s2609

Dispatch Pattern, Testing, Spares and Tools

Painting of Main Engine

The painting specification (Fig. 9.01) indicates theminimum requirements regarding the quality andthe dry film thickness of the coats of, as well as thestandard colours applied on MAN B&W engines builtin accordance with the Copenhagen standard.

Paints according to builders standard may be usedprovided they at least fulfil the requirements statedin Fig. 9.01.

Dispatch Pattern

The dispatch patterns are divided into two classes,see Figs. 9.02 and 9.03:

A: Short distance transportation and short termstorage

B: Overseas or long distance transportation orlong term storage.

Short distance transportation (A) is limited by a du-ration of a few days from delivery ex works until in-stallation, or a distance of approximately 1,000 kmand short term storage.

The duration from engine delivery until installationmust not exceed 8 weeks.

Dismantlingof theengine is limitedasmuchaspossible.

Overseas or long distance transportation or longterm storage require a class B dispatch pattern.

The duration from engine delivery until installation isassumed to be between 8 weeks and maximum 6months.

Dismantling is effected to a certain degree with theaim of reducing the transportation volume of the in-dividual units to a suitable extent.

Note:Long term preservation and seaworthy packing arealways to be used.

Furthermore, the dispatch patterns are divided intoseveral degrees of dismantling in which 1 com-prises the complete or almost complete engine.Other degrees of dismantling can be agreed upon ineach case.

When determining the degree of dismantling, con-sideration should be given to the lifting capacitiesand number of crane hooks available at the enginemaker and, in particular, at the yard (purchaser).

The approximate masses of the sections appearfrom Fig. 9.03. The masses can vary up to 10% de-pending on the design and options chosen.

Lifting tools and lifting instructions are required for alllevels of dispatch pattern. The lifting tools (4 12 110 or4 12 111), are to be specified when ordering and itshould be agreed whether the tools are to be returnedto the engine maker (4 12 120) or not (4 12 121).

Furthermore, it must be considered whether a dry-ing machine, option 4 12 601, is to be installed dur-ing the transportation and/or storage period.

Shop trials/Delivery Test

Before leaving the engine makers works, the engineis to be carefully tested on diesel oil in the presenceof representatives of the yard, the shipowner andthe classification society.

The shop trial test is to be carried out in accordancewith the requirements of the relevant classificationsociety, however a minimum as stated in Fig. 9.04.

MAN B&W Diesels recommendations for trials areavailable on request.

An additional test may be required for measuring theNOx emmissions, if required, option: 4 14 003.

MAN B&W Diesel A/S S26MC Project Guide

480 100 100 178 54 99

9.01

Spare Parts

List of spares, unrestricted service

The tendency today is for the classification societiesto change their rules such that required spare partsare changed into recommended spare parts.

MAN B&W Diesel, however, has decided to keep aset of spare parts included in the basic extent of de-livery (4 87 601) covering the requirements and rec-ommendations of the major classification societies,see Fig. 9.05.

This amount is to be considered as minimum safetystock for emergency situations.

Additional spare parts recommended byMAN B&W Diesel

The above-mentioned set of spare parts can be ex-tended with the Additional Spare Parts Recom-mended by MAN B&W (option: 4 87 603), which fa-cilitates maintenance because, in that case, all thecomponents such as gaskets, sealings, etc.re-quired for an overhaul will be readily available,see Fig. 9.06.

Wearing parts

The consumable spare parts for a certain period arenot included in the above mentioned sets, but canbe ordered for the first 1, 2, up to 10 years service ofa new engine (option 4 87 629), a service year beingassumed to be 6,000 running hours.

The wearing parts supposed to be required, based onour service experience, are divided into 14 groups,see Table A in Fig. 9.07, each group including thecompo-nents stated in Tables B.

Large spare parts, dimensions and masses

The approximate dimensions and masses of thelarger spare parts are indicated in Fig. 9.08. A com-plete list will be delivered by the engine maker.

Tools

List of standard tools

The engine is delivered with the necessary specialtools for overhauling purposes. The extent of themain tools is stated in Fig. 9.09. A complete list willbe delivered by the engine maker.

