Doosan Man b&w Diesel Engine 6s5 [PDF]

Zitiervorschau

1-

Volume2

for Manual Maintenance r MANB&WDiesel Engines DOOSAN 6550MG Ship

No.: HN0452

- MANB&W EngineType : DOOSAN ProjectName: UNIC0452 Project No.: ML 1628

Telephone

Sinchon-dong, Changwon-City Technical Service : +82552606181 DOOSAN ENGINE C0.,LTD. 69-3, Korea641-370 Parts Gusromen rEAM Kyungnam, Sales: +82552606374 Snrsmcrron Tefefax : +8255260677213

INTRODUCTION

CYLINDERCOVER

PISTON WITH ROD AND STUFFING BOX C Y L I N D E RL I N E R A N D CYLINDER LUBRICATOR CROSSHEADWITH CONNECTINGROD CRANKSHAFT,THRUST BEARING A N D T U R N I N GG E A R

MECHANICAL CONTROLGEAR

STARTINGAIR SYSTEM

EXHAUSTVALVE

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FUEL OIL SYSTEM

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TURBOCHARGER SYSTEM

SAFETY EQUIPMENT

ASSEMBLY OF LARGE PARTS

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902 903

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904

Gross Section through Engine

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iTriTTfTT-illANB&Ul Gheckingand MaintenanceSchedules Edition Page

SchedulesindiThe Checkingand Maintenance at which it is deemed appropricatethe intervals ate to inspectthe individualcomponentsof the engineand to carryout overhauls,if necessary, basedon the engineconditionor on timecriteria.

900-1 217 1 (5)

Designmodifications may necessitate a revision in whichcasethe revisedinof the instructions, structionsand changedoverhaulingintervals,if any, will applyand supersedethoseoriginallyissued (see e.g our Service Letters).

interThe statedNormalhours of serviceshouldonly In additionto the checkingand overhauling be usedas a guide,as differencesin the actual vals statedin this schedule,pleasenotethatthe the qualityof the fuel oil or lu- periodicalsurveyrequirements of the classificaserviceconditions, bricatingoil, the treatmentof coolingwater,etc. tion societymay requireadditionalchecksand overhaulsto be carriedout. For furtherinformawill decisivelyinfluencethe actualservicerepleasereferto the classification intervals between necessary tion the society. sults,and thus overhauling.

The proceduresare divided into three categories: Conditioncheckingprocedures

markedunderthe headingNormal hours of servicewith a C, dealwith the serviceconditionof a numberof enginecomponents,and form the basisfor estimatingwhetherfurtheroverhaulingis necessary.In a numberof casesthe condition referto VolumeI of the instruction checkingprocedures book,in whichmoredetaileddescriptions andworkingprocedures canbe found.

Condition-basedoverhauling procedures

whichunderthe headingNormalhours of arethoseprocedures service are markedwith an O, and oppositewhich,underthe headingOverhaulto be basedon procedureNo. (columnP), a procedurenumberis stated. Thisprocedurenumbernormallyrefersto one of the aboveconwhichformthe basisof the overhaul. ditioncheckingprocedures Forthis reason,the intervalsstatedarefor guidanceonly.

Time-basedoverhaulingprocedures

alsomarkedwithan O underthe headingsNormalhours of service or Based on observations,are the procedures where an actualbasisfor estimationis lacking.lt is recommended, therefore,to carryout theseprocedures at the overhauling intervals statedas a basis. Wherea symbolO or C is indicatedin Basedon observations (columnB), this is due to the factthatspecialserviceconditions maymakecheckingor overhauling necessary beyondthe actual standardschedulesindicated.

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i|ANB&WGheckingand MaintenanceSchedules

Plate Edition

900-1 217 2 (5)

Page

V : See Volume I "Operation" A : Adjustment to be carried out C : Check the condition

H : Check new/overhauledparts after 500-1500 hours B : Based on observations P : Overhaul to be based on procedure No. or refer to

M : See maker's instructions O : Overhaul to be carried out

No.

Procedure

H

2

4

6

8

16

B

32

P

901 Cylinder Cover -1

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GylinderCover

-1.5 Checkingof cyl.coverstud 902 Piston with Rod and Stuffing Box -1

Piston

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Checkingof the screwsfor connectionof pistonrod - crosshead. Pistonringsonly

C

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Pistoncomplete -2

PistonRod StuffingBox Checkingof the innerandouterscrews on stuffingboxflange

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902-1

9 0 3 C y l i n d e rL i n e r a n d C y l i n d e rL u b r i c a t i o n

o 90l''t 1000hoursand 2000hours: Inspection throughscavengeports

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Measuringwear insideliner -2

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CylinderLubricators

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904 Crossheadwith ConnectingRod

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Crosshead

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FleciprocatingParts

C,

-4

CrankpinBearing

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Crankshaft,Thrust Bearingand Turning Gear 'r , G,ian,kshaft Deflection

G

-2

M a i nB e a r i n g

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905

-3 -5

s AxialVibrationDamper

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Schedules iii'!7.?1,TI.ilANB&tI Gheckingand Maintenance

Plate

Edition Page

V: A: C: M:

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900-1 217 3 (5)

partsafter500-1500hours Checknew/overhauled Basedon observations Overhaulto be basedon procedureNo' or referto

See VolumeI "OPeration" Adjustmentto be carriedout Chec kt he c o n d i ti o n See maker'sinstructions Overhaulto be carriedout

N o r m a l h o u r s o f s e r v i c e( x 1

906 MechanicalControl Gear -1

Chain GheckTighteningBoltof SparyPipeJoints Newor ovefrauledsparypipejointto be checkedl retightenedafter500, 1500and 4000hours

-2

C h a i nT i g h t e n e l New or overhauledchainto be checked/ after500, 1500and 4000 hours retightened A,G

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-4

CamshaftBearings

-5

GamshaftCouPlingFittedbolts

907 Starting Air SYstem

'i,;.7,','..,siuttrng,*ir'Di#ributor,'i,',, -2

S t ar t ingA i r V a l v e

'' '' "'''G;t i#i ifi*n"orin' ' ' ' F unc t ion a lc h e c k o f o v e rs p e e dd e v i c e

Functionalcheck of speed-settingsystem (enginewith bridgecontrolsystem) 908 Exhaust Valve

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High:P#;t*Fild'

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ExhaustValve Conventional hard-facedvalve seats; overhaulat intervalsof 6000 hours *,tonic exhaustvalves; checknew valvesafter6000 hours overhaulat intervalsof 16000 subsequently, hours

-3

ExhaustValve Actuator

-4

ExhaustValveRollerGuide

-5

ExhaustValveCam

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900-1 217 4 (5)

Schedules Edition T1T.;'AI*B&,' Gheckingand Maintenance Page

V: A: G: M: O:

See VolumeI "Operation" Adjustmentto be carriedout Chec kt he c o n d i ti o n See maker'sinstructions Overhaulto be carriedout

No.

