MANRI Baw S50MC-C ACCESSORY MANUALInstructions for Main Engines This book forms part of a set of books consisting of three volumes entitled: Vol.|_ OPERATION Vol. I|_ MAINTENANCE Vol. Ill COMPONENTS, 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 an MAN B&W main diesel en- gine. Deviations may be found in a specific plant. In addition, the books can be used for ref- erence purposes, for instance in correspondence and when ordering spare parts. Itis essential that the following data is stated in spare parts orders as it is used by us to ensure the supply of the correct parts for the individual engines: 1. Name of vessel 2. Engine No. built by 3. Plate No, 4, Part No. 5. Quantity required (and description) Example: M/S Nybo - 7730 B&W — P90201-0036 - 059 10 off (piston ring) + )The Plate No. may consist of either of these two sets of digits, as the pages are In the process of being updated with new numbers: P90201-0036 or 0201-036. To ensure optimum efficiency, reliability and lifetime of the engine and its components, only original spare parts should be used when replacing parts on the engine. When used in texts and illustrations, the designation “D” refers to the information given on the data sheets inserted in the respective books. Reliable and economical operation of the diesel engines is conditional upon its correct oper- ation and maintenance in accordance with MAN B&W Diesel A/S’ instructions. Emissions re- lated maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S’ instructions and any additional instructions to that effect included in the Technical File. Consequently, it is essential that the engine room personnel are fully acquainted with the con- tents of this book and, in respect of instructions on emissions related maintenance of the die- sel engine, also the additional instructions to that effect set out in the Technical File. This book is subject to copyright protection, and should therefore not, in whole or in part, 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 AVS. MAN B&W Diesel A/S STX Engine Co.,Ltd. Tegiholmsgade 41 80, Seongsan-dong, Changwon, DK-2450 Copenhagen Kyungnam, Republic of Korea Denmark Technical Service Teleph.:+45 33 85 11 00 Teleph.:+82 55 282 0590 Telex :16592 manbw dk Telefax +82 55 282 6907 Telefax: +45 33.85 10 30 Part Sales Teleph.+82 55 280 0560-6 Telefax.:+82 55 282 1388Contents This instruction book is divided into fourteen Chapters as listed belows; Chapter Title of Turbocharger (Type : TCA 66-20) 02 Lubricator (Type : ALPHA Lubricator) 03 Tuning Gear (Type : YRTG 20-27) 04 Aux. Blower (Type : HAA-334/120n) 05 Air Cover (Type : LKM-(Y)JT) 06 Rollerchain (TSUBAKIMOTO Chain) 07 Press. SM, Press. Transmeter 08 Resistance Bulb 09 Thermocouple 10 High Pressure Pump (Type : AHP-2500) 1" Fuel Pump Test Device (Type : VTU-1100N) 12 Oil Mist Detector (Type : Schaller VN215/87) 13 Exh. VIV Grinding Machine (Type : SEG-S0MC/50MC-C-3ph440V) 14 Axial Vibration Monitor(Type : AVM-KN30-13)Technical Documentation Exhaust Gas Turbocharger SUX Enpaco CJ a Operating Manual ........ Work Cards ............. Spare Parts Catalogue .... Turbocharger Works No. of turbocharger .. Engine... D36 6671-1 E SEX Enpaco co, Ltd. 452-7, Nae-dong, Changwon, Gyunsangnam-do, 641-050 Korea + Phone +482 55 280 070+ Fax ++82 55 282 1938 E-mail: sdlee28Sestwenpaco.cakr + http:/www.stxenpaco.cokt 6671 cr/araii-o1 E 05.05 1© 2005 STX Enpaco Co., Ltd. Ail rights reserved, including the reproduction in any form or by photorrechanical means (photocopyimicro- copy), in whole or in part, and the translation, 6671 c12isn-01 E 05.05 2Technical Documentation Exhaust Gas Turbocharger C1 Operating Manual Exhaust Gas Turbocharger. TCA6S D36 6671-1 E SUKEnpaco co, Ltd. 452-7, Nae-dong, Changwon, Gyunsangnam-do, 641-050 Korea + Phone ++82 55 280 0770 «Fax ++82 55 282 1938 E-mail: sdlee285@stxenpaco.cokr + http:/www.stxenpacocokt Ci-01€ o7.04 TCAGG 3 SEX: — Gd 6671Table of contents C1 1 Introduction 1.4 Product Liabiity, 1.2 Scope of Supply.. 