. Chain block 7. Foot liner h. Bole €. Cross head guide i. Shackle Eyeplate for scaveging trunk Insection and adjustment Check the connecting rod top, lower bearing clearance and cther c Refer to 0060-05 for clearance measuring position Check for no slack of bolts and nuts, or their defec: stopper against turning is sufficient 3. Adjust the compression pressure by varying the thickness of foot liner Foot liner adjusting procedure Fig. & See a 1. Put the crank sha D.<. position Install the supporting plate (b) with bolt (h) 3. Install the stopper (c} on to the hole of the c: guide 4. Loosel tight. (1) until it supporting plate lower erea. Take ow the cross h lower face. ide shoe (6)sage camshatt , | } Y \\ 5: \) coast See qe 12, 2350-01-2/2 See Pig. B 7, Install the chain block (g) on the eyeplate for scavenging trunk (3) using the wire rope (el ané shackle (i). 8, Wind clothes on the connecting rod (2) lower area ané install the tie belt (£). Hook the tie belt (£) to the chain block (g). 9, Hold the connecting rod with the chain block (g) and turn the crank shaft until the crank pin posi- tion comes to make a gap in the crank pin upper area (3) for insertion of foot liner (7) When turning the crank shaft, hold the crank pin bearing (3), (4) to keep steady. Fig. ¢ After installing the foot liner (7), turn the crank shaft so that the crank pin bearing (3) (4) comes at the position as shown in Fig. ¢ Lift up the exhaust side crank pin bearing tightening bolt (1) and tighten it. Remove the supporting rod (4) and tighten the crank pin bearing tightening bolt (1) of camsnafc side. Refer to for tightenine pro- cedure (2350-05). Attach the coupling bolt (5) of connecting rod (2) and crank pin upper bearing (3). Stop the crank pin bearing tightening bolt (1) against turning2 UEC-L Connecting Rod and Crosshead GROUP 2350 7 Removing and Fitting of Lower Crank Pin Bearin: S ITEM oz Using tools Name of parts Byebolt g. Bolt 1. Crank pin bearing tightening bole b. Lifting piece h. Bolt 2. Crank pin bearing lover part Lifting piece i. Chain block Connecting rod Lifting piece 3. Chain block 4. Eyeplate of scavenging trunk Wire rope k. Chain bloc Keep the crank pin at the position of T.D.C as shown in Fig. A Attach the eyebolt (a) and shackle (£) to the crank pin bearing lower part (2). Attach the lifting pieces (bl and (c) to the respective side of cam shaft side door upper area and exhaust side door upper area with bolt (g). Put the chain blocks (i) and (3) on the lifting pieces and stretch them ce the adequate tension Take out the nut of crank pin bearing tightening bolt (1) and pull out the bolt downward Loose the chain blocks (i) and (3) and lower the bearing lower part (2) gradually until it comes to the bed plate bottom level. Take out the chain block (i) Turn the, crank shaft until the position indicated in Fig. B.2350-02-2/2 9. Attach the lifting piece (a) on the upper area of the connecting rod (3) with bolt (h), and put the chain block (i) taken out in the above item on it. 30. Lift up again the bearing lower part (2) until it comes over the column door lower part by means of chain blocks (i) and (3). 11, Add the shackle (£), wire rope (e) and chain block (k) attached to the eye plate of scavenging trunk (4) to above and pull it to outside, and adequately handle the chain blocks (i) and (3) to take the bearing out from the engine. Procedure for fitting Fitting the crank pin bearing lower part (2) in counter order removing process. of the aboye42 UEC-L Connecting Rod and Crosshead Removing -and Fitting of connecting Rod GROUP 2350 ITEM 03 sing tools Pin Lifting piece Tie belt Lifting piece Lifting piece Wire rope Wire rope Shackle Shackle Shackle Chain block Chain block Chain block Bye plate of Metal stopper Bolt Bolt Procedure of Removing ae 2. Reamer bo: 3. Connecting rod (cam shaft side! 4, Crosshead pin (exhaust side) 5. Crank pin bear 6. Protective mat cavenging trunk piece I 1. Attach the 1 to the re: with bolt (el 2. Turn the crai jon of 5 upper part ( belt (2). Rel 