Procedure

909

Fuel Oil System

H : Check new/overhauledparts after 500-1500 hours B : Based on observations P : Overhaul to be based on procedure No. or refer to

H

2

4

6

16

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Fuel PumpBarrelAssembly

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FuelPumpPunctureValve

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LiftingGear RollerGuide Fuel Valve

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,t'1.,1 - 1 2 SpindleGuide/Non-Return Valve

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F u e lP u m pR o l l e rG u i d e

910 TurbochargerSystem -1

Air Gooler

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Non-Return Valve

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ButterflyValves

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Turbocharger Turbine

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WaterMistCatcher

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Gheckingand MaintenanceSchedules

Plate Edition

900-1 217 5 (5)

Page

V : See Volume I "Operation" A : Adjustment to be carried out C : Checkthe condition

H : Check new/overhauledparts after 500-1500 hours B : Based on observations P : Overhaul to be based on procedure No. or refer to

M : See maker's instructions O : Overhaul to be carried out

No.

Procedure

H

2

4

6

8

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16

32

B

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9 1 1 S a f e t yE q u i p m e n t -1

SafetyValve

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ReliefValve

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Functionaltest of alarm systemfor thrust bearingand slow down /shut down system

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Checkingand adjustment of pressuregauge

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Gheckingand adjustmentof thermometers

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Checkingand adjustment of thermostats

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C,heclri:ng:, and,adiu$t.ment, Of,pr*ss*restai$

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Checkingand adjustment of turninggear switch

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912 Assembly of Large Parts HoldingDown and End Chock Bolts(Castlron chocks)

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HoldingDownand EndChockBolts(Epoxy chocks)

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-3

Stay Bolts

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913

GeneralTools

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-1 ,...,.,Fll Tools d.iaultc

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StandardTightening Torques

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TorqueSpanner

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Tightening Gauge

-7

Screwsand Nuts

-11

LubricatinqProcedures

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INTRODUCTION

C Y L I N D E RC O V E R

PISTONWITH ROD AND STUFFINGBOX C Y L I N D E RL I N E R A N D CYLINDER LUBRICATOR CROSSHEADWITH CONNECTINGROD CRANKSHAFT,THRUST BEARING A N D T U R N I N GG E A R M E C H A N I C A LC O N T R O LG E A R

STARTINGAIR SYSTEM

EXHAUSTVALVE

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FUEL OIL SYSTEM

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TURBOCHARGER SYSTEM

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SAFETY EQUIPMENT

ASSEMBLY OF LARGE PARTS

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Standard Tools: SeeSection913

SAFEW PHECAUTIONS X

Stoppedengine

X

Blockthe startingmechanism

X

Shut off startingair suPPlY

X

Engagetuming gear

X

Shut off coolingwater

X

Shut off fuel oil

Plate Edition Data

Cylinder Cover Data

Shut off lubricatingoil

X

Lock turbochargerrotors

Data Ref.

Description

D-1 Weight of exhaustvalve stud D-2 Weightof cyl.cover comPlD-3 Weightof coolingiacket D-4 Screwing-intorqueexhaustvalve studs

D-5 Screwing-intorque startingvalve studs

D-6 Screwing-intorque-

28 kg 1595kg 52 kg

200 Nm

1 4 5N m

1 4 0N m

D-7 HydraulicPressurefor cylindercover: * tightening

900 bar

D-8 HydraulicPressurefor cylindercover: - dismantling

90G-990 bar

D-10 Tighteningtorquehigh-Pressure PiPe (exhaustvalve) D-11 Weightof high-Pressure pipe (exhaustvalve)

40-200 Nm

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Value Unit

fuel valve studs

D-9 Tighteningtorquefuel oil high-Pressure PiPe (fuelPumpifuelvalve)

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Mount and tighten the screws for the cooling jacket.

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CylinderCover Overhaul

5.

Plate Edition Page

9 0 1 - 1. 3 217 6 (11)

5. Reconditionthe valve boresas follows: Fuel valve bore 6. The tool consistsof a commonspindlewith handle,and of a guide,a carboncutter,a seatingfacecutter,and a grindingmandrel. Clean the fuel valve bores,usingthe carbon cutter.lf required,reconditionthe fuel valveseatingwith the appropriatecutter. Grindthe seatingwiththe grindingmandrel and a grindingcompound(e.9.Carborundum No. 200).

6,

After the milling/grinding, clean the bore and seating carefully,and check that the seatingis not damaged. Exhaustvalve bore 7. The tool consistsof a spindlewith handle and a grindingdisc. After cleaningthe valve bore and seating, grindthe seatingwiththe grindingdisc and a grindingcompound(e.g. Carborundum No. 200). Afterthe grinding,cleanthe boreand seating carefully,and checkthat the seatingis not damaged.

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CylinderCover Overhaul

8.

Starting valve bore 8 . The tool consistsof a guide,a cutter,and a grindingdisc. Reconditionthe starting valve bore and seatingin the same way as describedfor the fuel valvebore. When replacingvalves on a cylindercover that is mountedon the engine,recondition the valve bores/seatingin the same way as describedhere,but withoutdismounting the studs. 9. Clean the bores for safety valve/indicator cock.

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Plate Edition Page

901-1.3 217 7 (11)

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CylinderCover Overhaul

Plate

Edition Page

9 0 1 - 1. 3 217 8 (11)

10. Lubricatethe threadswith 'NeverSeize'or (MoS2)and mount Molybdenum Disulphide the valve studs.

10.

D-4 D-6

Tightenup the studsin accordancewiththe screwing-in torque stated on the data sheet. Fill up the groovesbetweenthe valvestuds and the boresfor the valvestudswith permatexto preventwater or oil from entering the boresduringoperationof the engine.

D-5 -go

Providethe water connectionflangeswith new gaskets,and keep the cylindercover readyfor replacement. o N N (t o (t)

Alwaysfit new or overhauledvalvesbefore a cylindercoveris mountedon the engine.

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Cylinder Cover Mounting

1.

1. Placea new sealingring on top of the cylinderliner. 2 . Lift the cylinder cover by means of the crane and carefully wipe the contactsurface whichfacesthe cylinderliner. Providethe coolingwaterconnectingpipes with new O-ringsand lubricatethem with greaseor soft soap. Lowerthe covercarefully into position. Duringthe landing,carefullycheckthatthe coolingwaterconnectingpipesengagecorrectlywith the holes in the coolingjacket.

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9

3 . Mount the cover nuts on the studs and screwdown.

2.

Placeeightspacerrings,one aroundeach jackson nut, and mountthe eighthydraulic the studs. Connect the high-pressure pump to the jacks by means of the distributor block and the eight high-pressurehoses. Vent the system and increase the pressure as stated under D-7. For operation of the hydraulic tools, see Procedure 913-1.

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Tighten the nuts by applyingthe tommy bar through the slots in the spacer rings.

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Relieve the system of pressure. Finally, remove the hydraulic jacks and spacer rings from the nuts.