13 Addresses 2 Safety. 21 General Safety Instructions... 22. Salety during Operation 23. Safety during Maintenance/Repairs 3 Technical Data 1g exhlet Gs unboctaigar teen ne mrnere nme : aos 32 Operating Media : ar 4 Description 44° Exhaust Gas Turbocharger. 33 42 Lube Oil System... = sr, 43. Sealing Air System... 42 44 Acceleration System 45 4.5 Cleaning System — Dry Cleaning... —— nannies 87 4.6 Cleaning System — Wet Cleaning of the Turbine. 49 4.7. Cleaning System —_Wet Cleaning, Compressor. ae 4.8 Cooling System — Turbine Dise Turbocharger on the Four-stroke Engine 53 5 Operation 8.1 Starting Operation/Putting Out of Operation. 55 52 Emergency Operation ofthe Engine 58 5.3. Malfunctions/FAUIIS 0.0. 6 Maintenance.. 6.41 General Rematk..urunn 62 Tools/Special Toots. 63 Maintonance Schedule... 6.3.1 Maintenance Schedule (Turbocharger on the Four-stroke Engine) 6.3.2 Maintenance Schedule (Turbocharger on the Two-stroke Engine) ... 6.4 Remarks to the Maintenance Work. 6.5 _ Inspection of Individual Components: 6.6 _ Inspection Report Index 283 StXtwo— Gand 6671 C1-01E 07.04 TCAGE 4Introduction Product Liability Personnel Requirements Technical Documentation Sep Gd 6671 For improper usage of the turbocharger, the danger of C111 1 Safe and economic operation of the engine system including the turbo- charger requires extensive knowledge. Also, the operatabiity can be maintained or regained only through maintenance and repair work when these are carried out with expertise and skill by trained person- nel. The rules of proper craftsmanship are to be observed. Negligence is to be prevented, ‘The echnical documentation supplements this ability through special- ized information, draws attention to dangers and points out the safety regulations to be observed. The MAN B&W Diesel AG asks you to ob- serve the following guidelines: Z\ warnine accidents is given! Improper usage of the turbocharger can lead to damage of the turbocharger or its individual components. Damaged components pose a potential risk of injury for the operating and maintenance personnel. + Before putting into operation for the first time, carefully read the technical documentation at hand, especially the sections C1 — Operating Manual and Work Cards with the therein included. safety instructions. + Use the turbocharger only for the purpose intended for by the manufacturer. + Do not unnecessarily stay in the vicinity of the turbocharger. ‘Staying within the vicinity of the turbocharger is permitted for maintenance which is expressly to be carried out during ‘operation (see Maintenance Schedule, Section G1 - Chapter 6.3.1/6.3.2) + Carry out maintenance on the turbocharger regularly and properly within the specified intervals (see Maintenance Schedule, Section C1 - Chapter 6.3.1/ 6.3.2) + Perform any and all repair work exclusively with original MAN B&W Diesel spare parts (see Section C3 - Spare Parts Catalogue). Important! In the case of infringement of the before mentioned safety instructions, the MAN B&W Diesel AG shall deny any and all ability. 