The dimensions and masses of the main tools ap-pear from Figs. 9.10.

Most of the tools can be arranged on steel platepanels, which can be delivered as an option: 4 88660, see Fig. 9.11 Tool Panels.

If such panels are delivered, it is recommended toplace them close to the location where the overhaulis to be carried out.


480 100 100 178 54 99

9.02


480 100 100 178 55 00

9.03

Fig. 9.01: Specification for painting of main engine: 4 81 101

Components to be paintedbefore shipment from workshop

Type of paintNo. ofcoats/

Total dryfilm

thicknessm

Colour:RAL 840HRDIN 6164MUNSELL

Component/surfaces, inside engine, ex-posed to oil and air1. Unmachined surfaces all over. However casttype crankthrows, main bearing cap, crossheadbearing cap, crankpin bearing cap, pipes insidecrankcase and chainwheel need not to bepainted but the cast surface must be cleaned ofsand and scales and kept free of rust

Engine alkyd primer, weatherresistant

Oil and acid resistant alkyd paint.Temperature resistant to mini-mum 80 C

2/80

1/30

Free

White:RAL 9010DIN N:0:0.5MUNSELL N-9.5

Components, outside engine2. Engine body, pipes, gallery, brackets etc. Engine alkyd primer, weather re-

sistant

Final alkyd paint resistant to saltwater and oil, option: 4 81 103

2/80

1/30

Free

Light green:RAL 6019DIN 23:2:2MUNSELL10GY8/4

Heat affected components:3. Supports for exhaust receiverScavenge air-pipe inside

Paint, heat resistant to minimum200 C

2/60 Alu:RAL 9006DIN N:0:2MUNSELL N-7.5

Components affected by water and cleaningagents4. Scavenge air cooler box inside Complete coating for long term

protection of exposed to moder-ately to severely corsive environ-ment and abrasion

2/75 Free

5. Gallery plates topside Engine alkyd primer, weather re-sistant

2/80 Free

6. Purchased equipment and instrumentspainted in makers colour are acceptableunless otherwise stated in the contract

ToolsUnmachined surfaces all over on handtools andlifting tools

Purchased equipment painted in makers colouris acceptable, unless otherwise stated in thecontract

Oil resistant paint 2/60 Orange red:RAL 2004DIN 6:7:2MUNSELLN-7.5r 6/12

Tool panels Oil resistant paint 2/60 Light grey:RAL 7038DIN:24:1:2MUNSELL N-7.5

Note:All paints are to be of good quality. Paints according to builders standard may be used provided they at least fulfil theabove demands.Delivery standard for point 2, is a primed and finally painted condition, unless otherwise stated in the contract.

178 3U0 20-7.1

Class A + B: Comprises thefollowing basic variants:

Dismounting must be limited as much as possible.

The classes comprise the following basic variants:

A1 Option: 4 12 021, or B1, option: 4 12 031

Engine

Spare parts and tools

A2 Option: 4 12 022, or B2 option: 4 12 032

Top section inclusive cylinder liner, cylindercovers complete, camshaft, piston rods com-plete, connecting rods complete, cooler boxwith cooler insert, exhaust receiver,turbocharger(s) and platforms with pipes

Bedplate/cranshaft section inclusive turninggear and pipes

Remaining parts, stay bolts, chains and etc.

Note:The engine supplier is responsible for the necessarylifting tools and lifting instruction for transportationpurpose to the yard. The delivery extent of the liftingtools, ownership and lend/lease conditions is to bestated in the contract.

Furthermore, it must be stated whether a drying ma-chine is to be installed during the transportationand/or storage period.