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Plate

Edition Page

9 0 1 - 1. 4 217

e (11)

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Cylinder Cover Mounting

Edition Page

901-1.4 217 1 0 ( 11 )

Note! of To facilitatemountingand dismantling the flangeclamps,andto preventseizure on accountof heating,applya coat of 'Never SeezNS 160'or a corresponding preparation to: - the contactfaces of the flanges pipe) (exhaustpipe/intermediate - the insideof the clamp - the threadof the clampscrew - the screwsof intermediate pipe/ exhaustvalve 4 . Mountthe drainpipefromthe coolingwater

connectionbetweenexhaustvalveand cylinder cover. Place the intermediatepipe betweenthe exhaustpipe and the exhaustvalve. Align the intermediatepipe so that the pipe holesin the flangeof the intermediate are in linewiththe threadedholesin the exhaustvalve. 5.

Mountscrewswith washersin the intermediate pipe/exhaust valveflangesand tighten up the screwsdiagonally. 5 . When mountingthe clampconnecting the

pipe/excompensatorand the intermediate haustvalveit may,in somecases,become necessaryto use the 'compensator extender' tool. Tightenthe screw on the tool to bring the compensatorinto alignmentwith the exhaustvalveintermediatepipe.

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CylinderCover Mounting

6 . Attachthe insulationjacket.Mountthe cool-

ing water outletpipes. Mount the return oil pipe and the air pipe for pneumaticclosingof the exhaustvalve. Mountthe startingair pipe and controlair pipe for the startingvalve. pipefor the 7 . Fit and adjustthe high-pressure hydraulicvalvegear,and thenfastenit. See Procedure908-1. Fit the fuel oil high-pressure pipe between the fuel pumpand the fuel valves(checking that the pipe fits properlyat the seats and that all parts are clean and providedwith new O-rings). Liftthe unionnut up on the pipeand tighten the couplingpiecewiththe specialspanner head and the torque spanner.SeeData. Connectthe outletpipe from the returnoil pipe on the fuel valves. Connectthe air pipesand outletpipesto the fuel oil alarm system. Shut the drainvalvesand openthe cooling water inlet.After ventingthe cylindersection,shutthe vent cocksand openthe cooling wateroutletvalve. Openthe fueloil, lubricating oil andair suppliesto the alarmsystem. Caution ! The air supplyto the exhaustvalvemust alwaysbe connectedbeforestartingthe camshaftoil pumps. This is very important,becauseotherwisethe valvewill openmorethan intended.

Plate

Edition Page

9 0 1 - 1. 4 217 11(11)

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Cylinder Gover Stud Checking

Plate Edition Page

901-1.5 1 (1)

I n s p e c t h e c y l . c o v e rs t u dv i s u a l l yi n c o n d i t i o nt h a t t h e c y l . c o v e rs t u d sa r e tightened fully. Checkwitha 0.05mmfeelergaugethat thereis no clearancebetweenbottomof cyl.coverstudnut and top surfaceof cyl. cover.

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Plate 90151-122

GylinderGoverPanel

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Item No.

GylinderGoverPanel

Item Description

071 083 095 105 117 172 201 901

Grindingtool for Exh.valveseat Millingand grindingtoolfor fuelvalve seat I ,Ui S'ae,r Mifing and grindingwheeltorJud vaTve valveseat Dismantling leverfor fuel valve Handlefor sundrytype Grindingringfor startingvalve Pinwrenchfor startingvalve Testingdevicefor safetvvalve Liftingchain for cyl.cover Handlefor sundrytype *) Toolpanel

901 201

*) Toolpanel,complete with tools

046 058 060

") Optionalextras

Item No.

Item Description

Plate 9 0 1 5 -11 2 2

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GylinderGover- Tools

Plate 90161-95

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Item No.

015 027 039 040 052 166

CylinderCover - Tools

PartDescription Hydraulictoolsfor cylindercover Hydraulicjack Spacerring O-ringwith back-upring, 1201130 mm O-ringwith back-upring,80/90mm Studsetter,M 56 x 5,5

l!?rn No. II

partDescription

Plate 90161-95

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CylinderGover- Tools

Plate 90162-15

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PartDescription Dism stand for starting valve Cover for Exh. valve bore

GylinderGover- Tools

PartDescription

Plate 90162-15

INTRODUCTION

CYLINDERCOVER

PISTON WITH ROD AND STUFFING BOX C Y L I N D E RL I N E R A N D CYLINDER LUBRICATOR C R O S S H E A DW I T H C O N N E C T I N GR O D CRANKSHAFT,THRUST BEARING A N D T U R N I N GG E A R

MECHANICAL CONTROLGEAR

STARTINGAIR SYSTEM

EXHAUSTVALVE

x

ul CT

FUEL OIL SYSTEM

TURBOCHARGER SYSTEM

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SAFETY EQUIPMENT

ASSEMBLY OF LARGE PARTS

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Plate Edition Data

Piston Data

SAFETYPRECAUTIONS X

Stoppedengine

X

Blockthe startingmechanism

X

Shut off startingair supply

X

Engageturninggear

X

Shut off coolingwater

X

Shut off fuel oil

X

Shut off lubricationoil

-

40-200,140-760Nm

Lock turbochargerrotors 2xM12

Data Description

18

1 (2)

Standard Tools: See Section913

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Ref.

102-1

Value Unit

D-1 Radialwidth: - new pistonring 1 7 . 2m m - worn pistonring 1 4m m vertical height: D-2 Maximum - grooveNos. 1 1 3 . 3m m - grooveNos.2.3 and 4 1 0 . 3m m D-3 Max. permissibleburn-away: - standardpiston top 1 5m m D-4 Nominalheight: - ring grooveNos. 1 12.7mm - ring grooveNos. 2.3 and 4 9.7 mm - pistonring Nos. 1 12.4mm - pistonringNos.2.3 and 4 9 . 4m m 3 . 4m m D-5 Workingringgap (Topring) 0.35- 0.40mm D-6 Verticalclearance D-7 Pistoncomplete 865 kg 200 kg D-8 Pistoncrown Piston skirt D-9 57 kg D - 1 0Tighteningtorque 80 Nm pistonskirt D-11 Pistoncoolingpipe 21 kg 80 Nm D-12 Tighteningtorquecoolingpipe D - 1 3 Piston rod 508 kg D - 1 4Tighteningtorque300 Nm pistoncrownlrod D - 1 5Test pressure 7 bar 1624kg D - 1 6 Cyl. coverwith exhaustvalve 430 Nm D - 1 8Tighteningtorque of piston D - 1 9Tighteningtorque80 Nm stuffingbox

Plate 90451-56

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Piston Data

Plate

102-1 18

2 (2)

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Piston Checking

1.

Scavenge port inspection To detect possible leakages from the piston or c y l i n d e rc o v e r ,k e e p t h e c o o l i n gw a t e r a n d c o o l i n g o i l c i r c u l a t i n gd u r i n g t h e s c a v e n g ep o r t i n spection. 1 . R e m o v et h e i n s p e c t i o nc o v e r s o n t h e c a m s h a f t s i d e o f t h e c y l i n d e rf r a m e . Note! The scavenge port inspectioncan also be carried out f rom within the scavenge air receiver.

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Clean the openings.

2.

B e g i n t h e i n s p e c t i o na t t h e c y l i n d e rw h o s e piston is nearestBDC.