07.04 ‘TCAGS 5Scope of Supply 1.2 Scope of Supply Each turbocharger is adapted especially to the engine system of a cer- tain customer. Due to this customization, a standardized scope of sup- ply is not given for the turbocharger. ‘The following scope of supply is effective only for the turbocharger with the Serial No. Type ‘Turbocharger type TOASS for engine type Casing design Gas-admission casing, insulated Position Z, Gas outlet casing, insulated Position T., Casing foot Position F,, = Compressor casing Position Vz, = Built-in equipment Compressor diffuser”) Turbine nozzle ring") Fig. 1: Compressor diffuser Fig. 2. Turbine nozzle ring Auxiliary equipment Silencer with air fter © Air intake casing 1) Flow cross-section punch-marked on face side of component SUeme Ga 6671 C1 12-018 07.04 ToASS 6Accessories (optional) 1D Counter flange and seal for gas outlet casing 1D Counter flange and seal for air intake casing Cleaning device for turbine Wet cleaning B Dry cleaning Cleaning device for compressor ‘Speed measuring device Number of compressor wheel blades Final speed of range 20000 rpm ‘Speed indicator Di analogous Bi digital 1 Emergency and post-lubrication system B Tools for Works No. Spare parts for Works No. 1D Special spares Ddet assist 1 Variational parts IMO certification Documentation Inscriptions on the turbocharger, operating tags English Inscription on labeling tags English System of units metric Operating manuals English Quantity Shipment mode Di disassembled Ci partly disassembled assembled 1 packed for overland transportation seaworthy packed tropical packed Anti-corrosion packaging AN 400 Inquiries For inquiries on any parts delivered by STX Enpaco, the STX Enpaco is at your disposal (for addresses, see Chapter 1.3). hand 6671 C11.2-01€ 07.04 TOAGSAddresses STX Enpaco, Works Addresses and contact persons 1.3 Table 1 contains the addresses of the STX Enpaco Works and of the technical office in Changwon, as well as the telephone and fax numbers of the responsible departments, ready to fully assist you if required, Gyunsangnam-do, 641-050, Korea Phone: ++82 55 280 0770 Fax: +482 55 282 1938 Location ‘Address Subject | Contact person [Changwon Works /STX Enpaco Co, Ld. Service Phone: ++82 55 280 0770 '452-7, Nae-dong, Changwon, turbocharger |Fax: ++82 55 282 1938 | E-Mail: sclee285@ strenpaco.co.kr Web: ww.stxenpaco.co.kr Table 1: Locations and adresses of the STX Enpaco MAN B&W Diesel AG, Works ‘Addresses and contact persons Table 2 contains the addresses of the MAN B&W Diesel AG Works and. of the technical office in Hamburg, as well as the telephone and fax numbers of the responsible departments, ready to fully assist you if re- Phone: +49 821-322-0 Fax: 449 821-320-3382 quired Location ‘Address ‘Subject Contact person [Augsburg Works MAN B&W Diesel AG ‘Service Phone: +49 821-322-3008 86224 Augsburg turbocharger |Fax: +49 821-322-3998 Germany E-Mail: turbocharger@manbw.de Web: www.manbw.com Hamburg Works MAN B&W Diesel AG Service Center, Hamburg Works Rossweg 6 20457 Hamburg Germany Phone: +49 40-7409-0 Fax: 449 40-7409-104 "Technical Office Hamburg MAN BEW Diesel AG Sales Office, Hamburg Admiralitatsstrabe 20459 Hamburg Germany Phone: +49 40-378515-0 Fax: +49 40-378515-10 Web: __wuw.manbw.com Table 2 Locations and addresses of the MAN B&W Diesel AG StXtr0 Gad 6671 C113-01€ o7.04 i TOASS 8Service addresses Norderlaan 181 2030 Antwerpen, Belgium WAN B&W do Brasil Industri | Service Center Rio | Rua Olga, 84 Bonsucesso io de Janeiro, RJ 21041 140, Brazil mércio Ltda. Country [Address Telephone/Fax/E-Mail ‘Argentina Turbogen Phone +54 11 4521-5667 Lugones 1855 Phone +54 11 4521-1914 1430 Buenos Aires Phone +54 11 4522-5632 Argentina Fax +5411 4521-8283 E-Mail turbogenrutfa@arnet.com.ar Australia MAN B&W Diesel Australia Ply Ltd. Phone +61 2 8874-0700 396 Lane Cove Road Fax 461 2:9889-5337 North Ryde NSW 2113 E-Mall service @manbw.com.au Web www.manbw.com.au Malling address: P.O. Box 734 North Ryde NSW 1670, Australia [Belgium 7 [Phone +32 5 543-8500 Phone +32 8 543-8502 |Fax +323 544-7254 | s@manvoll 55 21 2290-9993 455 21 2290-9144 (Spares) +55 21 2290-8749, Fax Fax E-Mail armovath @manbw.com.br E-Mail manbw@manbw.com.br (Canada [Dynamic Engineering ine. Phone +1 604 253-4427 1270 Frances Street Fax +1 604 253-9553 Vancouver E-Mail B.C. V6A 125 \dynamic@dynamicengineering.com Canada Web _www.dynamicengineering.com China MAN B&W Diesel Technical Services Phone +86 21 5866-2108 (Shanghai) Co., Ltd, Fax +8621 5866-2109 Wai Gao Giao Free Trade Zone E-Mail service @manbw.sh.cn JAo Na Road, No. 151 ‘Web vavw.mbd-china.com Pudong, Shanghai 200131 Kemkien Technical Service Ltd. Phone +852 2861-2812 117IF. East Town Building Fax +852 2861-2465/1168 41, Lockhart Road E-Mail kissales@turbokts.com Wanchai ‘Web www.turbokts.com Hong Kong Denmark MAN B&W Diesel AIS, Holeby Phone +45 5469-3100 Oestervej 2 Fax +45 5469-3033 /4960 Holeby E-Mail service/holeby @manbw.dk Denmark Web _www.manbw.com MAN B&W Diesel AIS, Alpha Diesel | Service Center Denmark |Langerak 74 | 9900 Fredrikshavn | Mailing address: Niels Juels Vej 15 19900 Frederikshavn Denmark MAN B&W Diesel A/S Teglholmsgade 41 2450 Copenhagen SV Denmark [Phone +45 3385-1100 Phone +45 9620-4100 Phone +45 2040-6059 Fax +45 9620-4041 E-Mail alpha@manbw.dk Web www.manbw.com Fax +45 3385-1049 E-Mall diesel-service @manbw.dk Web _http:/iwww.manbw.ck Table 3: Service adcresses SUX emce Gd 6671 C113-O1€ 07.04 ToASSCountry ‘Address Telephone/Fax7E-Wail ] (Germany MAN B&W Diesel AG Phone +49 40-7408-0 | ‘Service Center Werk Hamburg Fax +49 40-7409-104 | Hachmannkai E-Mail service-hamburg@manbw.de | | Rossweg 6 Web hitp:/Amww.manbw-service.com | | 20457 Hamburg | Germany | Great Marine Turbo Engineering Ltd. Phone +44 151-647-8141 Britain ‘The Turbocharger Centre Fax +44 151-666-2143 | Abbey House - Abbey Street E-Mall service@marineturbo.co.uk | Priory Trading Estate Web _ http:/iwwnw.marineturbo.co.uk Birkenhead L41 SJU Great Britain ‘Turbo Service International Ltd. Phone +44 8086-1000 190 Commercial Road Fax +44 8086-3000 ‘Totton E-Mail sales @turbosi.com ‘Southampton S040 3A Web _ http:/www.turbosi.com Groat Britain (Greece ‘Turbotechniki Ltd, Phone +30 10 4002 585 2, llias 8 Tripoles Str. Fax +30 104009 280 18863 Perema Piraeus E-Mail turbotec@hol.gr Greece Traly ‘La Meccanica Turbo Diesel S.R-L Phone +39 010 246-1111/7499 Calata Gadda Fox +39 010 246-1144 16126 Genova Porto E-Mail mtd@mtd.it Italy Web _www.mtd.it Netherlands | Turbo Biower Service B. V. Phone +31 10-426-7383/2679 17, Nieuwe Waterwegstraat Fax +31 10-473-3050 /3115 HE Schiedam E-Mall info @turbo.n! Netherlands Web _http:/iww.turbo.nl Philippines MAN B&W Diesel Technical Service Phone +63 2 776-3369 (Philippines) inc. Phone +63 2 776-3347 Km. 17, West Service Road Fax +632776-3384 Bigy. Marcelo Green E-Mail service@manbw.com.ph South Super Highway Web www.manbw.com.ph Paranaque City Philippines Singapore MAN B&W Diesel (Singapore) Pte. Ltd. Phone +65 6349-1600 ‘Tuas Avenue 2 Fax +65 6862-1409 Singapore 639460 Fax +65 6861-3314 (Spares) Fax +65 6861-8590 (Service) E-Mail spares@manbw.com.sg Web _service@manbw.com.sg South Africa |IMS Engineering (Ply) Ltd. Phone +27 21 511 8201 1124 Marine Drive Service Road Paarden Elland 7420 (Cape Town, 7405 Fex +2721 511 8238 E-Mail adejong @imsgroup.co.za [South Africa Spain Premenasa-Turbos Preccion Mananica Naval | Phone +34 91 778-1262 (Central) S.A. Fax +3491 778-1285 CiLuis 1, num. 26 E-Mail turbos @premenasa.es Poligono Industrial de Vallecas Web www.premenasa.es /28031 Madrid ‘Spain (South) Turbo Cadiz 8. L. [Phone +34 95 688-9204 Pol. ind. Fadricas clHilladores, 3 11100 San Fernando (Cadiz) Spain | Phone +34 95 688-9205 Fax +3495 688.9206 E-Mail tc@turbocadiz.com [Web _www.turbocadiz.com Table 3: Service addresses SU trom -G 6671 C11S-0O1E 07.04 TOASS 10Country Address Telephone/Fax/E-Mail (Worth) MINDASA Phone +34 942-558-600 Mecanizacion Industrial Astilareo S. A. Fax +34 942-558-360 Poligono Industrial de Guamizo | Aparto de Correos No. 37 39610 Astillereo-Cantabria | Spain I _ Turkey GTS Turbo Dizel Service Phone +80 216 302-7082 Aydintepe Mah. G-50 Fax +9016 392-1067 ‘Sokak E-Mail turbintr@ superoniine.com Gemdok Sani Sitese No. 10 Tuzla, Istanbul Turkey United Arab [Dubai Drydocks Phone +871 4 845-0626 Emirates | Jumeriah Beach Road Fax 4971 4345-0116 |P.0. Box 8988 E-Mail drydocks @emirates.netae Dubai Web wmw.drydocks.gov.ae UAE - USA Dresser Rand Company- Phone +1 713 627-0542 (Goutn centra)) | Service Division |Fax +1713 827-0353 Turbocharger Business Unit E-Mail 41416 Lumpkin Road Bruce_V_Homer@Dresser-Rand.com Houston TX. 77043. USA USA H.W. Ramberg Inc. Phone +1 718 625-3960, (North east) _|37 Van Dyke Street Fax +1718 875-1239 | Brooklyn E-Mail dieselservice @ ramberg.com | N.Y. 11231-1590 Web www.ramberg.com USA USA | Motor Services Hugo Stamp Inc. Phone +1 954 763-3660 (Southeast) [3190 S. W. 4th Avenue Fax +1 954 763-2872 | Fort Lauderdale E-Mail service@mshs.com Florida 33315 E-Mail info@mshs.com USA Web _ www.shs.com USA (Golten Marine Company Phone +1 310 549-2550 (24h) (West) /322-930 Broad Avenue Fax +1310 549-1350 Wilmington E-Mail california @goltens.com CA 90744-5869 ‘Web www.goltens.com USA Table 3: Service addresses Note! For the current list of service addresses contact: Mr. 8. D. Lee Turbocharger Plant Phone: ++82 55-280-0770 Fax: +482 55-282-1938 E-mail: sdlee285@strenpaco.co.kr Ms, Barbara Weidner Turbocharger Service Office Phone: +49 821-322-1198 Fax: +49 821-322-3998 E-mail: TC-Service-Augsburg @manbw.de SEX emico— head 6671 C1 1.5-01 E 07.04 TCASS "i SUXemaco— GQ) 6671 C1 1.3-01E 07.04 TCAGE 12Safety 2 General Safety Instructions 21 Safely Instructions Safety instructions are always noted down prior to the description of any action. They are categorized in 4 hazard levels and differentiated by the degree of hazard seriousness for personnel or equipment. Danger Levels 1-3, Generally, the safety instructions of the hazard levels 1-3, © Danger, © Warning, © Attention are indicated as follows: Z\ DANGER ‘When the respective caution measures are not complied with, there is, j\ imminent danger which will result in: ‘© Death or serious injury, ‘¢ Total damage to property or © Serious environmental damage. Z\ warning When the respective caulion measures are not complied wilh, a poten Oo Bally hazardous sitiation willbe cased which can load te © Serious damage to property or © Serious environmental damage. ZN ATTENTION When the respective caution measures are not complied with, a haz~ @ ardous situation could be caused which can lead to: © Personal injury, © Possible damage to property. ‘A symbol appropriate to the hazard is always depicted in the marginal Column, Iteither indicates a hazard (hazard symbol) or the correspond- ing protective measures (safety symbols): StXrrec— fad 6671 Ci 21-02 E 07.04 TOAGS 13Safely Symbols 6e@@ee00 Wear Wearhard Wear safety protective hearing hat gloves: goggles protection 0 ® Wear gloves Wear Read protective manual clothing Danger Symbols Wamingota Danger of Tripping Danger of Corrosive hazard slipping hazard. == electric.