This book must in no case be wholly or partially copied and published ‘or passed to unauthorized persons without the permission of HYUN- DAI HEAVY INDUSTRIES CO., LTD. ENGINE & MACHINERY DIVISION.Instructions for Main Engine Type S50MC-C This book forms part of a set of books consisting of three volumes entitled: Vol.| OPERATION Vol. i MAINTENANCE Vol. Ill COMPONENTS AND DESCRIPTIONS: ‘The purpose of these books is to provide general guidance on operation and maintenance and to describe the constructional features of a standard version of the above engine type. Deviations ‘may be found in a specific plant. In addition, the books can be used for reference purposes, for instance in correspondance and when ordering spare parts. It is essential that the following data is stated in spare parts orders as it is used by us to ensure the supply of the corract parts for the individual engines: Name of vessel Engine No. built by Plate No. Part No. Quantity required (and description) gape Examble: M/S Nybo - 7730 BAW - 90201 - 00 - 059 10 off (piston ring) Furthermore, to ensure optimum efficiency, reliability and lifetime of the engine and its components, only original spare parts should be used. The designation 'D’ used in texts and illustrations refers to the information given on the data- sheets inserted in the respective books. As reliable and economical operation of the diesel engines is conditional on correct operation and maintenance, it is essential that the engine-room personnel is fully acquainted with the contents of this book. This book is subject to copyright protection. The book must not, either wholly or partly, be copied, reproduced, made public or in any other way made available to a third party without the written consent of this effect from MAN B&W Diesel A/S. Hyundai Heavy Industries Co., Ltd. Engine & Machinery Division 1, Cheonha-Dong, Dong-Ku, Ulsan, Korea http:// www.hhi.co.kr http:// as.hyundai-engine.com Engine After Service Dept. Engine Parts Sales Dept. TEL : (82) 52-230-7412~20 TEL : (82) 52-230-7311~20 FAX : (82) 52-230-7581 FAX : (82) 52-230-7582 (82) 52-250-9641 E-mail : engineas@hhi.co.kr E-mail : eservice@hhi.co.krVY SYMBOLS DISMANTLE, REMOVE, WITHDRAW MOUNT, CONNECT, FIT UNSCREW, LOOSEN, TURN IN DIRECTION OF ARROW ‘SCREW ON, TIGHTEN. TURN IN DIRECTION OF ARROW CONNECTION IOF CRANE LOOSEN-TIGHTEN WITH HYDRAULIC TOOLS PAY ATTENTION, CHECK INDICATES DIRECTION, SHOWS DETAIL CLOSE VALVE, COCK OPEN VALVE, COCK LUBRICATE WITH PRESCRIBED LUBRICANT CLEANINDEX INTRODUCTION ... CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER .... CROSSHEAD WITH CONNECTING ROD .. CRANK SHAFT AND THRUST BEARING MECHANICAL CONTROL GEAR .. STARTING AIR SYSTEM . EXHAUST VALVE . FUEL OIL SYSTEM .. TURBOCHARGER SYSTEM SAFETY EQUIPMENT ... ASSEMBLY OF LARGE PARTS. GENERAL TOOLS 900 905 906 907 908 909INDEX INTRODUCTION CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR SYSTEM EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS GENERAL TOOLSPea Te DL ud Note: Updates regarding some of the checking and guiding overhaul intervals indicated on the following sheets are to be found in Service Letter SLO3-423/UM dated March 2003 The Checking and Maintenance Schedules indi- cate the intervals at which it is deemed appropri- ate to inspect the individual components of the engine and to carry out overhauls, if necessary, based on the engine condition or on time criteria. ‘The stated Normal hours of service should only be used as a guide, as differences in the actual service conditions, the quality of the fuel oil or lu- bricating oil, the treatment of cooling water, etc. Checking and Maintenance Schedules 900-1 Design modifications may necessitate a revision of the instructions, in which case the revised in- structions and changed overhauling intervals, if any, will apply and supersede those originally is- sued (see e.9 our Service Letters). In addition to the checking and overhauling inter- vals stated in this schedule, please note that the periodical survey requirements of the classifica tion society may require additional checks and overhauls to be carried out. For further informa- will decisively influence the actual service re- sults, and thus the intervals between necessary overhauling tion please refer to the classification society. ‘The procedures are divided into three categories: Condition checking procedures marked under the heading Normal hours of service with aC, deal with the service condition of a number of engine compo- nents, and form the basis for estimating whether further over- hauling is necessary. In a number of cases the condition checking procedures refer to Volume | of the instruction book, in which more detailed descriptions and working procedures can be found. Condition-based overhauling procedures are those procedures which under the heading Normal hours of service are marked with an O, and opposite which, under the heading Overhaul to be based on procedure No. (column P), a procedure number is stated. This procedure number normally refers to one of the above con- dition checking procedures which form the basis of the overhaul. For this reason, the intervals stated are for guidance only. Time-based overhauling proce- dures also marked with an O under the headings Normal hours of service or Based on observations, are the procedures where an actual basis for estimation is lacking. It is recommended, therefore, to carry out these procedures at the overhauling inter- vals stated as a basis. Where a symbol O or C is indicated in Based on observations (column B), this is due to the fact that special service conditions may make checking or overhauling necessary beyond the actual standard schedules indicated When referring to this page, please quote Maintenance Schedules 490050 Edition 0272 "Page 1 (5)Dae Checking and Maintenance Schedules 900-1 MAN B&W Vs See Volume | “Operation’ H: Check new/overhauled parts after 500-1500 hours ‘A: Adjustment to be carried out B: Based on observations ©: Check the condition P : Overhaul to be based on procedure No. or refer to M: See makers instructions 0: Overhaul to be carried out R: Parts to be replaced pee ee Normal hours of service (> 1000) No. Procedure H[2[4[e6[ef[wel]sa|{oele 901 Cylinder Cover | -1 Cylinder Cover ° 902 Piston with Rod and Stuffing Box | 1 Piston €| 6 | oor, v Piston rings only ° | Piston complete | ° | -2 Piston Rod Stuffing Box | | co 902-1 903 Cylinder Liner and Cylinder Lubrication | | | eee “1 Cylinder Liner | | © |eort 1000 hours and 2000 hours: | c c 7 Inspection through scavenge ports ! ‘Measuring wear inside liner ° ° -2 Cylinder Lubricators co o | vM 904 Crosshead with Connecting Rod “1 Crosshead Bearing ¢ ° 2 Crosshead | ° 3 Reciprocating Parts oO -4— Crankpin Bearing ic @ | 5 Connecting Rod | ° 905 Crankshaft, Thrust Bearing and Turning Gear | +1 Crankshaft Deflection o ; c ea -2 Main Bearing jc Cc AC, | 905-1 ° v -3 Thrust Bearing Cc C. 4 Journal Bearing c Cc AC, | 905-1 fe} v -5 Axial Vibration Damper co]. * check inlet accumulator nitrogen pressure, ** check outlet accumulator nitrogen pressure When referring to this page, please quote Maintenance Schedules A90050 Edition 0272 Page 26)eae Checking and Maintenance Schedules 900-1 MAN B&W V: See Volume | “Operation H:: Check newioverhauled parts after 500-1500 hours [Az Adjustment to be carried out B : Based on observations : Check the condition P : Ovethaul fo be based on procedure No. or refer to M: See makers instructions ©: Overnaulto be carried out A: Pars tobe replaced _[—‘Wormat hours of service (510007 —_] No. Procedure H 4[e[e|w{s|Bl|P_ | | | 906 Mechanical Control Gear | 1 Chain c c Vv -2 Chain Tightener c c | A New or overhauled chain to be checked/ | | | retightened after 500, 1500 and 4000 hours | | | “3 Camshaft ¢c c AC -4 Camshaft Bearings c | co Camshaft Coupling, Fitted Bolts c oo] ] 1907 Starting Air System | 1 Starting Air Distributor 6 c A -2 Starting Air Valve | co |e Governor, change of oil ° M F..ctional check of overspeed device c | M Functional check of speed-setting system Ci | M (engine with bridge control system) 908 Exhaust Valve | | -1 High-Pressure Pipe ° -2 Exhaust Valve | Conventional hard-faced valve seats; ° ‘overhaul at intervals of 6000 hours Nimonic exhaust valves; e io) check new valves after 6000 hours subsequently, overhaul at intervals of 16000 hours “3 Exhaust Valve Actuator ‘ ° Pras, -4 Exhaust Valve Roller Guide lec) c o|v }-5 Exhaust Valve Cam eae : -7 Exhaust Valve Special Running | c 909 Fuel Oil System ea “1 Fuel Pump Lead | Ac| v -3__ Fuel Pump Cam [A | 9004 When referring to this page, please quote Maintenance Schedules A90050 Ecition 0272 Page 3 (5)al Checking and Maintenance Schedules Oty 900-1 V: See Volume “Operation H.: Check newioverhauled parts after 600-1500 hours | A> Adiustment tobe carried out 8: Based on observations : Check the condition P-. Overhaul fo be based on procedure No. or refer to M: See maker's instructions ©: Overhaul to be carried out Ri: Parts tobe replaced [RENE ern curWoX saricaT (331000) Ha No. Procedure BP “4 FuelPump ° -8 Fuel Pump Top Cover o 6 Fuel Pump Bartel Assembly ° -7 Fuel Pump Suction Valve 8 Fuel Pump Puncture Valve -9 Fuel Pump Shock Absorber ° 11. Fuel Valve Fuel Nozzle “12. Spindle Guide “13. Non-return valve “14 Fuel Oil High-Pressure Pipes o | -15 Fuel Pump Roller Guide co 910 Turbocharger System | +1 Air Cooler OnL¥ -2_Non-Retum Valve ° “3 Auxiliary Blower Joep “8 Turbocharger Turbine o |v -6 Water Mist Catcher is 911 Safety Equipment “1 Safety Valve eo 2 Relief Valve o Functional test of alarm system for thrust i i bearing and slow down /shut down system ; Lae Checking and adjustment of pressure gauge Cc ‘Checking and adjustment of thermometers ae + Checking and adjustment of thermostats c Checking and adustment of pressurestats c ; Checking and adjustment of tuming gear switch When referring fo this page, please quote Maintenance Schedules 490060 Eation 0272 Page 4 (5)Pe TN Checking and Maintenance Schedules 900-1 EEE = See Volume | “Operation H: Check new/overhauied parts after 500-100 hours ‘A= Adjustment to be caried out B: Based on observations ©: Check the condition P= Overhaul to be based on procedure No. or refer to M: See makers instructions (©: Overhaul tobe carried out Ri: Parts tobe replaced i Normal hours of service (1000) No. Procedure Hl27T4a][e]elw]sa| ele ] 912 Assembly of Large Parts | -2 Holding Down and End Chock Bolts(Epoxy) | ¢ c 3 Stay Bolts c G 913 General Tools | 1 Hydraulic Tools -4 Standard Tightening Torques | | -5 Torque Spanner 6 Tightening Gauge -7 Screws and Nuts 11__Lubricating Procedures When referring to this page, please quote Maintenance Schedules A90050 Eudltion 0272 Page 5 (5)INTRODUCTION CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR SYSTEM EXHAUST VALVE FUEL OIL SYSTEM INDEX TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS GENERAL TOOLSPy) Ad Cylinder Cover 101-1 Data SAFETY PRECAUTIONS Standard Tools: See Section 913 X | Stopped engine X | Block the starting mechanism Zz, X | Shut off starting air supply X | Engage turning gear X | Shut off cooling water f X | Shut off fuel oil —_ ‘Shut off lubricating oil X | Lock turbocharger rotors a —=O Data —— = _ 50-300 Nm Ret. Deserption Vae Unt D-1 Weight of exhaust valve stud 10 kg eeoml) iomacin D-2 Weight of cyl. cover compl. 