2 . W i t h t h e p i s t o n i n B D C , i n s p e c tt h e p i s t o n c r o w n a n d t h e c y l i n d e rw a l l . Note down the results. See Volume l, Operation, Chapter 707. 3 . T u r n t h e e n g i n e .W h i l e t h e p i s t o ni s p a s s i n g the scavenge air ports, inspect the piston r i n g s ,t h e r i n g l a n d sa n d t h e p i s t o n s k i r t . C h e c k t h e m o v a b i l i t ya n d t h e t e n s i o no f t h e p i s t o n r i n g s , b y p r e s s i n ga g a i n s tt h e m w i t h a wooden stick.

C!

C!

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Note down the results.

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Plate Edition Page

902-1.1

208 1 (18)

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Piston

WE-ilIANB&u|

Checking

902-1.1 2O8 2 (18)

4. After turningthe pistonupwards,past the scavengeair ports, inspectthe piston rod and the lowerpart of the cylinderwall. Notedownthe results. the inspection coverson the cyl5. Re-mount inderframe.lf necessary,replacethe gaskets. Pistonrings and piston crown 6. Removethe pistonfrom the cylinderand placeit on the pistonsupport. See Procedure902-1.2.

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Piston

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Checking

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7. Take off the piston rings by means of the ring expander. C l e a n a n d i n s p e c tt h e r i n g s . 8. Measure and record the radial width and t h e h e i g h to f t h e r i n g s . See Volume l, Operation, Chapter 707.

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Worn rings must be replaced if the radial width is less than stated in Data. 9. Piston rings with milled pressure relief groovesmust be replacedif the radialdepth of the grooves has worn down to less.than 1 mm.

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902-1.1

208

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Checking

Plate Edition Page

902-1.1

208 4 (18)

10.

D-2

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1 0 . C l e a n t h e r i n g g r o o v e sa n d c h e c k t h e m f o r burn marks or otherdeformation. Measurethe ring grooveswith a dial gauge o r a c a l i p e rg a u g e . Clearancein piston ring grooves: T h e m a x i m u mv e r t i c a lh e i g h ti n a w o r n r i n g groove must not exceed the value stated in Data. The groove is also worn o u t i f t h e r e i s n o c h r o m i u ml a y e r . 1 1 . T h e n o m i n a l h e i g h t s o f ring grooves of a new piston crown or new p i s t o nr i n g sa r e a s stated in Data.

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1 2 . C l e a n t h e p i s t o nc r o w n a n d c h e c k t h e b u r n away by means of the template. For maxim u m p e r m i s s i b l eb u r n - a w a yv a l u e , s e e D a ta.

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C h e c k t h e b u r n - a w a yo n t h e w h o l e c i r c u m ference of the piston crown. R e g a r d i n gt h e m a x i m u mp e r m i s s i b l eb u r n away of piston top with welded-on layer of lnconel. see Data.

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|WWEIIANB&UT

Plate

Piston

Edition

Checking

Page

1 3 . B e f o r e m o u n t i n ga n e w p i s t o n r i n g , m e a s ure the pistonring gap. I n s e r tt h e p i s t o n r i n g i n e i t h e ra n e w c y l i n d e r l i n e r o r i n t h e b o t t o mo f a u s e d c y l i n d e r (below the ring travel zone) during the m e a s ur i n g .

D-5

For minimumring gap, see Data. 1 4 . F i t t h e p i s t o n r i n g s ( a l t e r n a t e l yr i g h t - h a n d a n d l e f t - h a n dc u t s w i t h t h e r i n g g a p s s t a g gered 180' and with the rop mark upwards) by means of the ring expander.

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T h e r i n g e x p a n d e rp r e v e n t su n i n t e n d e dd e f o r m a t i o no f t h e r i n g s .

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15. Check the vertical clearance between the new piston ring and the new or reconditioned ring groove with a feeler gauge. See Data.

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D-6

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902-1.1

208 5 (18)

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'T'I7FIIWE.]I|ANB&-[|

Plate

Piston Dismantling

1.

902-1.2

Edition Page

6 (18)

1 . Turn the crossheaddown far enough to give access to the piston rod stuffing box, the tighteningscrews for the piston rod, and to t h e t e l e s c o p i cp i p e .

2 . Release the stuffing box by removing the innermost screws f rom the stuffing box flange. Note!

from the flange. 3 . R e m o v et h e s t u d a n d N u t . w a s h e r

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Piston Dismantling

Plate Edition Page

902-1.2 208 7 (18)

4.

4 . M o u n tt h e t w o d i s t a n c ep i e c e so n t h e p i s t o n rod foot to protect the lower scraper ring a n d t o g u i d e t h e s t u f f i n gb o x . 5 . D i s m o u n tt h e c y l i n d e rc o v e r . See Procedure 901-1.3. Carefullysmooth out any wear ridges at the top of the cylinder liner by using a hand grinder. See Procedure 903-1.2. a

6 . T u r n t h e c r o s s h e a dt o T D C , w h i l e c h e c k i n g t h a t t h e g u i d e p i n s o f t h e d i s t a n c ep i e c e s e n t e r t h e h o l e s i n t h e s t u f f i n gb o x .

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Plate

Piston Dismantling

Edition Page

902-1.2 208 8 (18)

7. The top of the piston is now free of the cyli n d e rl i n e r . lf necessary, remove one or two cylinder cover studs, using a stud setter. Clean the lifting groove of the piston crown a n d m o u n t t h e l i f t i n gt o o l i n s u c h a m a n n e r 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 t h e l i f t i n gg r o o v e a n d t i g h t e n i t u p a g a i n s t the stop of the tool.

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8 . P l a c et h e t w o h a l v e s o f t h e s u p p o r t a r o u n d o n e o f t h e o p e n i n g si n t h e p l a t f o r m . Lift the piston out of the cylinder and lower the piston rod foot and stuffing box through t h e o p e n i n gi n t h e p l a t f o r m . Place the two halves of the support around the piston rod and secure the two halves with screws. L

P l a c e a c o v e r o v e r t h e o p e n i n gf o r t h e p i s ton rod stuffing box in the bottom of the cyli n d e ru n i t .

Clean,measureand recondition the cylind e rl i n e r . See Procedure903-2.1.

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Plate

Piston

Edition Page

Dismantling

10.

1 0 . T u r n t h e c r o s s h e a dd o w n f a r e n o u g ht o p e r m i t m o u n t i n go f t h e p r o t e c t i v er u b b e rc o v e r on the crosshead bearing cap.

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The protectiverubber cover should remain in place to protect the crosshead bearing j o u r n a lf r o m i m p u r i t i e su n t i lt h e p i s t o ni s r e mounted. Low lifting height

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l f t h e s p a c e c o n d i t i o n sa b o v e t h e e n g i n e m a k e i t i m p o s s i b l et o r e m o v et h e p i s t o n i n t h e n o r m a l way, the piston can be removed as follows:

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902-1.2 208 e (18)

f

WWEIIANB&IT

902-1.3

Piston

Edition

Overhaul

Page

1.

1 . Position new O-rings on the platform

D-7

aroundthe pistonoverhaulcut-out. 2 . Ease the pistondown so that the stuffing box is belowthe floor. Lift the O-rings and assemblethe two halvesof the pistonsupportaroundthe piston rod. Positionthe O-ringson the pistonsupport. 3 . Dismount the lockingwireand screwup the

supportscrewsof the pistonsupportto a positionjust belowthe pistonskirt.