412 000 002 178 55 01

Fig. 9.02: Dispatch pattern, engine with turbocharger on the aft end

9.04

A1 + B1

Engine complete

A2 + B2

Bedplate/cranchaft 178 40 85-9.0

Top section


412 000 002 178 55 01

Pattern Section

4 cylinders 5 cylinders 6 cylinders 7 cylinders 8 cylinders

Mass Length Mass Length Mass Length Mass Length Mass Length

in t in m in t in m in t in m in t in m in t in m

A1+B1 Engine complete 31.5 3.8 36.5 4.3 42.3 4.8 47.5 5.3 52.9 5.8

A2+B2 Top section 20.2 3.8 23.9 4.3 28.2 4.8 31.9 5.3 36.0 5.8

Bedplate/cranchaft 10.8 3.2 12.0 3.7 13.4 4.2 14.9 4.7 16.1 5.2

Remaining parts 0.5 0.6 0.7 0.8 0.9

Pattern Section

9 cylinders 10 cylinders* 11 cylinders* 12 cylinders*

Mass Length Mass Length Mass Length Mass Length Height Width

in t in m in t in m in t in m in t in m in m in m

A1+B1 Engine complete 58.2 6.3 67.9 6.8 73.6 7.3 78.9 7.8 4.9 3.3

A2+B2 Top section 39.7 6.3 46.7 6.8 50.9 7.3 54.6 7.8 3.5 3.3

Bedplate/cranchaft 17.5 5.7 20.1 6.2 21.5 6.7 23.0 7.2 1.6 1.9

Remaining parts 1.0 1.1 1.2 1.3

The weights are for standard engines with solidforged crankshaft, integrated crosshead guides in frame boxand MAN B&W turbocharger.

All masses and dimensions are approximate and without packing and lifting tools. The masses of turningwheel, turbocharger specified in dispatch pattern outline can vary, and should be checked.

Moment compensators and tuning wheel are not included in dispatch pattern outline. Turning wheel isincluded.

Note:

* 10-12S26MC engines are with turbochargers on exhaust side

The masses can vary up to 10% depending on the design and the options chosen.

Fig. 9.03: Dispatch pattern, list of masses and dimension for engines with turbocharger aft

178 40 86-0.0

9.05

Before leaving the factory, the engine is to be care-fully tested on diesel oil in the presence of represen-tatives of Yard, Shipowner, Classification Society,and MAN B&W Diesel.

Minimum delivery test:

Starting and manoeuvring test at no load

Load testEngine to be started and run up to 50%of Specified MCR (M) in 1 hour.

Followed by:

0.50 hour running at 50% of specified MCR



0.50 hour running at 110% of specified MCR.

Only for Germanischer Lloyd:

0.75 hour running at 110% of specified MCR.

At each load change, all temperature and pressurelevels etc. should stabilise before taking new engineload readings.

Governor tests, etc:

Governor test

Minimum speed test

Overspeed test

Shut down test

Starting and reversing test

Turning gear blocking device test

Start, stop and reversing from engine sidemanoeuvring console.

Fuel oil analysis to be presented. All tests must becarried out on diesel or gas oil.

An additional test may be required for measuring theNOx emissions, option: 4 14 003.


486 001 010 178 55 02

178 36 00-7.1

9.06

Fig. 9.04: Shop trial running/delivery test: 4 14 001

Cylinder cover, section 901 and others1 Cylinder cover complete with fuel, exhaust,

starting and safety valves, indicator valve andsealing rings (disassembled)

Piston, section 9021 Piston complete (with cooling pipe), piston

rod, piston rings and stuffing box,studs and nuts

1 set Piston rings for 1 cylinder

Cylinder liner, section 9031 Cylinder liner with sealing rings and gaskets

1/2 set Studs for 1 cylinder cover

Cylinder lubricator, section 9031 Cylinder lubricator, of largest size, complete

Connecting rod, and crosshead bearing, section 9041 Telescopic pipe with bushing for 1 cylinder1 Crankpin bearing shells in 2/2 with studs

and nuts1 Crosshead bearing shell lower part with

studs and nuts2 Thrust piece

Main bearing and thrust block, section 9051 set Thrust pads for one face of ech size, if different

for "ahead" and "astern"

Chain drive, section 9061 Of each type of bearings for:

Camshaft at chain drive, chain tightener and in-termediate shaft

6 Camshaft chain links (only for ABS, DNVC, LR,NKK and RS)

1 Cylinder lubricator drive: 6 chain links or gearwheels

1 Guide ring 2/2 for camshaft bearing

Starting valve, section 9071 Starting valve, complete

Exhaust valve, section 9082 Exhaust valves complete (Only 1 for GL)1 Pressure pipe for exhaust valve pipe