1613 kg D-3 Weight of cooling jacket 38.5 kg D-4 Screwing-in torque for 200 Nm exhaust valve studs +5 Screwing-in torque for 145. Nm starting valve studs D-6 Screwing.in torque for 140 Nm fuel valve studs D-7_ Weight of high-pressure 22.7kg | pipe (exhaust valve) 0-8 Hydraulic pressure for cylinder cover: —dismantling 1500-1650 bar — tightening 1500 bar D-8 Tightening torque — 100 Nm {uel oll high-pressure pipe (fuel pump/fuel valve) D-10 Tightening torque — 36Nm high-pressure pipe (exhaust valve) D-11 Weight of tuel oi! high-pressure pipes Bkg Page 1 (2)101-1 Cylinder Cover babies MAN Baw Data 1 @ oll |g T _ 20 BY) Ih 7 U Spare Parts Plata ~ Rem No. Descipton ay. 90101-104 114 O-rings 2 90101-104 198 Sealing ring 1 90302-122 201 O-rings 4 Page 2 (2)eA Tey Cylinder Cover 901-1.2 bala Dismantling 1. Set blocking device A on the main starting valve in the BLOCKED position. Engage turning gear B. Close fuel oil inlet valve C. Close cooling water inlet valve D. Close cooling water outlet valve E. ‘pen cooling water drain cocks F and G. Shut off the control air and safety air supply. Vent the manoeuvring system through the ball valve. Also shut off the air supply on the pressure reduction unit for the hydraulic/pneumatic exhaust valve, and vent the system, When referring to this page, please quote Procedure MS0101 Edition 0226 Page 1 (10)Peau le Cylinder Cover Dismantling DEL a 2. Remove the cooling water inlet and outlet pipes from the exhaust valve and cylinder cover. Remove the drain pipe from the interme ate pipe between the cylinder cover and the exhaust valve. Dismount the fuel oil high-pressure pipes between the fuel valves and pump. Dismount the control air pipe from the start- ing valve. Remove the starting air pipe. 3. Remove the screws which fasten the high- pressure pipe to the oil cylinder on the ex- haust valve and the hydraulic activator, and lift the high-pressure pipe away. Dismount the drain oil pipe between the ex- haust valve and the hydraulic activator, the air pipe for pneumatic closing of the ex- haust valve, and the pipes for the sealing air arrangement. 4. Remove the protective jacket enclosing the intermediate pipe between the exhaust re- ceiver and the exhaust valve. Dismount the screws in the flange between \ the intermediate pipe and the exhaust re- ceiver. The four lowermost screws need not be dismantled, just loosened. Remove the protective caps from the cylin- der cover nuts. Page 2 (10) When referring to this page, please quote Procedure M90101 Edition 0226eat Cylinder Cover 901-1.2 Nd Dismantling 5. Place eight spacer rings over the nuts, and screw the eight hydraulic jacks onto the studs, Connect the high-pressure pump to the jacks by means of the distributor block and the high-pressure hoses. Using the vent screws of the hydraulic jacks, vent the system and increase the pressure as stated in Data. For operation of the hydraulic tools, see Procedure 913-1. Loosen the nuts by applying the tommy bar through the slots in the spacer rings. Relieve the system of pressure. Disconnect the high-pressure hoses from the jacks. Remove the hydraulic jacks and spacer rings, and unscrew the nuts. 6. Hook the engine room crane on to the lifting attachment on top of the exhaust valve. Lift away the cylinder cover complete, and land it on a couple of wooden planks. 7. Remove and discard the sealing ring be- tween cylinder cover and cylinder liner. When referring to this page, please quote Procedure M90101 Edition 0226 Page 3 (10)bhatt 901-1.3, Cylinder Cover Overhaul Leabeidhctah 1. Dismount all valves and pipes on the cylin- der cover, Dismount all studs on top of the cylinder cover. 2. Remove the four screws which secure the cooling jacket to the cylinder cover. Lift the cylinder cover free of the cooling jacket and land it on a couple of planks. If the cooling jacket sticks, use dismantling screws to force the jacket/cover apart. Remove and discard the O-rings from the cover, and carefully clean the cooling jacket and the cylinder cover. p 3. Provide the cylinder cover with new O- rings, well lubricated with oil, 4, Lift the cylinder cover and guide the jacket/ cover into position, using the guide pin as a reference (camshaft side). Mount and tighten the screws for the cool- ing jacket. Page 4 (10) When referring to this page, please quote Procedure M90101 Edition 0226Pate OL Cylinder Cover 901-1.3 Overhaul 5. Recondition the valve bores as follows: Fuel valve bore 6. The tool consists of a common spindle with handle, a guide, a carbon cutter, a seating face cutter and a grinding mandrel Clean the fuel valve bores, using the car- bon cutter. If required, recondition the fuel valve seating with the appropriate cutter. Grind the seating with the grinding mandrel and a grinding compound (e.g. Carborun- dum No. 200). After the milling/grinding, clean the bore and seating carefully, and check that the seating is not damaged. Exhaust valve bore 7. The tool consists of a spindle with handle and a grinding disc. After cleaning the valve bore and seating, grind the seating with the grinding disc and grinding compound (e.g. Carborundum No. 200). After the grinding, clean the bore and seat- ing carefully, and check that the seating is not damaged. When referring fo this page, please quote Procedure M90101 Edition 0226 Page 5 (10)901-1.3 Cylinder Cover Paty Overhaul Le Starting vaive bore 8. The tool consists of a guide, a cutter, and a grinding disc Recondition the starting valve bore and seating in the same way as described for the fuel valve bore. When replacing valves on a cylinder cover that is mounted on the engine, recondition the valve bores/seating in the same way as YY described here, but without dismounting the. ‘studs. | | 3 9. Clean the bores for safety valve/indicator | | ig : 3 ; : VE 8eau Cylinder Cover 901-1.3 Lisesadsilh Overhaul 10. Lubricate the threads with ‘Never Seize’ or | 10. Molybdenum Disulphide (MoS2) and mount the valve studs Tighten up the studs in accordance with the screwing-in torque stated on the data sheet. Fill up the grooves between the valve studs and the bores for the valve studs with per- matex to prevent water or oil from entering the bores during operation of the engine. Provide the water connection flanges with new gaskets, and keep the cylinder cover ready for replacement. ‘Always fit new or overhauled valves before ‘a cylinder cover is mounted on the engine. When referring to this page, please quote Procedure M90101 Edition 0226 Page 7 (10)Peat Tey 901-1.4 Cylinder Cover Mounting TENE 1. Place a new sealing ring on top of the cyl- inder liner with the guide tabs in the fore and aft direction. This is to ensure that the tabs fit into the two gas blow-out grooves milled in the cyl- inder cover guide recess. 2. Lift the cylinder cover by means of the crane and carefully wipe the contact sur- face which faces the cylinder liner. Provide the cooling water connecting pipes with new O-rings and lubricate them with grease or soft soap. Mount a new ‘klinger’ sealing ring in the groove of the flange of the intermediate pipe. Lower the cover carefully into position. During the landing, carefully check that the cooling water connecting pipes engage cor- rectly with the holes in the cooling jacket. 3. Mount the cover nuts on the studs and screw down. Place eight spacer rings, one around each ‘ut, and mount the eight hydraulic jacks on the studs. Connect the high-pressure pump to the jacks by means of the distributor block and the high-pressure hoses. Using the vent screws of the hydraulic jacks, vent the system, and then increase the pressure as stated in Data For operation of the hydraulic tools, see Procedure 913-1, Tighten the nuts by applying the tommy bar through the siots in the spacer rings. Relieve the system of pressure. Finally, remove the hydraulic jacks and spacer rings from the nuts. Page 8 (10) When referring to this page, please quote Procedure M90101 Eaition 0226ae Cylinder Cover 901-1.4 Chew Mounting 4. Mount the protective caps on the cylinder cover studs. Align the intermediate pipe so that the holes in the flange of the intermediate pipe are in line with the threaded holes in the ex- haust receiver. Mount the screws of the flange between the intermediate pipe and the exhaust receiver. Note! Lubricate the screws with ‘Never Seize’ ‘or Molybdenum Disulphide (MoS,) before mounting. 