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Removethe pistonskirt screws.

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10 (18)

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Plate

Piston Overhaul

4.

Edition Page

902-1.3 208 11 ( 1 8 )

4 . Screw the four screws of the support downwards untilthe skirt restson the support. l f t h e s k i r t w i l l n o t b u d g e ,f r e e i t b y m e a n s o f t w o d i s m a n t l i n gs c r e w s . 5 . D i s m o u n tt h e l o c k i n g w i r e a n d t h e i n n e r most screws between the rod and the piston crown. Lift away the piston crown. 6 . D i s m o u n tt h e s c r e w s o f t h e c o o l i n go i l p i p e flange.

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M o u n tt h e e y e b o l t sa n d l i f t o u t t h e c o o l i n g oil pipe.

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Overhaul

A l t e r n a t i v e l y , t h e p i s t o nc a n b e d i s m a n t l e d i n t h e f o l l o w i n gw a y :

7.

Note! T i l t i n go f t h e p i s t o nm u s t o n l y t a k e p l a c e w i t h t h e p i s t o n r o d s t u f f i n gb o x m o u n t e d o n t h e p i s t o nr o d .

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7 . A t t a c h t h e l i f t i n gt o o l t o t h e b o t t o m o f t h e p i s t o nr o d f o o t . H o o k t h e c r a n eo n t o t h e l i f t ing tool. Lift the foot of the piston rod clear of the w o o d e n b l o c k .M o v e t h e p i s t o n r o d s t u f f i n g box up the piston rod until it is in contact w i t h t h e c o l l a r ,R e m o v et h e t w o d i s t a n c e p i e c e sf r o m t h e p i s t o n r o d f o o t . Note! D u r i n gt h e l i f t ,f o l l o ww i t h t h e c r a n et o k e e p t h e c r a n e p o s i t i o n e dv e r t i c a l l y a b o v e t h e f o o t o f t h e p i s t o nr o d . K e e p l i f t i n gu n t i lt h e p i s t o nr o d i s i n a v e r t i cal position.

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Plate

Edition Page

902-1.3 208 12(18)

a

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Piston

ITE-IilANB&I1

Overhaul

10.

Edition

902-1.3 208

Page

13(18)

Plate

1 0 . P l a c e t h e p i s t o n i n a n u p r i g h tp o s i t i o nw i t h the piston crown resting on wooden blocks.

D-13

D i s m o u n tt h e l o c k i n g w i r e a n d t h e i n n e r most screws between the rod and the piston crown. Lift the piston rod away and land it in a horizontal position on a couple of wooden blocks. 1 1 . R e m o v et h e l o c k i n gw i r e a n d t h e s c r e w s i n the skirt and mount two eye bolts in the h o l e s i n t e n d e df o r d i s m a n t l i n gs c r e w s . L i f t the skirt and land it on a coupleof planks.

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1 2 . T h o r o u g h l yc l e a n a n d i n s p e c t a l l p a r t s o f the piston. Regarding check of the piston crown, see Procedure 902-1.1.

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R e p l a c ea l l s e a l i n g r i n g s o f t h e p i s t o n . A l l the new sealingrings must be coatedwith l u b r i c a t i n go i l b e f o r e t h e p i s t o n i s a s s e m bled. Coat all screws with Molybdenum Disulp h i d e( M o S 2 ) . Assemblethe piston in the reverseorder to d i s a s s e m b l yU. s e t h e g u i d e s c r e w t o e n s u r e the correct positioningof the piston rod in relationto the piston crown. N ot

Tighten all the screws diagonally to the torque stated in Data.

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Piston Overhaul

Plate Edition

902-1.3 2OS

Page

14 (18)

1 3 . L o c k a l l t h e s c r e w s w i t h l o c k i n gw i r e . M o u n t t h e l o c k i n gw i r e i n s u c h a w a y t h a t the wire is tightened if one of the screws works loose. See Procedure 913-7. 14. Fill the pistonand piston rod with lubricating oil. M o u n t t h e p r e s s u r e - t e s t i n tgo o l a r o u n d t h e base of the piston rod. Pressure-test the piston at the pressure stated on the data sheet. Check the contact surfaces of the piston a n d t h e s e a l i n gr i n g s f o r t i g h t n e s s .

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Check that there are no cracks in the piston crown.

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D-15

Piston

iziEfrE-ilIANB&UI

2.

Mounting

tu

Plate

Edition Page

942-1.4

208 15(18)

1 . Checkthe pistonrings and pistoncrown in a c c o r d a n c ew i t h P r o c e d u r e9 0 2 - 1 . 1 . C o a t t h e p i s t o n r i n g s ,p i s t o n r o d a n d c y l i n d e r l i n e r w i t h l u b r i c a t i n go i l .

2 . M o u n t t h e l i f t i n gt o o l o n t h e p i s t o n c r o w n . 3 . Ensure that the stuffing box is correctly pos i t i o n e do v e r t h e g u i d e p i n s i n t h e d i s t a n c e pieces mounted on the piston rod foot. C o a t t h e O - r i n g so f t h e s t u f f i n gb o x w i t h o i l . 4 . Remove the protective rubber cover from the crosshead.

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Piston Mounting

5.

5. Removethe cover from the piston rod stuffing box o p e n i n g i n t h e b o t t o m o f t h e c y l i n derunit. 6. Turn the crosshead to a position 45' from TDC. M o u n tt h e g u i d e r i n g f o r p i s t o nr i n g so n t h e c y l i n d e rl i n e r . 7. Lower the piston into the cylinderliner w h i l e g u i d i n gt h e p i s t o nr o d f o o t t h r o u g ht h e c u t - o u t i n t h e s t u f f i n gb o x f l a n g e - u n t i l t h e piston rings are inside the liner, corres p o n d i n gt o t h e l i f t i n gt o o l l a c k i n ga b o u t 3 0 m m i n l a n d i n go n t h e g u i d e r i n g .

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Plate

902-1.4

Edition Page

16(18)

208

f

TiiEI

EI'|ANB&IT

Piston Mounting

Plate Edition

902-1.4

Page

17 (18)

8 . Turnthe crossheadto TDC while checking

that the guideringof the crossheadenters the centreholein the pistonrod. 9 . After turningthe pistonfully to TDC, un-

screwthe adjustableclaw of the liftingtool and pull the liftingtool free of the lifting groovein the piston Removethe liftingtool and the guide ring for pistonrings. Turnthe crossheadwith the pistonrod and pipedownfar enoughto perthe telescopic mit tighteningof the pistonrod screws.

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10. Remove the distance pieces from the piston rod foot.