Fuel pump, section 9091 Fuel pump barrel, complete with plunger1 High-pressure pipe, each type1 Suction and puncture valve, complete

Fuel valve, section 9091 set Fuel valves for half the number of cylinders

on the engine for ABS1 set Fuel valves for all cylinders on one engine

for BV, CCS, DNVC, GL, KR, NKK, RINa, RSand IACS

Turbocharger, section 9101 Set of makers standard spare parts1 a) Spare rotor for one turbocharger, including:

compressor wheel, rotor shaft with turbineblades and partition wall, if any

Scavenge air blower, section 9101 set Rotor, rotor shaft, gear wheel or equivalent

working parts1 set Bearings for electric motor1 set Bearings for blower wheel1 Belt, if applied1 set Packing for blower wheel

Safety valve, section 9111 Safety valve, complete

Bedplate, section 9121 Main bearing shell in 2/2 of each size1 set Studs and nuts for 1 main bearing


487 601 005 178 55 03

Delivery extent of spares

Class requirements Class recommendations

CCS:GL:

China Classification SocietyGermanischer Lloyd

ABS:BV:

American Bureau of ShippingBureau Veritas

KR: Korean Register of Shipping DNVC: Det Norske Veritas ClassificationNKK: Nippon Kaiji Kyokai LR: Lloyds Register of ShippingRINa: Registro Italiano NavaleRS Russian Maritime Register of Shipping

9.07

Fig. 9.05: List of spares, unrestricted service: 4 87 601

a) Only required for DNVC and RS.To be ordered separately as option: 4 87 660 for

other classiftication societies

The section figures refer to the instruction books.Subject to change without notice.

178 39 43-4.2

For easier maintenance and increased security in operation

Beyond class requirements

Cylinder cover, plate 9010144

501

504

100

pcspcs%pcs%pcs%

Studs for exhaust valveNuts for exhaust valveO-rings for cooling jacketColing jacketSealing betw. cyl.cover and linerSpring housings for fuel valveColling water pipes between liner andcover for one cylinder

Hydraulic tool for cylinder cover, plate 90161188

setpcspcs

Hydraulic hoses compl. with couplingsO-rings with backup rings, upperO-rings with backup rings, lower

Piston and piston rod, plate 902011522

boxpcspcspcs

Locking wire, 1=63 mPiston rings of each kindD-rings for piston skirtD-rings for piston rod

Piston rod stuffing box, plate 902051555

1510

1203030

pcspcspcspcspcspcspcspcs

Self locking nutsO-ringsTop scraper ringsPack sealing ringsCover sealing ringsLamellas for scraper ringsSprings for top scaper and sealing ringsSprings for scraper rings

Cylinder frame, plate 90301501

50

%pcs%

Studs for cylinder cover (1cyl.)BushingNuts for cyl.cover studs (1cyl.)

Cylinder liner and cooling jacket, plate 9030214

1005050

pcspcs%%%

Cooling jacket of each kindNon return valvesO-rings for one cylinder linerGaskets for cooling water connectionO-rings for cooling water pipes

% Refer to one cylinder

Lubricator drive, plate 9030523

CouplingDiscs

Connecting rod and crosshead, plate 9040112

Telescopic pipeThrust piece

Chain drive and guide bars, plate 9060141 set

Guide barLocking plates and lock washers

Chain tightener, plate 906032 Locking plates for tightener

Camshaft, plate 9061111

Exhaust camFuel cam

Camshaft bearing and roller guide housing,plate 90613

1 Packing

Indicator drive, plate 90612100

3% Gaskets for indicator valves

Indicator valve/cock complete

Regulating shaft, plate 906183 Resilient arm, complete

Arrangement of engine side console, plate 906212 Pull rods

Main starting valve, plate 907021111

pcspcspcspcs

Repair kit for main actuatorRepair kit for main ball valve*) Repair kit for actuator, slow turning*) Repair kit for ball valve, slow turning