5. Mount the insulating jacket around the in- termediate pipe. When referring to this page, please quote Procedure M90101 Edition 0226 Page 9 (10)bat ley 901-1.4 Cylinder Cover Mounting Lidell | 6 Mount the return oil pipe, the sealing air pipe and the air pipe for pneumatic closing of the exhaust valve. Mount the high-pressure pipe for the hy- draulic valve gear. See Procedure 908-1.4, 7. Mount the starting air pipe and control air pipe for the starting valve. Mount the cooling water inlet and outlet pipes on the exhaust valve. Mount the drain pipe on the intermediate pipe between the exhaust valve and the cyl- inder cover. Using a crowfoot wrench and torque span- ner, mount the fuel oil high-pressure pipes between the fuel pump and the fuel valves (checking that the pipes fit properly at the seats and that all parts are clean and pro- vided with new O-rings). See Procedure 909-14.4. Connect the outlet pipe from the return oil pipe on the fuel valves. Shut the drain valves and open the cooling water inlet. After venting the cylinder sec- tion, shut the vent cocks and open the cool- ing water outlet valve. 3 3 Open the fuel oil, lubricating oil and air sup- plies to the alarm system. Caution | The air supply to the exhaust valve must always be connected before starting the camshaft oil pumps. This is very important, because other- wise the valve will open more than nor- mal Page 10 (10) When referring to this page, please quote Procedure M90101 Edition 0226INDEX INTRODUCTION CYLINDER COVER PISTON WITH ROD AND STUFFING BOX 8 CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR SYSTEM EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS GENERAL TOOLSPAU Te piston tort Data SAFETY PRECAUTIONS X | Stopped engine X_| Block the starting mechanism X | Shut off starting air supply X_| Engage tuming gear X | Shut off cooling water X | Shut off fuel oil X | Shut off lubricating oil Lock turbocharger rotors Data Ref. Description Value} Unit 01-05 | Cylinder cover stud, check distance 128 - 129] mm 02-01 | Test pressure 7| bar 102-02 _| Piston rod/erosshead, tightening torque 490| Nm 02-03 _| Piston rod/erown, tightening torque 300] Nm 102.05 _| Piston skin, tightening torque 80| Nm 102-06 | Cooling oi pipe, tightening torque 80] Nm 1002-07 _| Piston rodierosshead, tightening torque + angle 100/00} Nv> 102-08 _| Piston ring new, racial width 17.2] mm 102-09 | Piston ring worn, min. radial width 142] mm 02-10 | Groove No.1, max. vertical height 13.2] mm 02-11 | Groove Nos. 2, 3 and 4, max. vertical height 102] mm 0-12 _| Piston top, max. permissible burn-away 15| mm 02-13 _| Piston ring new, height of ring No. 1 124] mm | | bo2-14 | Piston rings new, height of ring Nos. 2, 3 and 4 9.4] mm 102-15 _| Minimum tree ring gap (before cismanting) 28| mm 102-16 | Minimum ring gap, ring No. 1 (new ring in new liner) 3.4] mm 1002-17 | Minimum ring gap, ring Nos. 2, 3 and 4 (new ring in new liner) 2.4| mm 02-18 |__| Vertical clearance, new parts 0.35-0.4] mm 02-19 | Vertical clearance, wom parts, max 0.87| mm 0220 _| Piston complete 921] kg 02-21 _| Piston erown 200 kg 02-22 —_| Piston rod 565| kg 02-23 _| Piston skit 57| kg 0224 _| Piston cooling pipe 21] ko 102.25 | Liting too, tightening torque 150] Nm 02-46 | CPR ring CL groove, min. depth 1.1] mm When roferring to this page, please quote Data 010201 Edition 0065 Page 1 (2)HYUNDAI Piston pau MAN B&W ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tem No. | Deseription 90251 146 | Lifting tool for piston rod foot 90251 78| Template tor piston top P90251 63 | Distance piece for stuffing box 90251 98 | Cover for stuffing box hole P902si 110 | Pressure test too! for piston Pe0251 183 | Piston ring expander e025 158 | Guide screw for piston crown Pe0251 160] Dismantling screw piston skirt 80261 019 | Guide ting for piston 90264 Tools for tilted lit 30265 058] Support for piston 90266 020] Litting toot for piston 30366 032| Crossbar for cylinder liner Pa04st 118] Rubber cover for crosshead Page 2 (2) When referring to this page, please quote Data D10201 Edition 0065Py Dy Piston 9021.1 Checking IEE Scavenge port inspection To detect possible leakages from the piston or cylinder cover, keep the cooling water and cool- ing oil circulating during the scavenge port in- spection. 1. The scavenge port inspection is carried out from the scavenge air receiver. An addition- al view of the rings is possible through the cleaning cover on the maneouvring side. Tum the engine at least @ a revolution and start with a unit arriving downwards, just above the scavenge air ports. Inspect the piston rod and the lower part of the cylinder wall. While the piston is pass- ing downwards, inspect the piston skirt, all the piston rings, the ringlands and the pis- ton top. 2. Inspect the rings, one at a time, and note down the results. See Volume I, Operation, Chapter 707. 3. Check the movability and the tension of the piston rings, by pressing against them with ‘a wooden stick. ‘When referring to this page, please quote Procedure M490201 Edition 0270 Page 1 (20)Piston Checking | | | | | Page 2 (20) When referring to this page, please quote Procedure M90201 Edition 0270 babs te) N) MAN B&W 4, Ririg grooves Measure the total clearance between the piston rings and the ring grooves. The total clearance must not exceed the value stated in Data. Measurements are to be taken at the top (E) and bottom (F) between the piston ring and piston ring groove. Total clearance = E + F. 5. Uppermost piston ring It possible, measure the depth of the pres- sure relief grooves with a caliper. The piston rings must be replaced if the ra- dial depth of the grooves has worn down to less than stated in Data D02-46. Checking of piston rings and piston crown, in connection with piston overhaul: 6. Remove the piston from the cylinder and place it on the piston support. See Procedure 902-1.2. Itis recommended to replace all the pis- ton rings whenever a piston is removed from the engine. For evaluation of the rings, see Volume |, Chapter 707.seat Piston 902-1.1 ilu Checking 7. Before dismantling the piston rings, meas- | 7. ure the free ring gap of all the piston rings. 8. Take off the piston rings by means of the ring expander. Clean and inspect the rings. 9. Measure the radial width of the rings. Note down the results See Volume |, Operation, Chapter 707. fe i 8 fa 9 1 Do02-08 | ee be 3 [LALA | | e , DO2-09 g EeY Wom ‘When referring to this page, please quote Procedure M90201 Eaton 0270 Page 3 (20)902-1.1 Max 2mm, " hae Tey Piston Checking SEE 10. Clean the ring grooves and check them for burn marks or other deformation. Measure the ring grooves with a caliper gauge, see Data D02-10 and D02-11. Clearance in piston ring grooves: ‘The maximum vertical height in a worn ring groove must not exceed the value stated in Data. The groove is also worn out if there is no chromium layer. 11. Clean the piston crown and check the burn- away by means of the template. For maxi mum permissible burn-away value, see Da- ta. Check the burn-away on the whole circum- ference of the piston crown. Note down the results for later reference. 12. Fit the new piston rings (alternately right- hand and left-hand cuts, with the ring gaps staggered 180° and with the ToP mark up- wards), using the ring expander. When mounting the piston rings, use the ring expander to prevent unintended defor- mation of the rings. Do not expand the rings more than neces- sary. The upper ring (CPR-ring) should not be expanded more than to the milled mark ‘on the ring expander. Page 4 (20) When referring to this page, please quote Procedure M90201 Edition 0270TN) GN Piston 902-1.2 MAN B&W Dismantling 1. Turn the crosshead down far enough to give access to the piston rod stuffing box and the screws for the piston rod. 2. Release the stuffing box by removing the innermost screws from the stuffing box flange. Note! Do NOT remove the outermost screws from the flange. 3. Remove the screws from the piston rod. ‘When referring to this page, please quote Procedure M90201 Edition 0270 Page 5 (20)902-1.2 Piston hd dlatel Cd Dismantling 4. Mount the two distance pieces on the piston rod foot to protect the lower scraper ring and to guide the stuffing box. 5. Dismount the cylinder cover. See Procedure 901-1.2. Carefully smooth out any wear ridges at the top of the cylinder liner. See Procedure 903-1.3. 6. Make a scratch mark in liner and piston cleaning ring to ensure the correct mount- ing. = _ Remove the piston cleaning ring, Carefully remove any wear ridges at the top of the cylinder liner. See Procedure 903-1.3. Page 6 (20) When referring to this page, please quote Procedure M90201 Edition 0270ey ONL Piston 902-1.2 Dismantling 7. Turn the crosshead towards TDC, while checking that the stuffing box lands correct- ly on the distance pieces 8. Turn to TOC. The top of the piston is now free of the cyl- inder liner. Clean the lifting groove of the piston crown and mount the lifting tool in such a manner that the two ‘fixed’ claws of the tool fit into the lifting groove of the piston Fit the third, adjustable, claw of the tool to the lifting groove and tighten it up against the stop of the tool, see Data 002-25. Lift the piston out of the cylinder liner. When referring to this page, please quote Procedure M90201 Edition 0270 Page 7 (20)902-1.2 Piston Ey) Dismantling Lach —— 9. If the lifting height is limited, it can be nec- essary to guide the piston rod foot in be- tween the cylinder cover studs. Note! Alternatively, with low lifting height, remove one of the cylinder cover studs with the stud setter. 10. Lower the piston rod foot and stuffing box through the opening in the platform. Place the two halves of the support around the piston rod and secure the two halves with screws. 11, Place a cover over the opening for tne pis- ton rod stuffing box in the bottom of the cyl- inder unit Clean, measure and recondition the cylin- der liner. See Procedure 903-1. Page 8 (20) When referring to this page, please quote Procedure M90201 Edition 0270ey Piston 9021.2 aE Dismantling 12. Turn the crosshead down far enough to per- | 12. mit mounting of the protective rubber cover on the crosshead bearing cap. The protective rubber cover should remain in place to protect the crosshead bearing journal from impurities until the piston is re- mounted. Low lifting height I the space conditions above the engine make it impossible to remove the piston in the normal way, the piston can be removed as follows: 13. Remove one or two cylinder cover studs, using the stud setter. Lift the piston high enough to give ample | 13, room over the cylinder cover studs. Place the supporting tools on the cylinder cover studs. When referring to this page, please quote Procedure M9020! Edition 0270 Page 9 (20)ee 902-1.2 Piston Dismantling MAN B&W 14, Place the collar ring on the supporting tools and mount the clamp on the collar ring Check that the distance pieces have con- tact with the piston. Remove the lifting tool from the piston. Hook the crossbar on to the crane and at- tach the collar ring to the crossbar. 