D-17

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Mountthe hydraulic screwson the studs. for operationof the hydrauiicjack, see procedure 913

a 7:ttrl:-:TlE ilAl,lB&u|

Piston Mounting

Plate EdiM

902-1.4

Page

18 (18)

1 1 . T i g h t e n d o w n t h e p i s t o n r o d s t u f f i n gb o x b y means of the screws through the inner holes in the stuffing box flange. See Data. 1 2 . M o u n tt h e c y l i n d e rc o v e rs t u d sw i t h t h e s t u d setter. See 903-1.4 1 3 . S m e a r t h e p i s t o n r o d w i t h m o l y b d e n u md i s u l p h i d e ,a n d t u r n t h e c r a n k s h a f ta c o u p l e of revolutions. M o u n t t h e c y l i n d e rc o v e r . See Procedure 901-1.4. N s

14. Start the engine and keep it running for a b o u t 1 5 m i n u t e sa t a n u m b e ro f r e v o l u t i o n s correspondingto very slow.

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T h e n s t o p t h e e n g i n ea n d i n s p e c tt h e p i s t o n rod and stuffing box.

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Piston Rod Stuffing Box Data

Standard Tools: SeeSection913

SAFETYPRECAUTIONS X

Stoppedengine

X

Blockthe startingmechanism

X

Shut off startingair suPPlY

X

Engageturninggear

X

Shut off coolingwater

X

Shut off fuel oil

X

Shut off lubricationoil

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Lock turbochargerrotors

Data Ref.

DescriPtion

Plate Edition Data

Value Unit

D-1 Stuffingbox comPlete

50 kg

D-2 Stuffingbox half

20 kg

D-3 Tighteningtorquefor stuffingbox halves

80 Nm

D-4 Tighteningtorquefor stuffingbox flanges

80 Nm

D-5 Tighteningtorquefor innerscrews

80 Nm

D-6 Verticalclearanceuppermostrings

0.16-0.28 mm

D-7 Verticalclearancelowermostrings

0.08-0.13mm

D-B Ring-endclearancesuppermostrings

4x6mm

D-9 Ring-endclearanceslowermostrings

3x3mm

D-l0 Checklengthfor the six uppermostsPrings: - F 0 = 0 N . . . . . . . . . . . .h. = .... - F1 = 79 +l- 3 N.......L1= - F 2 = 1 2 3+ l - 7 N . . . . L . 2=

6 3 9r n m 763 rnm 835mm

D-11 Checklengthfor the four lowermostsPrings: - F 0 = 0 N . . . . . . . . . . . .h. = .... - F1= 80 +/- 3 N.......L1= - F z = 1 1 7+ l - 7 N . . . .L. 2=

4 9 6m m 646 mm 7 1 4m m

102-2 17 1 (2)

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Piston Rod Stuffing Box Data

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075

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Plate Edition

102-2 17 2 (2)

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Plate

Piston Rod Stuffing Box

Edition Page

Checking

902-2.1 212

1 (e)

1.

1. After the piston rod stuffingbox has been dismantled,see Procedure902-2.2,check the followingring clearances: Uppermostscraperring and sealinqrinqs Vertical clearance between sealing ring sectionand groove. Clearanceat ring ends (scraperring). Totalclearance(scraperring). Clearanceat ring ends (sealingrings). Totalclearance(sealingrings). Lowermostscraperrinqs

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Vertical clearance between scraper ring and groove. Clearanceat ring ends. Totalclearance.

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The ring clearancesstatedin Data applyto new rings.

2.

D-10

As a general guide, it is recommendeddependingon the overhaulingintervalsand one's own experience - to replace sealing rings and scraper rings when the specified clearance values have changed by more than 50%. 2. Check the length of the springs at different loads. Adjust the loads to achieve the lengths stated in Data. lf the loads necessaryare outsidethe limits stated in Data,the springs must be discarded.

D-11

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TrT-illANB&U|

Piston Rod Stuffing Box Dismantling

Plate Edition Page

902-2.2 212

2 (e)

lf, in the periodbetweenpistonoverhauls,it becomes necessaryto inspect the piston rod stuffingbox, proceedas foflows: 1. Turnthe crossheadto about90" from TDC. Mount the rubber hose aroundthe piston rod to protectthe crossheadbearingfrom impurities. 2 . Removethe drainoil pipeand all innerrnost screws and all outer screws with locking wire exceptfor two screws placeddiametricallyoppositein the stuffingboxflange, longitudinally to the engine. 3 . Mount the worktableround the piston rod so that the two screws can be loosened throughthe holes.

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Piston Rod Stuffing Box Dismantling

4 . Remove the two long screws from the

worktable. Mountthem in the stuffingbox throughthe holes in the worktable. Removethe remainingtwo screwsfrom the stuffingbox. 5 . Turn the pistonto BDC, therebywithdraw-

ing the stuffingbox from the cylinderframe bottom. Removethe two long dismantlingscrews from the stuffingbox and mountthem in the worktable.

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6 . By means of the four short screws in the

worktable,pressthe stuffingbox out of the flange. For overhaulingthe stuffing box, see Procedure 902-2.3.

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Plate

Edition Page

902-2.2 212

3 (e)

f

TTiFTtE-ilANB&lT

Piston Rod Stuffing Box Overhaul

Plate

Edition Page

902-2.3 212

4 (s)

Outsidethe engine Normally,overhaulof the pistonrod stuffingbox is carriedout by routinemethodsin connection with the dismantling(pulling)of the pistons. During such overhauls,the piston rests on a supportplacedover one of the cut-outsin the top platform. Work on the stuffing box is then carried out from the platformbelow. o

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1. Mount two eye bolts in the stuffing box flange,and hook on two tackles. Liftthe stuffingbox a littleup the pistonrod, and mount the worktableround the piston rod at a suitableworkingheight. Landthe stuffingbox on the worktable,and removethe tackles and screws. 2. Removethe O-ringof the stuffingbox.lf the O-ring is intact and is to be used again, move it up the piston rod and secureit in this position,for examplewith tape. Removethe nuts from the stuffingbox assemblingbolts.

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Plate Edition

Piston Rod Stuffing Box Overhaul

Page

902-2.3 212

5 (e)

3. Take out the six bolts, and pull away one stuffingbox half. Mounttwo eye bolts on the stuffingbox half and removeit from the worktable. 4 . Usinga feelergauge,measurethe vertical

clearanceof the rings. See Procedure902-2.1. 5 . Removethe remainingstuffingbox half and

press all sealing rings and scraper rings down againstthe worktable. 6. Measurethe clearance betweenthe ring segmentsto determine whether replacement is necessary. See Procedure902-2.1.

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7.

Dismantle and stack the rings in the same order as when fitted in the stuffing box.

D-10 rv,-1rr =.

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Carefullyclean all the ring segments. Inspect and assess the surface quality of the sealing rings. lf their sliding surfaces have scratchesor marks, replace the rings.

D-11

7 . Check the lengths of the springs. See Procedure 902-2.1. 8 . Inspect the surface of the piston rod. lf small longitudinalscratches have occurred (caused by poorly adapted stuffing box rings), smooth the piston rod surface carefully with a fine grained carborundumstone. In the case of coarse scratches, it may prove necessary to machine-grindthe surface in a workshop.