*) if fitted


487 603 020 178 55 04

Fig. 9.06a: Additional spare parts recommended by MAN B&W, option: 4 87 603

9.08

178 39 44-6.1

Starting valve, plate 90704222

10012

%

PistonSpringBushingO-ringValve spindleLocking plate

Exhaust valve, plate 9080111

504

505050

10011

100

1100

1100100

pcspcs%pcs%%%%pcspcs%

pcs%pcs%%

Exhaust valve spindleExhaust valve seatO-ring exhaust valve/cylinder coverPiston ringsGuide ringsSealing ringsSafety valvesGaskets and O-rings for safety valvePiston completeDamper pistonO-rings and sealings between air pistonand exhaust valve housing/spindleLiner for spindle guideGaskets and O-ings for cool.w.conn.Conical ring in 2/2O-rings for spindle/air pistonNon-return valve

Valve gear, plate 9080235

pcspcs

Filter, completeO-rings of each kind

Valve gear, plate 9080512242442

pcspcspcspcspcspcspcspcs

Roller guide completeShaft pin for rollerBushing for rollerDiscsNon return valvePiston ringsDiscs for springSprings

Valve gear, details, plate 908061

1004

pcs%pcs

High pressure pipe, completeO-rings for high pressure pipesSealing discs

Cooling water outlet, plate 908102111

pcspcspcsset

Ball valveButterfly valveCompensatorGaskets for butterfly valve and comp.

Fuel pump, plate 909011133

5011

1004

pcspcspcspcs%pcspcs%pcs

Top coverPlunger/barrel, completeSuctions valvesPuncture valvesSealings, O-rings, gaskets and lock washersInternal springExternal springSealing and wearing ringsFelt rings

% Refer to one engine

Fuel pump gear, plate 9090212222

1002

pcspcspcspcspcs%pcs

Fuel pump roller guide, completeShaft pin for rollerBushings for rollerInternal springsExternal springsSealingsRoller

Fuel pump gear, details, plate 9090350 % O-rings for lifting tool

Fuel pump gear, details, plate 909041 pcs Shock absorber, complete

Fuel pump gear, reversing mechanism, plate 9090512

pcspcs

Reversing mechanism, completeSpare parts set for air cylinder

Fuel valve, plate 90910100100

3505033

%%pcs%%pcspcs

Fuel nozzlesO-rings for fuel valveSpindle guides, completeSpringsDiscs, +30 barThrust SpindlesNon return valve (if mounted)

Fuel oil high pressure pipes, plate 909131

100pcs%

High pressure pipe, complete of each kindO-rings for high pressure pipes

Overflow valve, plate 9091511

pcspcs

Overflow valve, completeO-rings of each kind


487 603 020 178 55 04

Fig. 9.06b: Additional spare parts recommended by MAN B&W, option: 4 87 603

9.09

178 39 44-6.1

Turbocharger, plate 9100011

pcspcs

Spare rotor, complete with bearingsSpare part set for turbocharger

Scavenge air receiver, plate 9100121

pcspcs

Non-return valves completeCompensator

Exhaust pipes and receiver, plate 9100312

1

pcspcs

set

Compensator between TC and receiverCompensator between exhaust valve andreceiverGaskets for each compensator

Air cooler, plate 9100516 pcs Iron blocks (Corrosion blocks)