16. Lift the piston to the maximum crane height. Run the crane athwartship and, at the same time, tilt the piston. Note! Tiiting of the piston must only take place with the piston rod stuffing box mounted on the piston rod, Keep the piston rod clear of the cylinder lin er and studs while carrying out the tilting, When space conditions permit, straighten up the piston and lead it over to the cut-out in the platform for overhauling the piston. When the piston is at a suitable height above the platform cut-out, position the pis- ton support around the ‘piston rod and clamp. Now lower the piston while guiding the sup port to the platform cut-out. After landing the piston and ensuring that it rests correctly on the support, remove the tilting tool Note! On engines with extremely low lifting | height, use the engine room double-jib | crane instead of the transverse piece. [fssinerernrere oer er trccrerernet rece Page 10 (20) When referring to this page, please quote Procedure 90201 Edition 0270Pe ANE Piston Overhaul 902-1.3 1. Ease the piston down so that the stuffing box is below the floor. 2. Assemble the two halves of the piston sup- port around the piston rod and land the pis- fon on the support. Check and remove the piston rings. See Procedure 902-1.1. 3. Dismount the locking wire and the inner- most screws between the rod and the pis- ton crown. ‘When referring to this page. please quote Procedure M90201 Edition 0270 Page 11 (20)902-1.3, Piston Overhaul HYUNDAI EE 4. Dismount the locking wire and screw up the support screws of the piston support to a position just below the piston skirt Remove the piston skirt screws. 5. Screw the four screws of the support down- wards until the skirt rests on the support If the skirt will not budge, free it by means of two dismantling screws. Lift away the piston crown. Remove and discard the sealing rings on the piston rod and on the skirt 6. Dismount the bolts of the cooling oil pipe flange. Mount the eye bolts and lift out the cooling oil pipe. After inspection of the cooling oil pipe, re- ‘mount the pipe. Page 12 (20) When relerring to this page, please quote Procedure M90201 Edition 0270PAUP NLA Piston Overhaul 902-1.3, Alternatively, the piston can be dismantled in the following way: 7. With the piston standing in the piston sup- port tool, remove the piston rod stuffing box, see Procedure 902-2.3. 8. Lift the piston with the lifting tool. Land the piston rod foot on a wooden plank. Note! During the lift, follow with the crane to keep the crane positioned vertically above the lifting point. Lower the piston crown to the platform and land it on a wooden plank, so that it is pos- sible to remove the lifting tool 9. Remove the lifting tool from the piston crown. Attach the lifting bracket to the bot- tom of the piston rod foot. Hook the crane on to the lifting bracket 10. Lift the piston rod foot clear of the wooden plank. Keep lifting until the piston rod is in a verti- cal position. When referring to this page, please quote Procedure M90201 Edition 0270 Page 13 20)ae 902-1.3 Piston Overhaul poeta "1 11. Place the piston in an upright position with the piston crown resting on wooden blocks. Dismount the locking wire and the inner- most screws between the rod and the pis- ton crown. Lift the piston rod away and land it in a horizontal position on a couple of wooden planks. D02-22 12. Remove the locking wire and the sorews in the skirt and mount two eye bolts in the holes intended for dismantling screws. Lift the skirt and land it on a couple of planks. 13. Thoroughly clean and inspect all parts of the piston. Regarding check of the piston crown, see Procedure 902-1.1 Replace all sealing rings of the piston. All the new sealing rings must be coated with lubricating oil before the piston is assem- bled. Coat all screws with Molybdenum Disul- phide (MoS>). Assemble the piston in the reverse order to disassembly. Use the guide screw to ensure the correct positioning of the piston rod in relation to the piston crown. Tighten all the screws diagonally to the torque stated in Data. a Page 14 (20) When referring to this page, please quote Procedure M90201 Edition 0270HYUN Piston 902-1.3, Overhaul TELA) 14. Lock all the screws with locking wire. 14, Mount the locking wire in such a way that the wire is tightened if one of the screws works loose. See Procedure 913-7. | 16. Fill the piston and piston rod with lubricat- ing oil | Mount the pressure-testing tool around the base of the piston rod. Pressure-test the piston at the pressure stated on the data sheet. Check the contact surfaces of the piston and the sealing rings for tightness. a 15. Check that there are no cracks in the piston crown. For overhaul of the stuffing box, see Proce- dure 902-2.3. When referring to this page, please quote Procedure M30201 Edition 0270 ~~ Page 15 (20)eae ed 902-1.4 Piston a Mounting bea | 2 1. Check the piston rings and piston crown in accordance with Procedure 902-1.1 Coat the piston rings, piston rod and cylin- der liner with lubricating oil. 2. Mount the lifting tool on the piston crown. 3. Ensure that the stuffing box is correctly po- sitioned over the guide pins in the distance pieces mounted on the piston rod foot Coat the O-rings of the stuffing box with oil. 4. Remove the protective rubber cover from F the crosshead, 3 3 ig Bi A 4, lg 8 Page 16 (20) When referring to this page, please quote Procedure M9020! Edition 0270eae Piston 902-1.4 Cas Mounting 5. Remove the cover from the piston rod stuff | 5 ing box opening in the bottom of the cylin- der unit 6. Turn the crosshead to a position 45° from ToC. Mount the guide ring for piston rings on the cylinder liner. 7. Lower the piston into the cylinder liner — while guiding the piston rod foot through the cut-out in the stuffing box flange — until the piston rings are inside the liner. NN When referring to this page, please quote Procedure M90201 Edition 0270 Page 17 (20)eae ey 902-1.4 Piston Mounting bends 8 | 8 Tum the crosshead nearly to TDC while is 10. 10. checking that the guide ring of the cross- head enters the centre hole in the piston rod After turning the crosshead fully to TDC, and ensuring that the piston rod has full contact with the crosshead, unscrew the adjustable claw of the lifting tool and pull the lifting too! free of the lifting groove in the piston Remove the lifting tool and the guide ring for piston rings. Tur down and land the stuffing box on the stuffing box flange. Check that the holes in the stuffing box and stuffing box flange are correctly centred, Remove the distance pieces from the piston rod foot, Page 18 (20) When referring to this page, please quote Procedure M90201 Edition 0270Dey Piston 902-1.4 COE eniee 11. Tighten down the piston rod stuffing box by means of the screws, through the inner holes in the stuffing box flange. See Procedure 902-2. 12, Mount and tighten the piston rod screws Tighten the screws to the specified torque and lock with locking wire. See Data. Use either Data 02-02 or Data 002-07. 13. Mount the piston cleaning ring according to the scratch mark. It the PC-ring is damaged (broken or cracked), it must be replaced by another ring. See Procedure 903-1. When referring to this page, please quote Procedure M90201 Edition 0270 Page 19 (20)Peat ley Ny) 902-1.4 Piston Mounting Lanai 14. 14. If the cylinder cover studs have been re- | moved, remount them. Ne Carefully clean the surfaces around the base of the studs and check the O-rings on the studs. | Mount the cylinder cover studs with the stud setter. Screw the stud down to contact and ‘one half revolution back. 15. Land the cylinder cover on the liner and check the distance the stud is protruding from the cylinder cover. Mf necessary, adjust the distance D01-05 by turning the stud. | 16. Tighten the cylinder cover and mount the necessary pipes. ie Ss See Procedure 901-1.4. is e Smear the piston rod with molybdenum di- ——————_——— =] _ sulphide, and turn the crankshaft a couple 15. of revolutions. Start the engine and keep it running for about 15 minutes at a number of revolutions corresponding to very slow. Then stop the engine and inspect the piston rod and stuffing box. Page 20 (20) When referring to this page, please quote Procedure M90201 Edition 0270er! Piston Rod Stuffing Box 102-2 Data SAFETY PRECAUTIONS INE. Stopped engine Block the starting mechanism ‘Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil ‘Shut off lubricating oil Lock turbocharger rotors, Geile Data Ret. Description Value] Unit 02-26 Stuffing box flange, outer screws tightening torque 80| Nm 02-27 Stuffing box flange, inner screws tightening torque 80| Nm 02-28 Stuffing box halves, tightening torque 80| Nm 02-29, Uppermost rings, ring-end clearance 4x6) mm 02-30 Lowermost rings, ring-end clearance 3x3) mm, 02-33, Check length for the six uppermost springs: 02-34 FO =O Nevcrcesnnne LO 639) mm, 02-35 WF 1=1534-7NWWL 763) mm 02-36 -F 2= 163 +/-10N...L 835) mm. | Do2.37 Check length for the four lowermost springs: 02-38 A FOF ONeccrcerrnene b 496] mm 002-39 -F1=150H-7N... LT = 646) mm 002-40 -F2=200+/-10N.....L 714) mm, 02-44 ‘Stuffing box complete 63] kg 002-45 Stuffing box half 19| kg When referring to this page, please quote Data D10202 Edition 0048 Page 1 (2)eater Ny) 102-2 Piston Rod Stuffing Box Data Cd The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits inthe plate number, e.g. 90951 refers to chapter 909. Plate tem No.