4, Install the 1 with shackle ge) with sh fonnecting ro! the clo 5, Turn the eran it as shown the pin (a) u column to sup; guide shoe. necting rod) ting pieces (4), (e) ive side of cam r upper area and exhaust side door upper area k shaft to the .D.C, 3. Remove the crosshead pin bearing ) and the reamer fer to Pig. By ifting piece (b) (h) and tie belt le (4) on the On the to protect th k shaft to position Fig. A, and insert © the hole of the sort the crosshead 37LFig. © Put the chain blocks (k) and (1) on the lifting pieces and stretch| them to the adequate tension, Turn the crank shaft clokwise and handle the chain blocks (x) and (1) to move the connecting rod (3) to the position as specified in Pig. C. Change the hook of cha: (2) to the shackle (h). block Attach the metal stopper piéce (0) to crank pin upper bearing with bolt (p) to hold the crank pin metal. Pass the wire rope (f) through the reamer bolt hole of crank pin upper bearing (5) and put the chain block (m). (Protec the reamer bolt hole by cloths ete.) Lay the protective mat (6) on the column door exhaust side lower part. Turn the crank shaft and handle the chain blocks (k), (1) and (m) to position the connecting rod as shown Fig. Dy For the above oper-| ation, be careful for not damaging guide by touch of connecting rod. 13, Change the hooking of the chain block (x) to the eye plate of scaveno- ing trunk (n) as shown in Fig, D, anq| put the hook to the shackle (n), Change the hooking of the chain block (1) to the shackle (}) of the tie belt te), 14, Handle the chain blocks (2) and (m) to balance, and take out thh connecting rod by the chain block (k). Procedure for Fitting Fitting the connecting red, in counter order of the above removing processae Connecting Rod and Cross Head GROUP 2350 UEC-L : Removing -and Fitting of Cross Head Pin ITEM 04 Using tool Name_of parts: a. Pin £. Bolt 1. Cross head pin b, Lifting piece g. Bo. 2. Guide shoe c. Shackle h. Chain block 3. Cross head guide wire rope i. Chain block e. Lifting piece 3, Dismantling process 1. When removing the connecting rod, hold the cross head pin (1) with the pin (a) in the manner as shown in Fig. A. 2. Install the lifting piece (b), wire rope (a) and bolt (£) on the cross head pin (1). Lift it slightly with the upper crane to remove the pin (a) and lower it. 3. After the upper side of cross head guide shoe (2) passed through th lower side of cross head guide (3) of column, turn by 90°, Attach the lifting piece (e) on the exhaust side door upper area of the column, and put the chain block (h) on it. Attach the wire rope (4) to the hook of chain block (h). Draw out the cross head pin to outside by means of the chain block (h) until it comes over the column door lower part, and remove the hook of, upper crane. ©. Put the chain block (i) on the eyeplate for scavenging air trunk (3) with the shackle (c). 7, Handle the chain blocks (h) and (i) to take out, Assembling process a jemble the cross head pin in counter order of dismantling,~ Connecting Rod and Crosshead UEC-L Tightening Procedure for Crank Pin Bearing Bolt Using tools a. Spanner rts Connecting rod 4. Nut b, Thickness gauge 2. Crank pin upper bearing Tightening bolt 3. Crank pin lower bearing Tightening Procedure Clean the threaded area of the tightening bolt (5) and nut (4), and coat then with Molykote. 2, ‘Tighten the nut (4) in order@,@ alternately by handful with a 200 mm long spanner. As for the standard of the nut turning angle, the degree obtained by tightening shall be zero point. 3. Tighten the nut (4) in order @, @ alternately three tines by 10° ata time, Measure that the clearance Ay and Az betweeen the upper bearing (2) and the lower bearing (3). Ascertain that the clearance hy Ae equal to Az. 4, Tighten the nat in order @, @ alternately by 20° at a time so as xo the nut turning angle becones standard tightening values. Refer to the tightening valves for main bolts (0070-01) for the nut turning angle. ‘Turn the crank shaft to the position of BDC, and measure the bearina clearance. 