Safety valve, plate 91101100

2%pcs

Gasket for safety valveSafety valve, complete

Arrangement of safety cap, plate 91104100 % Bursting disc


487 603 020 178 55 04

The plate figures refer to the instruction bookLiable to change without notice

Where nothing else is stated, the percentagewill refer to one engine

9.10

Fig. 9.06c: Additional spares part recommended by MAN B&W, option: 4 87 603

178 39 44-6.1


487 611 010 178 55 06

Table AGroup No. Plate Qty. Descriptions

1 90201 1 set Piston rings for 1 cylinder

1 set O-rings for 1 cylinder

2 90205 1 set Lamella rings 3/3 for 1 cylinder


3 90205 1 set Top scraper rings 4/4 for 1 cylinder

1 set Sealing rings 4/4 for 1 cylinder

4 90302 1 Cylinder liner

1 set Outer O-rings for 1 cylinder

1 set O-rings for cooling water connections for 1 cylinder

1 set Gaskets for cooling water connections for 1 cylinder

1 set Sealing rings for 1 cylinder

5 90801 1 Exhaust valve spindle

1 set Piston rings for exhaust valve air piston and oil piston for 1 cylinder

6 90801 1 set O-rings for water connections for 1 cylinder

1 set Gasket for cooling for water connections for 1 cylinder

1 set O-rings for oil connections for 1 cylinder

7 90801 1 Spindle guide

2 Air sealing ring

1 set Guide sealing rings for 1 cylinder

8 90801 1 Exhaust valve bottom piece

1 set O-rings for bottom piece for 1 cylinder

9 90805 1 set Bushing for roller guides for 1 cylinder

1 set Washer for 1 cylinder

10 90901 1 Plunger and barrel for fuel pump

1 Suction valve complete


11 90910 1 Fuel valve nozzle

1 Spindle guide complete


12 1 Slide bearing for turbocharger for 1 engine

1 Guide bearing for turbocharger for 1 engine

13 1 set Guide bars for 1 engine

14 2 Set bearings for auxiliary blowers for 1 engine

The wearing parts are divided into 14 groups, each including the components stated in table A.

The average expected consumption of wearing parts is stated in tables B for 1,2,3... 10 years service of a new engine, aservice year being assumed to be of 6000 hours.

In order to find the expected consumption for a 6 cylinder engine during the first 18000 hours service, the extent stated foreach group in table A is to be multiplied by the figures stated in the table B (see the arrow), for the cylinder No. and servicehours in question.

Fig. 9.07a: Wearing parts, option: 4 87 629

178 33 98-2.2

9.11


487 611 010 178 55 06

Table B

GroupNo

Service hours 0-6000 0-12000

Number of cylinders

Description 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12

1 Set of piston rings 0 0 0 0 0 0 0 0 0 4 5 6 7 8 9 10 11 12

2 Set of piston rod stuffing box,lamella rings 0 0 0 0 0 0 0 0 0 4 5 6 7 8 9 10 11 12

3 Set of piston rod stuffing box,sealing rings 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

4 Cylinder liners 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

5 Exhaust valve spindles 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

6 O-rings for exhaust valve 4 5 6 7 8 9 10 11 12 8 10 12 14 16 18 20 22 24

7 Exhaust valve guide bushings 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

8 Exhaust seat bottom pieces 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

9 Bushings for roller guides for fuelpump and exhaust valve 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

10 Fuel pump plungers 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

11 Fuel valve guides and atomizers 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

12 Set slide bearings per TC 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

13 Set guide bars for chain drive 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

14 Set bearings for auxiliary blower 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Table B

GroupNo.


Number of cylinders

Description 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12




4 Cylinder liners 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0











Fig.9.07b: Wearing parts, option: 4 87 629

9.12

178 30 98-2.2


487 611 010 178 55 06

Table B

GroupNo.


Number of cylinders

Description 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12




4 Cylinder liners 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0











Table B

GroupNo.


Number of cylinders

Description 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12




4 Cylinder liners 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0











Fig. 9.07c: Wearing parts, option: 4 87 629178 30 98-2.2

9.13


487 611 010 178 55 06

Table B

GroupNo.


Number of cylinders

Description 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12




4 Cylinder liners 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0


6 O-rings for exhaust valve 36 45 54 63 72 81 90 99 108

40 50 60 70 80 90 100

110

120



9 Bushings for roller guides forfuel pump and exhaust valve 4 5 6 7 8 9 10 11 12 4 5 6 7 8 9 10 11 12






Fig. 9.07d: Wearing parts, option: 4 87 629

9.14

178 33 98-2.2


487 601 007 178 55 07

9.15

Fig. 9.08 Large spare parts, dimensions and masses

Rotor for turbochargerType VTR304

80 kg

Rotor for turbochargerType NA34

40 kg

Cylinder cover 177 kgCylinder cover inclusive

starting and fuelvalves 190 kg

Piston completewith piston rod

153 kg

Cylinder liner 218 kgCylinder liner inclusive

cooling jacket387 kg

All dimensions are given in mm178 43 60-3.0

The engine is delivered with the following standardtools for dismantling and mounting of spare parts.Mass: Approximately 350 kg