| Description 90251 109] Mounting tool for stuffing box spring 90251 122| Worktable for stuffing box 90451 118 | Rubber cover for crosshead Page 2 (2)DP Piston Rod Stuffing Box 902-2.1 TEA cai 1. After the piston rod stuffing box has been dismantled, check the following clearanc- es: See Procedure 902-2.2 Uppermost scraper ring and sealing rings Clearance at ring ends (scraper ring) Total cleararice (scraper ring). (002-29) Clearance at ring ends (sealing rings). Total clearance (sealing rings). (002-28) Lowermost scraper rings Clearance at ring ends. Total clearance. (D02-30) The ring clearances stated in Data apply to new rings. ‘As a general guide, it is recommended — depending on the overhauling intervals and one’s own experience — to replace sealing rings and scraper rings when the specified clearance values 002-29 and D02-30 have been halved 2. Check the length of the springs at different loads. Adjust the loads to achieve the lengths stated in Data. If the loads necessary are outside the limits stated in Data, the springs must be discard- ed. Itis recommended to renew the springs for the sealing rings when the rings are re- newed When referring to this page, please quote Procedure M90202 Edition 0221 Page 1 (9)Phat ey 902-2.2 Piston Rod Stuffing Box Dismantting EEE In connection with dismantling of the piston, only the innermost screws in the stuffing box flange should be removed. If, in the period between piston overhauls, it be- comes necessary to inspect the piston rod stuffing box, proceed as follows: 1. Turn the crosshead to about 90° from TDC. Mount the rubber cover around the piston rod to protect the crosshead bearing from impurities. 2. Remove the drain oil pipe and all innermost screws and all outer screws except for two screws placed diametrically opposite in the stuffing box flange, longitudinally to the en- gine. 3. Mount the worktable around the piston rod. so that the two remaining screws in the stuffing box flange can be loosened through the holes. Page 2 (9) When referring to this page, please quote Procedure M90202 Edition 0221Pee AE Piston Rod Stuffing Box Dismantling 902-2.2, 4. Remove the two long dismantling screws from the worktable. Mount them in the stuffing box through the holes in the worktable. Remove the remaining two screws from the stuffing box. 5. Turn the piston to BDC, thereby withdraw- ing the stuffing box from the cylinder frame. bottom, 6. Remove the two long dismantling screws from the stuffing box and mount them in the worktable. By means of the four short screws in the worktable, press the stuffing box out of the flange. For overhauling the stuffing box, see Pro- cedure 902-2.3. When referring to this page, please quote Procedure M90202 Edition 0221 Page 3)Ae 902-2.3 Piston Rod Stuffing Box Overhaul uanedl atdd Normally, overhaul of the piston rod stuffing box is carried out by routine methods in connection with the dismantling (pulling) of the pistons. During such overhauls, the piston rests on a support placed over one of the cut-outs in the top platform. Work on the stuffing box is then carried out from the platform below. Overhaul inside the engine is carried out in the same way as outside the engine, 1. Mount two eye bolts in the stuffing box flange, and hook on two tackles. Lift the stuffing box a litle up the piston rod, and mount the worktable round the piston rod at a suitable working height. Land the stuffing box on the worktable, and remove the tackles and eye bolts. | 2. Remove the O-ring of the stuffing box. If the O-ring is intact and is to be used again, move it up the piston rod and secure it in this position, for example with tape Remove the nuts from the stuffing box as- sembiing bolts. Page 4 (9) When referring (0 this page, please quote Procedure M90202 Edition 0221PA Piston Rod Stuffing Box 902-2.3 ill Overhaul 3. Take out the six bolts, and pull away one | 3. stuffing box half, Mount two eye bolts on the stuffing box half and remove it from the worktable. 4. Using a feeler gauge, measure the vertical clearance of the rings. See Procedure 902-2.1, 5. Remove the remaining stuffing box half and press all sealing rings and scraper rings down against the worktable. 6. Measure the clearance between the ring segments to determine whether replace- ment is necessary. See Procedure 902-2.1, Dismantle and stack the rings in the same order as when fitted in the stuffing box Carefully clean all the ring segments. Inspect and assess the surface quality of the sealing rings. If their sliding surfaces have scratches or marks, replace the rings. 7. Check the lengths of the springs. See Procedure 902-2.1. 8 Inspect the surface of the piston rod. If small longitudinal scratches have occurred (caused by poorly adapted stuffing box rings), smooth the piston rod surface care- fully with a fine grained carborundum stone. In the case of coarse scratches, it may prove necessary to machine-grind the sur- face in a workshop. 9. Clean the halves of the stuffing box hous- ing When referring to this page, please quote Procedure M90202 Edition 0221 Page 5 (9)902-2.3 Piston Rod Stuffing Box Lael Overhaul TA) 10. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be O positioned) with molybdenum disulphide (MoS) Assemble all the stuffing box ring units round the piston rod, on the worktable, in the following way: + Place the lowermost scraper ring seg- By ments on the worktable. IF + Place the spring round the segments, and hook the spring ends together. >= Repeat this procedure for the remaining scraper rings. ‘On top of the scraper rings, assemble the two sealing ring units (each consisting of a 4-part and an 8-part ring), Assemble the 8-part sealing ring so that the two guide pins face upwards, place the spring round the segments and, hook the spring ends together. ‘Assemble the 4-part sealing ring above the 8-part sealing ring. Push the two rings to- gether in such a manner that the guide pins in the lower sealing ring engage with the two holes in the upper sealing ring, Finally, assemble the uppermost ring unit (consisting of a 4-part scraper ring and an 8-part sealing ring) 11. Use the stuffing box half on the worktable to adjust the height of all the assembled ring units on the piston rod until the ring units are opposite the corresponding grooves in the stuffing box housing. Subse- quently, push the stuffing box half into con- tact with the piston rod, round the ring units. Note! If the stuffing box is assembled inside the engine, place two pieces of plywood of the same thickness as the flange on the worktable, to ease the assembling. Page 6 (9) When referring (0 this page, please quote Procedure M90202 Edition 0221hae ton Rod Stuffing Box 902-23, Lisasiled Overhaul 12. Check the ring clearance again. Then place the other half of the stuffing box housing on the worktable, pushing it into place round the rings. Mount and tighten up the fitted bolts to the torque specified on the Data Sheet. Mount the O-ring in the stuffing box groove. 13. Mount eye bolts and wire ropes, and lift the stuffing box a little, Remove the worktable and lower the stuff- ing box until it rests against the distance pieces on the piston rod foot. Remove wire ropes and screws. When referring to this page, please quote Procedure M90202 Edition 0221 Page 7 (9)ae ey 902-2.4 ton Rod Stuffing Box Mounting WT 1. In connection with mounting of the piston, | only the innermost flange screws are to be mounted and tightened, see data After overhauling the stuffing box inside the engine, assemble the stuffing box halves on top of the four screws. ‘Mount the two long screws from the workta- ble in the stuffing box. Turn down the short screws so that the stuffing box lands on the flange. 2. Turn the piston upwards until the stuffing box is in place in the cylinder frame. Note! Make sure that the two guide pins in the flange enter the guide holes in the bottom of the cylinder frame. 3. Mount two screws in the flange through the holes in the worktable. Page 8 (9) When referring to this page, please quote Procedure M90202 Edition 0221Piston Rod Stuffing Box 902-2.4 Mounting IEA 4. Remove the long screws from the stuffing box and mount them in the worktable. Remove the worktable from the piston rod. 5. Mount and tighten all the inner and outer screws for the stuffing box. See Data. 6. Remove the protecting rubber cover from the piston rod/crosshead ‘Smear the piston rod with molybdenum di- sulphide. Then turn the crankshaft a couple of revo- lutions. Start up the engine and keep it running for about fifteen minutes at a number of revo- lutions corresponding to very slow or idle speed. Then stop the engine and inspect the piston rod and stuffing box. When referring to this page, please quote Procedure M90202 Edition 0221 Page 9 (9)Pea PONE Piston and Piston Rod Panel Plate 90251-173 SSOMC-C Oo 00 SPlate 90251-173 Piston and Piston Rod Panel tem i MAN B&W No. oe eee Oty Standard No, 014 | Tool panel 026 | Name plate 051 | Chain for cyl. liner 063. | Distance piece 075 | Template 039 | Cover 109 | Hook for mounting of spring 110 | Pressure testing device 122 | Worktable 146 | Lifting tool 158 | Guide screw for piston crown 160. | Dismantling screw EN61V12120 183. | Piston ring expanderOU s MANE | Piston and Piston Rod - Tools Plate 0261-75 ‘S50MC-C ) 0302 O19 0301 — 044Plate 90261-75 Piston and Piston Rod - Tools Item MAN B&W No. eee ton Standard No. 019. | Guide ring for piston 020 | Lifting tool for piston 032 | Lifting crossbar 044 | Litting collar 056. | Support for piston 0301 | Cylinder cover for cylinder bore 0302 LadderINTRODUCTION CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR STARTING AIR SYSTEM EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS GENERAL TOOLSPe 7 . Cylinder Liner 100 Data itt SAFETY PRECAUTIONS Standard Tools: See Section 913, X | Stopped engine X | Block the starting mechanism EE. X | Shutoff starting air supply X | Engage turning gear —e X_| Shutoff cooling water X | Shut off fuel oil ——S= 280-760 Nm X | Shutoff lubricating oil Lock turbocharger rotors Data el, Description Value Unt D-1 Cylinder diameter, new 500 mm D-2 Cylinder liner, complete 1682 kg D-3 Cooling jacket 178 ko D-4 Screwing-in torque - 500 Nm cylinder cover studs D-5 Cylinder cover stud 2rkg Page 1 (2)103-1 Cylinder Liner ae MAN B&W Spare Parts Plato — tern No Desciption oy. 90101-104 138 Sealing ring 1 90302-122 201 O-ring 8 90302-122 071 O-ring 2 90302-122 095 O-ting 1 90302-122 129 Gasket 4 90810-043 107 Gasket 1 Page 2 (2)da Cylinder Liner 903-1.4 TA Checking 1. Dismount the cylinder cover, the piston and the piston cleaning ring. ‘See procedures 901- 1.2 and 902-1.2. Clean the cylinder liner and scavenge air ports. 