—materials location ‘shock Crush inflammable Hot surface Danger of Rotating hazard materials suspended gear hazard loads Bans Fire, open No access flames and for ‘smoking are_unauthorize prohibited! d persons! ‘The safety instructions of danger level 4 are indicated by means of the Danger Level 4 following designations: Important! For pointing out fault sources/handling errors; material damage can occur. Note! ‘Additional notes, information and tips. 07.04 TCAGS 4 StKtpe—fan 6671 6121-02 ESafety during Operation 2.2 Containment Safety The turbocharger is one of the highest loaded components in modern diesel engines. The high rotor speeds of a turbocharger result in high centrifugal force stresses at simultaneous high component tempera tures. A-consequence of additional extraordinary influences might be - tremely rare cases - a failure of the components. Precautions STX Enpaco - MAN turbochargers correspond to the required contain- ‘ment safety according tothe rules stipulated by the classification socie~ ties so that the state of the art prevents fragments from escaping, In extreme cases, particularly ifthe turbocharger has not been sutfci- cently or properiy maintained, there may be the risk of damages to persons ‘or property in vicinity of the turbocharger. To eliminate residual risks we kindly ask you to observe following rules: Important! Persons are by no means allowed to stay without any reason near the operating turbocharger. © Turbine and compressor are to be cleaned at regular intervals as specified in the operating manual. ‘© The maintenance of the turbocharger must be cartied out by trained personnel as well as in the maintenance intervals as stipulated in the operating manuals, ‘© Inadmissible operating conditions, such as frequent load releases, ‘compressor surging, excessive turbocharger speeds, must be avoided © Corrosive and erosive media in the intake air are to be avoided. Technical Documentation “The technical documentation of the system, particularly the operating and ‘maintenance manuals for the engine, turbocharger and the accessories required for engine operation, must be stored at a location where they are accessible for the operating and maintenance personnel at all imes. Regulations for Prevention of When operating the system and for all maintenance and repair work, Accidents the relevant regulations for prevention of accidents are to be observed. Its advisable to hang these regulations in the engine room and to ro- peatedly point out the dangers of accidents. SUXtmco— ean 6671 C122-01E 07.04 CASS 15.Safety Instruction Sign ~ Engine Room Important! To point out the most important regulations, bans and hazards during operation and maintenance the following satety instruction sign must be posted at the entry of the engine room: Fig. 3. Safety Instruction Sign — Engine Room Persons, who for operational reasons are to be within the danger area of 2.5 m around the engine, are to be instructed of the predominant hazards. Access to the danger area is permitted when the turbocharger is in proper operating condition and only when wearing suitable protective equipment. It is prohibited to stay within the danger area ‘without reason. Note! Explanations of instruction sign see Chapter 2.1 StKewxo- Gd 6671 6122-018 07.04 TCAGS 16Hearing Protection ~— 7X WARNING Exhaust Gases @ ‘Sound level exceeding 85 dB(A)! The danger of hearing impairment is given because sound levels are permanently above this value in the engine room when the engine is running. + Always wear hearing protection in the engine room! In the engine room, exhaust gases with harmful components NO,, S02, CO, HC and soot can be set free. Danger of Fire aN WARNING Health risk due to exhaust gases! ‘The exhaust gases of the engine are harmful to one’s health and detrimental to the environment when exceeding the limit values. + Carry out maintenance in accordance with the maintenance