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9 . Clean the halves of the stuffing box housing-

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Piston Rod Stuffing Box Overhaul

Edition Page

902-2.3 212

6 (e)

10. Lubricatethe pistonrod (in the area where all the ring units in the stuffingbox will be positioned) with molybdenumdisulphide (MoSj. Assemble all the stuffing box ring units round the piston rod, on the worktable,in the followingway: . Place the lowermostscraper ring segmentson the worktable. (t) o o F.. ro (! ct o) I

. Place the spring round the segments, and hookthe springendstogether. Repeat this procedurefor the remaining scraperrings. On top of the scraperrings,assemblethe two sealingring units (eachconsistingof a 4-partand an 8-partring). Assemblethe 8-partsealingringso that the two guide pins face upwards,place the springround the segmentsand, hook the springends together. Assemblethe 4-partsealingring abovethe 8-partsealingring. Pushthe two ringstogetherin sucha mannerthatthe guidepins in the lower sealingring engagewith the two holesin the uppersealingring. Finally,assemblethe uppermostring unit (consisting of a 4-partscraperring and an 8-partsealingring). 11. Use the stuffingbox 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 groovesin the stuffingbox housing.Subsequently,pushthe stuffingbox halfinto contact withthe pistonrod, roundthe ring units.

a TT,uTTrEt|AillB&11

Piston Rod Stuffing Box Overhaul

12. Checkthe ring clearanceagain. Then placethe other half of the stuffingbox housingon the worktable,pushing it into placeroundthe rings. Mountand tightenup the fitted boltsto the torquespecifiedon the Data Sheet. Mountthe O-ringin the stuffingbox groove. 13. Mounteye boltsand wire ropes,and lift the stuffingbox a little. Removethe worktableand lowerthe stuffing box until it rests againstthe distance pieceson the piston rod foot. Removewire ropes and screws.

Plate

902-2.3

M Page

7 (9)

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7f7'E]||ANB&II

Piston Rod Stuffing Box Mounting

Plate Edition

902-2.4 212

ffi

1. After overhauling,assemble the stuffing box halveson top of the four screws. Mountthe two longscrewsfrom the worktable in the stuffingbox. Turn down the short screws so that the stuffingbox landson the flange. 2. Turn the piston upwardsuntil the stuffing box is in placein the cylinderframe. Note! Makesurethat the two guidepins in the flangeenterthe guideholesin the bottom of the cylinderframe.

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3 . Mounttwo screwsin the flangethroughthe holesin the worktable.

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PistonRod StuffingBox Mounting

4 . Removethe long screwsfrom the stuffing

box and mountthem in the worktable. Removethe worktablefrom the pistonrod. 5 . Mountand tightenall the innerand outer

screwsfor the stuffing box. See Data. The outer screwsto be lockedwith locking wire. 6 . Removethe protectingrubber cover from

the pistonrod/crosshead. o

Smearthe pistonrod with molybdenum disulphide.

o GI

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o (t) co

Then turn the crankshafta coupleof revolutions. Start up the engineand keepit runningfor approx.fifteenminutesat a numberof revolutionscorrespondingto very slow or idle speed. Thenstopthe engineand inspectthe piston rod and stuffingbox.

@

o a N I N a a o

Plate

Edition Page

902-2.4 212

e (e)

---5

717'

Plate 90251-177

Piston and Piston Rod Panel

TIT.ltlANB&lI

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109

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7"-,,7, TWE-iIANB&II

Item No. 040 051 075 087 099 109 110 122 134 158 160

Piston and Piston Rod Panel

Item Description Liftingfor pistonrodfoot Liftingand tiltingscrew Templatefor pistontop Distancepiecefor stuffingbox Coverfor stuffingbox hole Mountingtoolfor stuffingbox hole Pressuretoolfor piston Workingtablefor stuffingbox expanderfor pistonring Guidescrewfor pistoncrown Dismantling screwfor pistonskirt

040- *) Toolpanel,completewithtools 1 6 0 .) Optionalextras *) Optionalextras

Item No.

Item Description

Plate -177 90251

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TTE-I||ANB&IT

Piston and Piston Rod

056

Plate 90261-95

I

7F7.7TIEilANB&Uf

Item No. 019 020 032 056

Item Description Guideringfor piston Liftingtoolfor piston Liftingcrossbar Supportfor piston

Piston and Piston Rod

Item No.

Item Description

Plate 90261-95

INTRODUCTION

C Y L I N D E RC O V E R

PISTON WITH ROD AND STUFFING BOX C Y L I N D E RL I N E R A N D CYLINDER LUBRICATOR

WITH CONNECTING ROD CROSSHEAD CRANKSHAFT,THRUST BEARING A N D T U R N I N GG E A R M E C H A N I C A LC O N T R O LG E A R

STARTINGAIR SYSTEM

EXHAUSTVALVE

x

FUEL OIL SYSTEM

z

TURBOCHARGER SYSTEM

ul CT

SAFETY EQUIPMENT

ASSEMBLY OF LARGE PARTS

(r)

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GylinderLiner Data

Stoppedengine

X

Blockthe startingmechanism

X

Shutoff startingair suPPlY

X

Engageturninggear

X

Shut off coolingwater

X

Shutoff fuel oil

X

oil Shutoff lubricating

fr* ---"-:-€

Lockturbochargerrotors

Data Ref.

Description

ValueUnit

D03-01 Liftingtool screws,tightening torque

1 5 0N m

D03-03 Cylinderdiameter,new

500 mm

D03-04 Pistoncleaningringdiameter, 498.3kg new D03-05 Cylinderliner,comPlete D03-06 Coolingjacket D03-16 Pistoncleaningringradial width,new max.wear D03-17 PC-ring/Liner deviation

1480kg 1 3 0k g

3 8 . 8m m

0.5mm

criteria: D03-1B PC-ringreplacement D03-19 Cyl. coverstud

2-3mm

Linerdiameter:500 mm Linerwear: lnstall: 0 - 0 . 5 0m m StandardPC-ring (newor max.wearof diameter0.50mm 0 . 5 0- 1 m m OversizePC-ring >1mm

D u m m yr i n g

Edition Data

Standard Tools: SeeSection913

SAFETYPRECAUTIONS X

Plate

280_760 Nm

103-1 0063 1 (2)

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,=ri

CylinderLiner

Trr'-[1ANB&tI

Data

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Plate

103-1

Edition 2 (2)

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CylinderLiner Checking

D03-03

Clean the cylinderliner and scavengeair ports. 2. Positionthe cylinderlinermeasuring tool. Measurethe cylinderliner with an inside micrometer at the positionsindicatedon the measuringtool. See Data. in the fore-and-aft 3 . Takemeasurements and athwartshipdirections. 4 . Checkand assessthe conditionof the cyl-

givinderlineraccordingto the description en in Volumel, Chapter707. o)

on the cylinderliner runningsurface,and grind awaythe wear ridges. SeeProcedure 903-1.3.

Page

903-1.1 0253 1(11)

1.

1. Dismountthe cylindercover, piston and PC-ring. See Procedure901-1.2. See Procedure902-1.2.

5 . Carefullyscratchover any scoresor marks

Plate Edition

N (f)

o

o

pointsof the cylinder 6. Checkthe lubricating pumping by cylinderoil to each individual point. lubricating Cleanany blockedlubricating duct. (o cf) N

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4.

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7.