2. Position the cylinder liner measuring tool. Measure the cylinder liner with an inside micrometer at the positions indicated on the measuring tool. See Data. 3. Take measurements in the fore-and-aft and athwartship directions. 4. Check and evaluate the condition of the cyl- inder liner according to the description giv- en in Volume |, Chapter 707. Carefully grind away any scores or marks ‘on (or wear ridge in the bottom of) the cyl- inder liner running surface by means of a grind stone Check the lubricating points of the cylinder by manually pumping cylinder oil to each in- dividual lubricating point. Clean any blocked lubricating duct. Mount the piston and cylinder cover. See Procedures 902-1.4 and 901-1.4. 5. Piston Cleaning (PC) ring: The PC-ring must follow the liner until the liner diameter at measuring point No. § has increased beyond 0.2% of the nominal liner diameter. Then it is recommended to re- place the PC-ring with a dummy ring. ‘The measurement A on the PC-ring in the athwartship direction is normally 2.0-0.5 mm smaller than the measurement in the top of the liner Hf the PC-ring is damaged (broken or cracked), it must be replaced by a dummy ring with an over-size bore, to ensure prop- er sealing between cylinder cover and cyl- inder liner. When referring to this page, please quote Procedure M90301 Edition 0236 Page 1 (9)be atley EA 903-1.2 Cylinder Liner Dismantling 1. Dismount the cylinder cover. See Procedure 901-1.2. Discard the sealing ring from the top of the cylinder liner. Turn the piston down far enough to make it possible to remove the wear ridges at the top of the liner. See Procedure 903-1.3. Dismount the piston See Procedure 902-1.2 Mount the two lifting screws in the cylinder liner. Note! Tighten the lifting screws to the torque stated in Data. 2 Check with a 0.05 mm feeler gauge that there is no clearance between the screws, and the cylinder liner. This must be done whenever the lifting tools are mounted on the liner. 2. Disconnect ~ at the exhaust side of the cyl- inder - the oil pipes leading from the cylin- der lubricator to the non-return valves. Dismount the four cooling water pipes - be- tween the cooling jacket and cylinder cover = and clean them carefully. Page 2 (9) When referring to this page, please quote Procedure M90301 Edition 0236ey Cylinder Liner 903-1.2 Lieb ilabatl Dismantling 3. Remove the screws of the cooling water in- let pipe. 4, Attach the crane hook to the lifting cross- bar. Hook the chains from the lifting tools on to the crossbar and lift the cylinder liner with the cooling jacket out of the cylinder frame. Low lifting height in the engine room may require the removal of one or more cylin- der cover studs before dismantling the cylinder liner. — pee Land the cylinder liner vertically on, for in- stance, a couple of planks. Clean the cylinder frame internally, taking special care with the contact surfaces for the cylinder liner at the top of the cylinder frame, Discard the O-rings on the cooling water pipes. Clean the pipes carefully. When referring to this page, please quote Procedure M90301 Edlion 0236 Page 3 (9)oo Cylinder Liner En Dismantling RTA 5. 5. The lifting screws are also used for trans- porting the cylinder liner. Note! The cylinder liner is not in balance, even with the cooling jacket mounted. To keep the liner in a horizontal position during transportation, use e.g. a wire rope connected from the scavenge ports to the traverse as shown on the sketch. Page 4 @) When referring to this page, please quote Procedure M90301 Euilion 0236Cylinder Liner 903-1.3 Overhaul 1 Unscrew the nuts on the non-return valves | 1 and remove the valves. Clean and inspect the non-return valves. 2. Attach two tackles to the crossbar, as shown Mount two lifting eye bolts in the cooling jacket Hook the tackles on to the lifting eye bolts ‘on the cooling jacket and haul tight Remove the two lifting screws from the cyl- inder liner Como Remove the four clamps which fix the cool- ing jacket to the cylinder liner. 2 3. Lift the cooling jacket away by means of the tackles, and land it on the wooden planks. When referring to this page, please quote Procedure M30301 Editon 0296 Page 5 (9)903-1.3 Cylinder Liner PAAR manlBEW) Overhaul fnaes taro Br 4. Check and assess the condition of the cyl- inder liner according to the description giv- en in Volume |, Chapter 707 Carefully scratch over any scores or marks on the cylinder liner running surface, by means of a rough grindstone held in the hand. Check in the top of the liner for a wear nidge (where the piston rings reverse direction). If there 1s any sign of a wear ridge, essary to create a groove by grinding. The groove serves to prevent the butld-up of a new wear ridg 5. Itis recommended to use a wear ridge mull- ing machine to create the groove. For use of the milling machine, see supplier's in- struction. 6. Alternatively, place an old piston ring on the top of the piston and turn to a position that enables the grinding disc to rest on the old piston ring while removing the wear ridge. Use a grinding disc with a round edge. Check the distance C before grinding to as- certain that the wear ridge was caused by the top ring at TOC ‘The maximum depth of the groove is calcu- lated a8 Spay, = D x 0.0045. Ene ce aa Re ae ay iy Z i) 4} ol § fy + T Note! It is of the utmost importance that the groove 1s made with a regular rounding as shown in the sketch. Page 6 (9) When referring to this page, please quote Procedure M90301 Edition 023610. cylinder liner Lower the cooling jacket on to the cylinder ner. Note! Make sure that the scratch marks in the camshaft side of the cylinder liner and cooling jacket coincide. ‘Mount the four clamps in the groove of the liner, and tighten the screws. SATE Remove the tackles from the lifting cross- HY UNDA! Cylinder Liner 903-1.3 MA CE) Overhaul 7 Replace the two uppermost O-rings on the bar and the cooling jacket lifting eye bolts. Mount the non-return valves for cylinder lu- brication. Tighten the nuts and connect the lubricating oll pipes. RETIREE When referring to this page, please quote Procedure M90301 Ealtion 0236 Page 7 (9)903-1.4 Cylinder Liner Mounting ERATE] MAS EE? Sea ~ a “5 Ny CTT Loosen the water connections on the cool- ing jacket. Mount the two lifting screws in the cylinder hiner. Hook the chains from the lifting crossbar on to the lifting screws, and lift the jacketliner assembly Mount the lowermost O-ring and apply a lit- tle lubricating oil on the ring. Check that the joint surfaces on the cylinder frame and cylinder liner are completely clean. Coat the joint surfaces with permatex or a similar liquid sealing compound. Mount the cylinder liner in the cylinder frame. Replace the O-rings on the water connections and mount the water connec- tions on the cooling jacket. If one or more cylinder cover studs have been removed during the dismantling of the cylinder cover, remount the studs using the stud setter and a torque wrench, see Data. Page 8 (9) When referring to this page, please quote Procedure M90301 Edition 0236Piney tk Cylinder Liner 903-1.4 BALA Mounting 3 Fit new gasket between the cooling water iniet pipe and the cooling jacket. Mount and tighten the screws. 4. Connect and tighten the oil pipes for the cylinder lubrication. Vent the cylinder lubricating system until oil, without air bubbles, comes out from the non-return valves Check that there is no leakage from the system. When this 1s in order, check that each indi- vidual lubricating point functions correctly. 5. Lubricate the upper part inside of the cylin der liner with cylinder lubricating of and mount the piston See Procedure 902-1.4. 6. Mount the sealing ring and the cylinder cov- er See Procedure 901-1 4. Tighten the upper water connections on the cooling jacket as soon as the cylinder cover 1s correctly positioned. When referring to this page, please quote Procedure M30301 Edition 0236 Page 9 (9)COA EGY SAFETY PRECAUTIONS X | Stopped engine X_| Block the starting mechanism x x Shut off starting air supply Engage tuming gear Shut off cooling water Shut off fuel oil ‘Shut off lubricating of Lock turbocharger rotors, CoA Cylinder Lubricators Data 103-2 Ref. Description Value] Unit 03-22 Minimum crankthrow angle 03-23 Maximum crankthrow angle 03-24 Optimum crankthrow angle 103] ° 114| ° 108} * When referring to this page, please quote Data D10302 Edition 0026 Page 1 (2)103-2 Cylinder Lubricators GRA Data mM BENT ‘The task-specitic tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tem No.| Description Page 2 (2) When refering to this page, please quote Data 010302 Edition 0026Pee OEE 1. Further mformation concerning other than nominal feed rates, feed rates for running- in and for part load operation, and recom- mended oil types, 1s given in instruction book Volume I, OPERATION. 2. The cylinder lubricators are mounted on the front end of the engine. For tubnieator number. See the sketch. 3. Each cylinder has six injection points. Check that the pumps for all injection points are activated during one revolution of the engine. 4. Turn the engine in AHEAO direction until the mark on No. 1 lubricator housing 1s in line with the mark on the scale at the lead: shaft. This indicates that the pump stroke is completed for lubricating point No. 1 5. Check that the crankthrow for cylinder No. 1 is positioned between 003-22 and DO3- 23 degrees past BDC. Use the numbers on the turning wheel to determine the exact position of the crank- throws. Cylinder Lubricators Checking TREE 903-2.1 Last woneston pont Lubeeaton pont No iwc Seen trom fore ‘When referring to this page, please quote Procedure M90302 Eamon 0240 Page 1 (4)903-2.1 Cylinder Lubricators Checking ps 6. Turn the engine further in AHEAD direction untii the mark on the second lubricator housing is in line with the mark on the scale at the lead-in shaft. This indicates that the pump stroke is completed for the last lubri- cating point on No. 2 lubricator. 