6. Ascertain that the clearance of bearing is within specified limit, then set the locking washer, Refer to the clearance of main parts (0060-05) for the clearance of bearing.2 UEC-L Piston and Piston Rod GROUP 2450 - Inspection and Wear Measuring ITEM mn Using tools Name of parts a. Piston ring groove 1. Piston head 6 iaeeeee nome 2. Piston skirt 7 inner b, Thickness gauge 3. Piston rod ~ ay ¢. Vernier calipe: 8 ae 4. Piston a ton inserting a g guide piece a, 1. Observe the fouling condition of the piston head (_) upper surface and check for no burnt Check the piston rings (4), (5) for no sticking or breakage and inspect the contamination of cuter surface 5. Measure the wear of the piston rings (4), (5) and ring groove. Pay atten- fn also for wear form the piston ring is worn exceeding ing limits, it shall be repla new one. For the us. see 0060-03 5. The piston ring to be reused after overhaul shall be suxely attached te the original ring groove When dismantled, check the piston head inside surface for carbon adhesion condition and clean it. In case where the carbon adhesion is pronounced, check the system oil and fuel injection system and if necessary, clean whole cylinder by dismantling. Check the rubbing surface between the rod stuffing box for no scratch. ton rod (3) and the piston Check for no slack or breakage of bolts or others, and replace them if necessary. Inspect the contacting surface between the piston head (1) and inner piece (9) and between the inner piece (9) and piston rod (3) for no fretting when dismantled. 10. oer: g shall be replaced with new one at every overhaul. (Note) If the burn out on the piston head 7 Mear measurin upper surface is pronounced, the Piston ring built-up welding is required. 1, Address to the engine maker. Measure the piston ring thickness (T} i: and width (8). Zr Measure (T) dimension at three points T, Tz, and Ty. + "See 0060-03 for standard clearange 37LWear measuring of ring 2. 2450-01-2/2 Piston ring cutting end Make measurement using the piston inserting guide piece (4). @D: Cylinder inner dianeter See 0960-03 for the clearance of main parts. roove Wear measuring of groove ee cess of ring groove dimension measuring b Y Yp. J), J ae \ See 0060-03 for the clearance of main parts Recording process of measured value ina) Cy We T eae 1 Ring Nor Ui ec eee a | o || T T t / Tale {3 | i r 4 $2 ty | y | | | +— 3 "a | | \ a [ il“i UEC-L Piston and Piston Rod GROUP 2450 Removing and Fitting ITEM 02 Using tools Name of parts 2. Eyebolt for piston lifing 2. Piston head 5. Cylinder b. Piston lifting tel 2) Cross head pin Liner ©. Wood 3. Piston roa 6. Piston rod @. Piston inserting guide piece 4. Piston fing stuffing e. Tie belt box Removing Fig. A Fig. Fig. 2. 1 $ Z I oy 4 z Fs SS Tie Ge | ij [| tightening nuts of cross head pin (2) and piston rod (3) before piston removing. 2. Place tha piston at the position of TDC, clean the screw hole for lift: located on the piston head (1) top surface, and insert surely the eyebolt Fig. D for lifting (a). ‘n the piston to the position of BOC and vemove the tightening nuts of piston rod (3) and cross head pin (2). Take out thé tightening bolts of piston rod stuffing box (6). 4, Attach the tie belt (e) for piston rod stuffing box. See Fig. A. Lift up the piston together with stuffing box (6) until the cylinder liner upper surface, and put wood on the cylinder to place the piston on it. See Fig. 8. iner upper surface and attach the it up slowly. Take out the piston ring (4) and the eyebolt lifting tool (b) to the first ring groove to See Fig. C. Put the piston in the maintenance pit on the engine floor after Removing. —+—— Fitting do 1, Put the pil ng guide piece of the cylinder liner (5), See Fig. D. 2. Insert the piston in counter order of | removing. 