CylinderLiner Checking

Plate Edition Page

903-1.1 0253

2 (111

7 . P i s t o nc l e a n i n g( P C ) r i n g : The PC ring is to be regarded as an integrated part of the liner and it is intendedto follow the service life of the liner. D u r i n g i n s p e c t i o no f t h e p i s t o n a n d l i n e r , the PC ring must also be inspected. W h e n t h e p i s t o n i s r e m o v e d ,t h e P C - r i n g must always be taken up before the piston. See Procedure 902-1.2.

FN

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= (t 8.

8. Measure the PC ring radial width B, and find the most worn place. Compare with d a t a D 0 3 - 1 6 a n d c a l c u l a t et h e w e a r o f t h e P C r i n g . M u l t i p l yt h e w e a r b y 2 t o g e t t h e PC ring diameter wear. Measure the liner in the fore-and-aft and athwartship directions at piston skirt TDC p o s i t i o n ,c o r r e s p o n d i n gt o m e a s u r i n gp o i n t N o . 5 o n t h e l i n e r m e a s u r i n gt o o l . C o m p a r e the measurementswith the diameter of a new liner as stated in data. Calculate the wear of the liner.

N

o

Compare the PC ring diameter wear with the wear of the liner.lf wear of the two components does not deviate more than D031 7 , t h e n r e i n s t a l tl h e P C r i n g . lf the deviation between PC ring wear and l i n e rw e a r i s m o r e t h a n D 0 3 - 1 7 ,o r i f t h e P C ring is broken or cracked, replace the ring with a new PC ring, an oversize ring or a d u m m y r i n g a c c o r d i n gt o t h e t a b l e i n D 0 3 18 on the Data sheet. lf it is needed to installan oversizePC ring, contact MAN B&W Diesel for advice.

When a new liner is installed,also a new PC ringmustbe installed. Whena newliner is ordered,alsoa new PC ring mustbe ordered.

I

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GylinderLiner Dismantling

1. Dismountthe cylindercover. See Procedure901-l .2. Discardthe sealingringfromthe top of the cylinderliner. Turnthe pistondownfar enoughto makeit possibleto removethe wear ridgesat the top of the liner. See Procedure903-1.3.

D03-01

Dismountthe pistonand the PC-ring. See Procedure902-1.2. Mountthe two liftingscrewsin the cylinder liner. Note! Tighten the liftingscrews to the torque stated in Data.

$ N N N

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2.

C h e c k w i t h a 0 . 0 5 m m f e e l e rg a u g e t h a t there is no clearancebetweenthe screws a n d t h e c y l i n d e rl i n e r . T h i s m u s t b e d o n e w h e n e v e rt h e l i f t i n g t o o l s a r e m o u n t e do n t h e l i n e r .

2 . Disconnect- at the exhaust side of the cyli n d e r - t h e o i l p i p e s l e a d i n gf r o m t h e c y l i n d e r l u b r i c a t o rt o t h e n o n - r e t u r nv a l v e s . D i s m o u n tt h e f o u r c o o l i n gw a t e r p i p e s- b e tween the cooling jacket and cylindercover - and clean them carefully.

N

s N N

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(f)

o

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Plate Edition Page

903-1.2 0253 3 (11)

f

CylinderLiner

|r,ErrlfrillNB&tI

Dismantling

3.

3.

Plate

Edition Page

903-1.2 0253 4 (11)

Remove the screws of the cooling water inlet pipe.

4. Attach the crane hook to the lifting crossbar. Hook the chains from the lifting tools on to t h e c r o s s b a ra n d l i f t t h e c y l i n d e r l i n e r w i t h the coolingjacket out of the cylinderframe.

Note! (fJ

requirethe removalof one or morecylinthe der coverstudsbeforedismantling c y l i n d elri n e r .

* N

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D03-05

ll ll tl ll tl

fg

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C l e a n t h e c y l i n d e rf r a m e i n t e r n a l l y t, a k i n g special care with the contact surfaces for t h e c y l i n d e rl i n e r a t t h e t o p o f t h e c y l i n d e r fr a m e . Discard the O-rings on the cooling water pipes. Clean the pipes carefully.

\ s

L a n d t h e c y l i n d e rl i n e r v e r t i c a l l yo n , f o r i n s t a n c e ,a c o u p l e o f p l a n k s .

f

ifrEfrEiIANB&IT

CylinderLiner Dismantling

5. The lifting screws are also used for transp o r t i n g t h e c y l i n d e rl i n e r .

Plate M

903-1.2

Page

5 (11)

5.

D03-05

00CICICI0

l

T,fliwtrwE-ilANB&lT

CylinderLiner Overhaul

1.

Plate Edition Page

903-1.3 6 (11)

1 . Unscrewthe nuts on the non-returnvalves

and removethe valves. Cleanand inspectthe non-returnvalves. 2 . Attach two tackles to the crossbar,as shown. Mount two liftingeye bolts in the cooling jacket. Hookthe tackleson to the liftingeye bolts on the coolingjacketand haul tight. s c\l c\

Removethe two liftingscrewsfrom the cyli n d e rl i n e r .

o)

z

Removethe four clampswhichfix the cooling jacketto the cylinderliner.

2.

3 . Liftthe coolingjacketawayby meansof the tackles,and land it on the woodenplanks.

N N CO N

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3.

D03-06

N c\l c? (f,

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Plate

CylinderLiner Overhaul

4.

4 . Check and assess the conditionof the cyli n d e r l i n e r a c c o r d i n gt o t h e d e s c r i p t i o ng i v e n i n V o l u m e l , C h a p t e r7 O 7 . Carefullyscratch over any scores or marks on the cylinder liner running surface, by m e a n s o f a r o u g h g r i n d s t o n eh e l d i n t h e hand.

X

ffi

C h e c k i n t h e t o p o f t h e l i n e rf o r a w e a r r i d g e (where the piston rings reversedirection).lf there is any sign of a wear ridge,it is necessary to create a groove by grinding.The groove serves to prevent the build-up of a new wear ridge. 5 . I t i s r e c o m m e n d e dt o u s e a w e a r r i d g e m i l l ing machine to create the groove. For use of the milling machine, see supplier's instruction. 6 . Alternatively,place an old piston ring on the top of the piston and turn to a positionthat e n a b l e st h e g r i n d i n gd i s c t o r e s t o n t h e o l d p i s t o n r i n g w h i l e r e m o v i n gt h e w e a r r i d g e . U s e a g r i n d i n gd i s c w i t h a r o u n d e d g e .

$

N N (o

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5.

Check the distance G before grindingto ascertain that the wear ridge was caused by the top ring at TDC. s

The maximum depth of the groove is calculated as Sr"* - D x 0.0045.

Note! grooveis madewitha regularrounding as shownin the sketch.

Edition Page

C' N

c? CO o (D

903-1.3 0253 7 (11)

f

'-T'rffifTE-illANB&u|

CylinderLiner Overhaul

Plate Edition Page

903-1.3 0253 I (11)

7 . Replacethe two uppermost O-ringson the

cylinderliner. 8 . Lowerthe coolingjacketon to the cylinder

liner. Note! Make sure that the scratch marks in the f u e l p u m p s i d e o f t h e c y l i n d e rl i n e r a n d coolingjacket coincide.