7, Check that the crankthrow for the aftmost cylinder is positioned between D03-22 and 03-23 degrees past BDC. 8. If one of the crankthrows is not in the cor- rect position, adjust the lubricators. See Procedure 903-2.3. | Do3-22 / 003-23 Page 2 (4) When refernng to this page, please quote Procedure M90302 Edition 0240Lae Cylinder Lubricators 903-2.3 we Adjustment Note! Any adjustment of lubricator No. 1 will alter the setting of lubricator No. 2. Therefore, any adjustment of lubricator No. 1 must be followed by a re-adjust- ment of lubricator No. 2. 1. Remove the guards over the couplings. Loosen the set screws in the couplings and pull the coupling wheels out of contact with the planet wheels, 2. For adjustment of lubricator No. 1, turn the crankshaft in AHEAO direction until the crankthrow for cylinder No. 1 is D03-24 de- grees past BDC for lubricator No. 1 It necessary, turn the lubricator shaft in AHEAD direction. Push the coupling wheels in to contact with the planet wheel for lubricator No. 1 and fasten the screws. For adjustment of lubricator No 2, turn the crankshaft in AHEAO direction until the crankthrow for the aftmost cylinder is DO3- 24 degrees past BDC. Use the numbers on the turning wheel to determine the exact position of the crank- throws. When refernng to this page, please quote Procedure M90302 Edition 0240 Page 3 (4)HYUNDAI ON Cylinder Lubricators Adjustment 3. Turn the pump shaft siowly in AHEAD direc tion until the mark on the scale at the lead- 1m shaft is in line with the mark on the tubrt- calor housing. 4, Re-engage the coupling wheel and tighten the set screw. Re-check the setting. See Procedure 903-2.1. Mount the guard over the coupling. Page 4 (4) When refernng to this page, please quote Procedure M90302 Edition 0240INDEX INTRODUCTION ‘CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR SYSTEM EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS GENERAL TOOLS 904904ee Crosshead Bearing 104-4 MAN Baw. nai SAFETY PRECAUTIONS Standard Too! X ] Stopped engine X | Block the starting mechanism ZX, X_| Shut off starting arr supply X_| Engage tuming gear X | Shut off cooling water f X | Shutoff uel oil 2 x 2400 kg, 2 x 600 kg X_| Shut off tubneating oi Lock turbocharger rotors <=> 50-300 Nm, 280-760 Nm Data correc eee a Ce D-1 Top clearance in crosshead bearing: Max. 0.50 mm Sep 1x 1.5m, 4x3m Min 0.15 mm 0-2 Oilwedge length L= vonm | 2x 10010 D-3 Hydraulic pressure " 2x 2000 kg = dismantling 1800-1650 bar : ~ tightening 4800 bar 4 D-4 Crosshead bearing cap 170 kg +5. Connecting rod complete 1400 ko D-6 Bearing shell, lower 30 kg D-7. Crosshead, complete 1300 kg D-8 Piston cod = tightening torque or 430 Nm ~ tightening angle 100Nen#40 * When referring to this page, please quote Data 010401 Eattion 0035 Page 1 (2)on Crosshead Bearing Pa Data Ut PA: ae. | OR 047 lo 9 035 oo he Plate Oy] Je TT 4 6 ose 90451 © i] OO |] oO ° love Ui, 4 D 059 D o oO 8 ° 8 ° el, rol, ~O||_° oO O}|0 8 131 2 106 fa = 118 ot Spare Parts Pate tem No Deserpion fi Page 2 (2) When referring to this page, please quote Data D10401 Ecition 0035abi sa Crosshead Bearing 904-1.1 ASR t Ae Checking The top clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing ‘components. For the top clearance of a specific bearing, see the measurement in the Adjustment Sheet in Volume 1, OPERATION. 1. Open the crankcase door at the relevant cylinder. 2. Tum the crankthrow concerned to 90° be- fore BDC on the exhaust side. 3. Measure the clearance in the crosshead bearing by inserting a feeler gauge be- tween the bearing cap dnd the crosshead journal, exactly next to the landing surface for the piston rod foot. See Data. SRE Ta 4, The difference between the actual clear- ance measurement and the measurement tecorded in the Adjustment Sheet (or the clearance noted for a new bearing installed later) must not exceed 0.1 mm. If so, the crosshead bearing must be disassembled for inspection. See Procedure 904-1.2. 5. The wear limit for a crosshead bearing shell is confined to a 50% reduction of the oil wedge length (L). See Data. 6. For further external inspection of the cross- head bearing, see Chapter 708, ‘Bearings’ in the instruction book, Volume |, OPERA- TION. When referring to this page, please quote Procedure M90401 Edition 0230 Page 1 (10)904-1.2 Crosshead Bearing CRATTTIN Dismantling MANJB&W] ‘This procedure applies to the following two dis- ‘mantling situations: * with piston mounted * with piston removed With piston mounted: 1. Turn the crankshaft down far enough to give access to the nuts and screws on the piston rod. Ox® 2. Mount two chains in the inner screw holes in the top of the crankcase, in the athwarth- ship direction, for suspending the piston rod. 3. Loosen and remove the locking wire from the screws on the piston rad foot. Remove the screws. Page 2 (10) When refernng to this page, please quote Procedure M90401 Edition 0230Crosshead Bearing 904-1.2 Dismantling 4. Mount a lifting eye bolt on each side of the | 4 piston rod. 5. Turn the crosshead to TDC. Hook the chains to the lifting eye bolts in the piston rod. Tum the crosshead downward, and the pis- ton rod will then remain suspended from the two chains. With piston removed: 6 Turn to BDC. 7. Place the spacer rings around the nuts and ‘screw the hydraulic jacks on to the studs Loosen the crosshead bearing cap nuts. For operation of the hydraulic jacks, see Procedure 913. Remove the hydraulic jacks and the spacer rings, and unscrew the nuts. When referring to this page, please quote Procedure M90401 Edition 0230 Page 3 (10)904-1.2 Crosshead Bearing gs Dismantling Ae 8 Mount the lifting attachments on the head of the connecting rod. 8. Suspend two tackles from the lifting brack- ets, in the athwarthship direction 10. Mount two eye bolls in the top of the cross- head bearing cap. Hook the tackles on to the eye bolts, and re- move the cap bearing from the engine. Check the upper part of the journal. Page 4 (10) When referring to this page, please quote Procedure M90401 Edition 0230Crosshead Bearing 904-1.2 lela Dismantling 11. Place the bearing cap on one side on a couple of wooden planks. 12, Fasten tackles to the fixed lifting brackets ‘on the frame box wall. 13. Tum the crosshead upwards until the piston rod lands on the crosshead. Ensure that the guide ring in the crosshead fits correctly the centre hole of the piston rod. Do not remove the chains or lifting eye bolts. When refernng to this page, please quote Procedure M30401 Edition 0230 Page 5 (10)904-1.2 Crosshead Bearing crn oer aw Dismantiing IMANIBSW] 14 Tum to TOC and attach the tackle hooks to the lifting attachments Haul the tackles tight. 15. Mount the four supports for guide shoes on the crosshead guides. Carefully turn the crank down towards the exhaust side, until the guide shoes rest on the supports. Agjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports, Haul the tackles tight 16. Turn the crankthrow carefully towards BDC ‘while ‘following’ with the tackles, thus con- tinuously supporting the connecting rod. 17. With the crosshead resting on the supports, check the lower part of the crosshead jour- nal and the lower bearing shell. Regarding checking of journal and bearing shells, see Volume |, OPERATION, Chap- ter 708, ‘Bearings’. Page 6 (10) When refernng to this page, please quote Procedure M90401 Edition 0290Crosshead Bearing 904-1.2 crm Dismanting 18. In cases where it 1s necessary to remove the lower bearing shell, tilt the connecting tod towards the door in the camshaft side, using the tackles. Dismount the locking screws, and turn the bearing shell so far up that an eye bolt can be mounted. Lift the bearing shell out of the engine. When referring to this page, please quote Procedure M30401 Editon 0230 Page 7 (10)904-1.4 Crosshead Bearing ye Mounting Rd With piston mounted/ With piston removed: 1. Mount and secure the bearing shell in the bearing housing. The excess height X is to ensure the cor- rect tightening-down of the bearing shell and must not be eliminated. 2. Raise the conne sition. 1g fod 10 an upright po- Tum to TDC while ‘following’ with the tack- les, for assembling the crosshead and the connecting rod, Take care that the guide shoes do not dam- age the bearing shell. 3. Remove the supports from the crosshead guides. Remove the tackles from the crosshead. Turn the crank throw to BDC. If the piston is mounted, slowly turn down until it is fully suspended from the chains. Page 8 (10) When refernng to this page, please quote Procedure M90401 Edition 0230abit Crosshea EEA Mout d Bearing 904-1.4 nting 4, Lift the bearing cap into the engine. Lower the bearing cap onto the crosshead and re- ‘move the tackles. Remove the lifting attach- ments from the connecting rod. Note! Take care that the bearing studs do not damage the crosshead. 5. Tighten all four crosshead bearing cap nuts simultaneously. See Data. For operation of hydraulic jacks, see Sec- tion 913. 