3. For the tightening of piston rod tightening bolt, refer to the tighten- ing standard, (0070-01),Piston and Piston Rod | Group 2450 UEC-L Piston Ring Removing and Piston head Airtightness Test ITEM 03 Using tools: ton ring removing tool 1. Piston ring on_ring removing ‘Three piston removing tools are to te used to resove the/3 UEC-L Piston. Cooling System Procedure for Removing GROUP 2460 ITEM o1 Using tool a. Centering tool 37L Name_of parts 1. Inner t 2. Sleeve 3. Sleeve 4. Sleeve 5. Inner t Procedure for Inspectig Check each Check for no looser belt at en port correctly fitted. ter: ‘Turn the crank sha! at 30° before the Loosen the inner t Fit the cei tering and adjust the pos. until the centerin: retainer (4) smoot} 4. | ube box retainer ube attaching bolt jon int for no loose bolt. ning of inner tube installin: and make sure that it is escopic piping inner tube ft until the piston comes position of TDC. ube attaching bolt (5). tool (a) to the in ition of the im ex tube g tool (a) is able to be inserted between the inner tube (1) and sleeve nly. Tighten the bolt (5) and vake out the centering tool. ‘Turn the crank shaft and make sure the inner tube is correctly fitted.UEC-L Camshaft Driving Gear GROUP 2560 Inspection and Adjustrient ITEM on Using tools: Name of parts a. Thickness gauge 2. Crank shaft gear Camshaft gear b. Oi2 stone 2. qéle gear 4. Bush 5. Gear shaft 6. supporter 7. Inspection eye 8. Backlash measuring eye Inspection 1. Examine gear teeth of the gear (1), (2) and (3) for surface roughening from the inspection eye (8), and recondition their surface ~ with oil stone if surfaces are roughened. 2, Measure the gear backlash and ensure that it is within the specified limits and compare it with the recorded value of the engine newly built time, 3. Measurement if to be made from the backlash measuring eye by mean of thickness guage. 4. The backlash shall be securely within the specified limits. Too great backlash gives rise to the pitching and also encourages vibration or noise. 5S. Measure the clearance between the shaft and bush of idle gears (2), (3) by taking out the supporter (7) and using the thickness gauge. 6. For the standard limits of the clearance between the shaft and bush : and the backlash, refer to 0060-06UEC-L Exhaust Valve Driving Gear |GROUP 2630 Inspection and Adjustment |ITEM 37L Name_of parts 1 2 3 4 5 6 7 8. Driving piston Camshaft Casing 14, Exhaust valve + Rocker arm shaft tightening bolt 8. Exhaust cam + Adjusting screw 10. Roller + Ball surface bearing 11, Rocker arm Rocker arm shaft 32, Piston for ei) cushion + Tapper 13, 0 ring + Push rod 15. Rocker arm bearing stané 13 12 Datil area A Inspection and adjustment For the clearance of the main parts, refer to 0060-08, 0060-08. Check for no slack of the tightening bolt (1) of rocker arm shaft, the adjusting screw (2) and the ball surface bearing (3). 3. Check if the lubrication is enough to the rocker arm shaft (4), the tappet (5) and the ball surface bearing Q) 4, If the lubrication is not properly done to the ball Surface bearing (3), push rod upper area (6), they will be heated. Check those part for heating by hand touch éuring operation. If those parts show rough surface when dismantled, face up together. 5. Check roughness of the contacting surface between the @riving piston (7) and the camshaft casing (8): Repair it with oilstone if necessary. 6. Check roughness of the contacting surface between the exhaust cam (8) and the roller (10). Repair it with oil stone if necessary. 7. Inspect if the stroke of oil cushion (3 mm) is assured when the bearing lubricating oil runs. Make dismantl- ing and inspection if necessary. 8. See 1430-07 for adjustment of tappet clearance.Lubricator Driving Gear Inspection and Adjustment a2 GROUP 2820 ITEM o1 of parts: Cylinder lubricator 9, Bevel gear Cylinder lubricator 10. Spur gear Lubricator for exhaust 11. Spur gear valve and rocker arm 12. Shaft 4. Indicator 13. shart 5. Adjusting knob 14. Shaft 6. Air vent 15. Universal 7. Spur gear joint 8. Bevel gear 16. Chain 19 20 ele 2 17. Tightener 18. Sprocket 19, Lubricator shaft 20. Lubricator housing 21. Tapper split pin 22. Gear 23. Sprocket 24, Tapper split pin es =a Lo ;% Ses Z 1. Make inspection at regular intervals during operation to ensure that the steel ball of indicator (4) is normally floating. 