Cylinder cover, section 9011 set Millingandgrinding tools forexhaustvalveseats1 set Cylinder cover studs, hydraulic jack1 Fuel valve extractor1 Cylinder cover lifting gear (part of cylinder

liner lifting gear)

Piston with rod and stuffing box, section 9021 set Lifting gears for piston1 Guide ring for piston1 Support for piston1 set Piston overhaul tools1 set Stuffing box overhaul tools1 set Tilting gears for piston1 Piston pressure testing tool

Cylinder liner and cylinder frame, section 9031 set Cylinder liner lifting gears1 set Piston lifting and tilting gears (only low lift)

Crosshead and connecting rod, section 9041 Lifting attachment for connecting rod1 Lifting tool for crosshead1 set Crosshead and crankpin bearing bolt

hydraulic jacks

Crankshaft and main bearing, section 9051 set Dismantling tools for lower main bearing shell1 Pin gauge for top dead centre1 Thrust bearing turning tool1 Crankcase relief valve testing tool

Camshaft, chain drive and reversingmechanism, section 9061 set Pin gauges for gear1 set Chain assembling tools1 set Chain disassembling tools1 set Main bearing studs, hydraulic jack1 set Cam adjusting tools

Starting air system, section 9071 set Starting valve overhaul tools

Exhaust valve and valve gear, section 9081 set Overhaul tools for high pressure connections1 Lifting device for roller guide1 Exhaust valve spindle and seat, pneumatic

grinding machine1 set Exhaust valve spindle and seat, checking

templates

Fuel valve and fuel pump, section 9091 Fuel valve test rig, VPU-6031 set Fuel pump barrel and plunger, lifting tools1 set Fuel oil high pressure pipe and connection,

overhaul tools1 set Fuel valve overhaul tools1 Fuel pump overhaul tool1 set Roller guide and fuel pump housing, lifting

tools

Turbocharger and air cooler system, section 9101 set Turbocharger overhaul and rotor cleaning

tools1 set Air cooler cleaning tools

Safety equipment, section 9111 Safety valve pressure testing tool

Main part assembling, section 9121 set Staybolt hydraulic jacks

General tools, section 913913.1 Accessories

1 Hydraulic high pressure pump,pneumatically operated

1 set High pressure hose and couplings

913.2 Ordinary hand tools1 set Torque spanners1 set Socket spanners1 set Ring ram spanners1 set Fork ram spanners1 set Special spanners

913.3 Miscellaneous1 set Shackles1 set Eye-bolts1 Indicator1 set Cylinder measuring tools


488 601 004 178 55 08

9.16

Fig. 9.09: Standard tools: 4 88 601178 42 04-7.0


488 601 004 178 55 08

9.17

Pos. Sec. Description Mass in kg1 902 Support for piston 27

Fig. 9.10a: Dimensions and masses of large tools178 42 08-5.0


488 601 004 178 55 08

9.18

Sec. Description Mass in kg

909 Fuel valve test rigSame pump as used for hydraulic jacks

15

178 30 32-7.0Fig. 9.10b: Dimensions and masses of tools


488 601 004 178 55 08

9.19

Pneumatic support grinding machine for exhaust valve spindles and bottom piecesDimensions in wooden box 440 x 380 x 185 mm, mass 25 kg.

Pneumatic or electric grinding machine for cylinder cover/cylinder liner, (option: 4 88 610)Mass 60 kg.

Fig. 9.10c: Dimensions and masses of tools

178 13 70-2.0

178 34 36-6.0


488 601 004 178 55 08

9.20

Fig. 9.10d: Dimensions and masses of tools

Sec. Description Mass in kg

913 Pump for hydraulic jacks and fuel valve test rig 20

178 43 48-5.0


488 601 004 178 55 08

9.21

Pos No. Description Mass in kg

1 901907909911

Cylinder coverStarting air systemFuel valve and fuel pumpSafety equipment

46

2 902903904905

Piston, piston rod and stuffing boxCylinder linerCrosshead and connecting rodCrankshaft and main bearing

31

3 906908

Camshaft, chain drive and reversingExhaust valve and valve gear

47

Fig. 9.11: Tool panels, option: 4 88 660

178 43 48-5.0

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main:

content:

s2609

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