6. Mount the piston. See Procedure 902-1.4. With piston mounted: 7. Turn the crosshead upwards until the piston tod lands on the crosshead. Ensure that the guide ring in the crosshead fits correctly n the centre hole of the piston rod. When referring to this page, please quote Procedure M0401 Eamon 0230 Page 9 (10)00s Crosshead Bearing GNC Mounting IMANIB&W; 8. Unhook the chains from the lifting eye bolts Im the piston rod. Remove the chains and eye bolts from the top of the crankcase, from the piston rod and from the crosshead bearing cap 9. Turn down to BDC, tighten the screws in the piston rod, and lock with locking wire, See Data. Mount the locking wire in such a way that the wire is tightened i a screw works loose. See Procedure 913-7. Page 10 (10) When referring to this page, please quote Procedure M90401 Edition 0230HYUNDAI Crosshead 104-2 IRE ba ‘SAFETY PRECAUTIONS Stopped engine Block the starting mechanism ‘Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oi! X | Shut off lubricating oil Lock turbocharger rotors Data Ref. Description Value] Unit 004-04 Crosshead bearing cap 160] kg 04-08 Cooling oil outte pipe, tightening torque 50] Nm Dos-12 Guide sinp screws, tightening torque 100] Nm 04-13 Guide plate, tightening torque 135] Nm 004-15 —_| Telescopic pipe, tightening torque 50] Nm 04-19 | Telescopic pipe. tightening angle 25|° Do4.21 ‘Crosshead complete 1100| kg (04-22 | Guide shoe 159} kg. 004-23 | Cooling oil outlet pipe 9] kg 1004-50 | Connecting rod, without bearing caps 1020| kg 013-01 | Hydraulic pressure, mounting 1500} bar 013.02 Hydraulic pressure, dismantling 4400 -1650| bar When refernng to this page, please quote Data D10402 Edition 0050 Page 1 (2)104-2 Crosshead Data The task-specific tools used in this procedure are shown on the plates at the end of ths chapter or in the chapters indicated by the first three digits n the plate number, e.g. P90951 refers to chapter 909, Plate Item No. | Description P904st 47| Wire guide | P904st 95 | Lifting attachment - connecting rod | P90as1 120] Lifting tools - crosshead | P90451 72) Chain for suspending piston | Poodst 96] Retaining tool telescopic pipe | P9oast 84] Torque wrench offset tool | Poca2 11 Guide shoe extractor, complete P9046 Crosshead - Hydraulic Tools 91951 10| Hydraulic pump, pneumatically operated 91351 46 | Hose with unions (1500 mm), complete P9135t 58 | Hose with unions (3000 mm), complete 91351 117 | Sway distributor block, complete 91356 Lifting Tools, Etc. 91359 Torque Spanners P9196 58 | Feeler gauge Page 2 (2) When referring to this page, please quote Data 010402 Edtion 0050Reba ey er Crosshead 904-2.2 ae Dismantling 1 Dismount the piston. 7 so See Procedure 902-1 2 2. Dismount the main bearing lubricating oi! pipes. 3. Dismount the cooling oil outlet pipe from the guide shoe and the drain oil slotted pipe. Loosen and remove the screws which se- cure the telescopic pipe to the guide shoe. In order to reach the screw in the corner be- hind the telescopic pipe, use the offset tool along with a socket wrench. 4. Mount the retaining tool for the telescopic pipe on the stuffing box housing for the tel- escopic pipe. Turn the crosshead to TOC. Suspend the telescopic pipe by means of the tool. Turn the crosshead to gain access to the nuts on the crosshead bearing studs, Mount two eye bolts in the top of the crank- case in the fore-and-aft direction Mount the spacer rings and the hydraulic jacks for loosening the nuts on the cross- head bearing studs For operation of the hydraulic tools, see Section 913, Loosen the nuts, remove the hydraulic jacks and unscrew the nuts When referring to this page, please quote Procedure M90402 Edition 0239 Page 1 (7)904-2.2 Crosshead Dismantling 5. Mount eye bolts in the crosshead bearing cap and hook the tackles on to the lifting brackets in the top of the crankcase Dismount the bearing cap and lift it out of the engine. 6. Mount the special lifting tool on the cross head. Mount the lifting attachments for fixing the connecting rod, on the head of the connect- ing rod. Fasten tackles to the lifting brackets on the frame box wall and attach the tackle hooks to the lifting attachments. Haul the tackles tight. Attach the flat-plaited wire strap to the en- gine room crane. Hook the engine room crane on to the lifting tool on the crosshead, and lift the cross- head 7. Using the tackles, tit the connecting rod to- wards the exhaust side, while turning the crankthrow towards the camshaft side. Transfer the tackles from one lifting attach- ‘ment to another as necessary. When the crankthrow is 90° after BDC, stop turning. By alternate use of the tackles, tilt the con- necting rod until it rests against a couple of wooden planks in the bottom of the bed- plate. Page 2 (7) When referring to this page, please quote Procedure M90402 Edition 0239Ey Crosshead 904-2.2 OAM ER Dismantling 8 Lower the crosshead to a position just above the main bearing caps Remove the guide strips and both guide plates from the guide shoes. Mount lifting eye bolts in both guide shoes. 9. Suspend two tackles from the eye bolts in the top of the crankcase, in the fore-and-aft direction, and attach the tackles to the guide shoes, Push one of the guide shoes against the middle of the crosshead. If necessary, use the guide shoe extractor tool. 10. Pull the “free end’ of the crosshead into the neighbouring cylinder unit Mount the guide shoe extractor on the op- posite guide shoe Pull off the guide shoe, remove the extrac- tor, and lift up the guide shoe When referring to this page, please quote Procedure M90402 Edition 0239 Page 3 (7)fF 904-2.4 Crosshead hee IL i Mounting bog) 5. Mount the guide plates on the side of the guide shoes. Tighten the screws and lock them with lock- ing wire. ‘See Procedure 913-7. Using the engine room crane, lift the cross- head to a working position and mount the guide strips on the side of the guide shoes. Tighten the screws and lock them with lock- ing wire, See Procedure 913-7. 6. Using the tackles, lift the connecting rod to a vertical position while turning the crank- throw to BDC 7. When the connecting rod is in a vertical po- sition, lower the crosshead and land it on the connecting rod Remove the lifting attachments from the connecting rod head. Remove the lifting tool from the crosshead. Page 6 (7) When referring to this page, please quote Procedure M90402 Edition 0239Phat UPN ts Crosshead 904-2.4 Mounting 8 Lift the crosshead bearing cap into the en- gine. 9. Mount the spacer rings and the hydraulic Jacks for tightening the nuts on the cross- head bearing studs. | For operation of the hydraulic tools, see Procedure 913 Mount the drain oil slotted pipe and the cooling oil outlet pipe on the guide shoe. Turn the crankshaft to TDC. Land the telescopic pipe on the guide shoe 10. For tightening the bolt in the corner behind the telescopic pipe, use the offset tool along with the torque wrench. 11. Mount the lubricating oil pipes on the main bearing caps. 12 Mount the piston. ‘See Procedure 902-1.4. When referring to this page, please quote Procedure M90402 Edition 0239 Page 7 (7)Dial Reciprocating Parts 104-3 Data DE Ae SAFETY PRECAUTIONS ‘Stopped engine Block the starting mechanism ‘Shut off starting air supply Engage turning gear Shut off cooling water ‘Shut off fuel of ‘Shutoff ubricating oil Lock turbocharger rotors 2 [x|x]=]=]=[x[=]= a 2 Description Vatue| Unit Acceptance criteria with piston in centre (F-A direction) 04-25 PF+PA, N max. 0.5| mm 004-26 PF+PA, O max. 0.7| mm 004-28 E+G, H+F, Nmax 05| mm 004-29 E+G, HeF, N min. 0.2| mm 04-30 E+G, HF, O max. 0.8! mm Do04-53 JL.K, M, Nimax. 0.9) mm Dos-54 JiL.K,M, Nmin 0.5] mm 04-55 JL K,M, O max. 4.4) mm, N: New and cold engine with staybolts tightened (less than 100 running hours). © Engine in service. When referring to this page, please quote Data 010403 Edition 0034 Page 1 (2); (RARE 104-3 Reciprocating Parts t 7 Data ’ IMANIB&W, ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Piate Item No. | Description P9o4s1 191 | Alignment toot P9136 58 | Feeler gauge | Page 2 (2) When referring to this page, please quote Data D10403 Edition 0034eh teas al Reciprocating Parts 904-3.1 Checking REL Aas In order to achieve uniform measuring cond tions on board, the ship's trim must be as close as possible to 0” 1 Mount a transparent plastic tube along the length of the bedplate. the framebox side. See T. Bend each end approx. 250 mm up along | a eapiate Fill the tube with water (possibly coloured) until the water level 1s approx. 100 mm from the end of the tube Trim the ship until the difference between the water level $ fore and aft is less than 1.5 mm per 1000 mm. Measurements are to be taken with a ruler. 2. Turn the engine in ASTERN direction to 45" after BOC (the guide shoe must rest against the crosshead guide). 3, Mount the tool between the guide shoe/ guide strip. For this purpose, use the third threaded hole from bottom of guide shoe (this hole ts normally used for fastening the guide strip to the shoe) By means of the two screws in the middle = of the tool, pull the guide shoes until they rest lightly against the end face of cross- head Note! When the too} is mounted, its not possi- ble to turn past TDC and BDC When refernng to this page, please quote Procedure M30403 Edition 0217 Page 1 (3)904-3.1 Reciprocating Parts RUE Checking “ 04-25 04-26 04-53 04-54 04-55 aca Tae 4, Check the centering of the piston in the cy!- inder liner by measuring the clearance (from the scavenge air space with a long feeler gauge) between the piston'skirt and the cylinder liner in the Fore and Aft posi- tions (PF-PA). ‘Make sure that the piston is clear of the cyl- inder liner in the fore-and-aft direction. 5. Measure the clearance between the guide strips and crosshead guides (J, K, L and ™). The clearance J, K, L and M is adjusted by the insertion of shims so that it is symmet- rical in relation to the clearance between the piston skirt and the cylinder liner Parallelism between the guide stip and guide 1s to be kept within a tolerance of 0.2 mm per 1000 mm. Page 2 (3) ‘When referring to this page, please quote Procedure M90403 Edition 0217CRA : Reciprocating Parts we Checking 904-3. 6. Check the clearance between guide shoe | © and crosshead guide (E, F, G and H) with a feeler gauge. 7. It is recommended that the measured re- sults are noted down so that possible later changes can be ascertained. — Coma y 04 Lag SmI Fuetpure Wien referring to this page. please quote Procedure M90403 Edition 0217 Page 3 (3)Ba Crankpin Bearing 104-4 Et Aad Data SAFETY PRECAUTIONS X | Stopped engine X | Block the starting mechanism X | Shut off starting air supply X | Engage tuming gear Shut off cooling water Shut off fuel oi! X_| Shut off tubncating oi! Lock turbocharger rotors Description Value] Unit 004-43 Crankpin beanng clearance, max. 0.6| mm 04-44 Crankpin beanng clearance, min 0.2| mm 004-46 Crankpin bearing, upper shell 17] kg 004-47 Crankpin beanng, lower shell 13] kg 004-48 Crankpin beanng cap + shell + beanng studs 150] ko 013-01 Hydraulic pressure, mounting “1500 bar 13.02 Hydraulic pressure, dismantling 1400 -1650) bar When referring to thus page, please quote Data 010404 Edition 0042 Page 1 (2)