2. Do not change carelessly the adjusting of the lubricator inside mechainsm and adjusting knob (5) 3. For handling of the lubricator, see the instruction book for the lubricator 16. 4. Refer to the clearance of main parts (0060-12) for clearance of i a each part. 3. The strainer of feeding port shall '8— be periodically cleaned,Setting standard ancy anely lubricator shall be set at specified crank angle and the setting mark provided on the housing shall be matched. See Y view The lubricator and the driving gear are initially set to meet the above specifications. Reassembly by removing only lubricator Reassembly by dismantling the lubricator driving gear ie Replacement o 1 : A 2820-01-2/5 Type of engine Before TOC of @ spcified cylinder (deg.) 5> and 6-cylinder 158° of No. 3 cylinder 7- and 8-cylinder 162° of No, 4 cylinder i Make the standard crank angle specified above by turning the crankshaft. The lubricator speed is reduced to one fourth of that of the crankshaft, so the match mark on the lubricator meets that of the crankshaft ence every four rotations of the crankshaft Align the match mark of the removed gear and the match gears, and i equally align the match marks of the lubricator-housiny (20) and the lubricator shaft (19). ‘Turn the crankshaft and set the standard crank angle listed above. Align the match marks of removed parts. Gear (7) and gear (21), bevel gear (8) and bevel gear (9), gear (10) and gear (11), and gear (10) and shafe (18) ! Align the match marks of the lubricator housing (20) and of the lubricator shaft (19). Drive the slotted taper pin (24) into the pin hole. After reassembly, recheck to ensure that all match marks are aligned { at the standard crank angle. lubricator with spare Turn the crankshaft and set the standard crank angle listed above Check to ensuxe that all match marks in the lubricator driving gear are aligned. Remove the lubricator. Install a new lubricator. Before this, the match marks of the lubricator housing (20) and of the lubricator shaft (19) are to be aligned. | Insert the taper split pin (21) into the new lubiicator shaft and the gear (10) (or (11). After completion of replacement, recheck to ensure that all match marks are aligned at the standard crank angle. 37Lrc . Lubricator Driving Gear GROUP 2820 UEC-L Inspection of Exhaust Valve and Rocker Arm Lubricator ITEM ” 13 Name of parts Inspection and adjustment 1 Lubricator 5. Claw clutch 9. Tightener Indicator 6. Priming handle chain 7. Strainer Adjusting knob 8. Air vent Be sure to make inspection at regular intervals during op Check that the steel ball of indicator (2) is properly floating. bo not change carelessly justment of the lubricator inside ‘The lubricator outlet and the o distributing valve attached to the cylinder cover 11 be periodically inspected Ensure that oil comes out from each outlet of distributor in order Make inspection by overhaul, if necessary The strainer (7) at the feeding port shall be periodically cleaned Check the tension of the driving chain (3) if normal. The tension is automatically adjusted by the tightener (9). Lubricate the chain with grease at regular intervals. Refer to 2820-02-2/3, 3/3 for the instal- lation and adjustment of the tightener Engaged Disengaged Clutch operating condition 37L2820-02-2/3 tment Procedure of Tightener. Braking screw (Yellow) Cam stopper: Disengaging screw (Red) Hub nut Spiral spring— (width across cam plate “Fixing bolt flats of os 3 hexagon 26 Fecentric ring (6s hole? gon 26) is (6s — Frame cam plate fixing screw ler sprocket ‘Tighten disengaging scxei screw driver. 2. Wind up spiral spring by turning hub put clockwise with spanner. (or by turning eccentric ring with bar lising 6 hole.) “Turning angle is to be decided by taking account of the position of idler sprocket in relation to the chain as well as spring tension. 3. Tighten braking screw (yellow) firmly after winding up. — ~ 4. Contact idler sprocket with the chain and fix frame with bolts at its right position. 5. After fixing frome, loosen disengaging PEON OS reg te eee ee When the Braking serev is loosened the GS ee Se es parer 6. 2820-02-3/3 In case of over tightening Loosen red screw keeping braking screw (yellow) tightened and turn back hub put with spanner. In case spring tension in opposite direction is to be given Loosen cam plate fixing screws, and remove cam plate, can stopper and spiral spring. Fit these parts inside out. Then directions of winding up and tension force become reverse. Remark ‘Tighten braking screw (yellow) firmly after winding up by all means. Be careful not to loosen disengaging screw (red) without tightening braking screw, otherwise the idler sprocket will react strongly. When the cam sto is not disengaged (spring tension is not given) even if the red screw is loosened, tighten braking screw (yellow) firmly first and then loosen it slowly.UEC-L Fuel Injection Pump GROUP 3100 Inspection and Adjustment of Injection Timing | (TEM oO Name of parts a. Timing adjusting 1. Puel injection pump 4. Starting Line spanner eee of fuel injection eee (marked on’ pump tion pro 3. Leck nut housing) 5. Indicating line (marked on plun jer guide) SS Turn the crank shaft il the starting line of fuel injettion (4) marked on fuel injection pump housing window and the indicating line (5) marked on the plunger guide are matched. Read the crank angle when the above both lines are matched. Record the crank angle of the fuel injection starting and serve it as reference date for next inspection. ‘ Adjusting process 1. Turn the crank shaft to the injection starting position crank angle of the cylinder to be adjusted. Drive the adjusting screw (2) until the starting line of fuel injection (4) matches with the plunger guide indicating line (5). Confirm the crank angle when the indicating line ($) coincides with starting line of fuel injection (4) by crank shaft turning. Lock nut (3) shall be tightened for certain.i UEC-L Fuel Injection Pump ae Dismantling and Assembling ITEM 02 Using tool Name_of parts Spanner 1. Pump casing 7. deflector 2. Plunger guide 8. Delivery valve 3. Control rack 9. Delivery valve seat 4. Control sleeve 10. Delivery valve holder 5. barrel LL. Spring 6. ismantling and assembly. 1. Use eyebolt (a) for pump removing and lifting up for fitting. } 2. The fuel injection pump dismantling and assembly shall be carried out on the working table covered by clean oil paper and in the vessel filled with flushing oil. 3. When parts are to be replaced, the plunger (6) and the plunger barrel ; (5), and the delivery valve (8) and the valve seat (9) shall be treated in pair. 4. When the control rack (3) and control sleeve (4) are dismantled, engage the rack teeth of control rack (3) with those of sleeve (4 —-.as shown below (x - X) when reassembling STOP.UEC-L Fuel Injection Pump Driving Gear GROUP 3130 Inspection and Adjustment ITEM o Name_of_part: 1. Driving piston Driving piston side stopper 2. Pump. stand 3. Roller Adjusting screw Special nut 4. Roller pin Camshaft casing 5. Bush Fuel can Inspection on stop time and turning time 2, Check if the lock nut (8) is not 2. Check to ensure that the rotation of roller (3) is smooth. when the roller does not rotates smoothly, the burnt of bush shall be suspected. Quick dismantle and replacement with spare part is to be carried out. eat Check the roller (3) and the fuel cam (10) surface for roughening condition and repair it with oilstone, if necessary. 4 Dismant] ing { Cr Cheke. the bush. (5) for no [ excessive scratch or burr of oil groove. Repair it or replace it with new spare part, if necessary. ih sna Check the rubbing surface between the driving piston (1) and the camshaft casing (9) fox roughen- ing condition and scratch. Repair it by mean of oilstone, Af necessary. 3. Check the clearance is within the standard limit between the driving piston (1) and the driving piston side stopper. 4. For the clearance of each part, zefer to 0060-09 for tne clearance