schedule! + Orient the operational management on behalf of the hazards! + Observe operating results critically! Z\ WARNING Potential danger of fire in the engine room! Fuel and lube oil are combustible and can easily ignite when contacting hot components in the engine room. + Do not conduct fuel and oil pipes alongside hot engine components (exhaust pipe/turbocharger) that are not insulated! + After maintenance and repair work on exhaust pipes and turbochargers, carefully and completely reattach all insulation and coverings! + Regularly check the tightness of all fuel and oll pipes (maintenance schedule)! + Eliminate any leakages immediately! The engine room must be equipped with firo-extinguishing equipment. ‘The proper function of this equipment is to be checked regularly. ZN DANGER Danger to life through suffocation! When a carbon dioxide fire-extinguishing system is put into ‘operation, danger of life is given due to suffocation. + Do not put carbon dioxide fire-extinguishing systems into operation before itis ensured that no more persons are in the engine room. SEX em: — GY 6671 c122-018 07.04 TCAGS 7Protective Covers Z\ warnine A Danger of burns and fire hazard from hot system components! Due to high operating temperatures the system components can become very hot. Persons can burn themselves on the hot, components and/or inflammable operating fluids can ignite. + Always have all coverings and insulations mounted to the turbocharger during operation of the engine. + Regularly check the tightness of all fuel and oil pipes! Alarm System StXemce— Gan) 6671 C122-018 ‘After assembly work, ensure that all coverings and protective covers from moving components as well as all insulations from hot compo- nents are reattached again. Engine operation with coverings removed is permitted only in special cases, such as for functional tests, It important operating data are exceeded, an alarm system will set off alarm, reduction or stop signals, depending on the danger potential. ‘The cause of the signals is to be thoroughly investigated and the ‘source of the malfunction to be corrected. The signals may not be ig- nored or suppressed, except when ordered by management or in cas- es of increased danger. Z\ warnine Ignoring or suppressing alarms and putting reduction and stop signals out of operation can lead to operational malfunctions which can result in serious personal injury and damage to propert ‘Turbocharger and engine are fitted with an alarm system which sounds an alarm in case of technical problems or malfunctions. ‘Therefore, an alarm always has a cause which must be rectified! + Do not ignore or suppress any alarm, reduction or stop signals! + Investigate the cause of every alarm, reduction or stop signal or report them + As faras possible, provide for swift rectification of the cause of alarms and signals! + Ignore or suppress alarms, reduction and stop signals oniy in cases of force majeure or when ordered by management! 07.04 TOAGS 18Operating Personnel Qualification of Personnel SUX eme GA 6671 C122-018 The engine and the systems required for its operation may be started, ‘operated and stopped only by authorized persons. The personnel must be educated, trained and familiar with the system and the occurring dangers. All persons operating the system or carrying out maintenance or repair ‘work on the syste must have read and understood all accompanying ‘operating and maintenance instructions. For Ship Systems: Operational management through the chief engineer on board or through a technical officer. Persons managing the operation must be in possession of a compe- tence certificate that corresponds with the national regulations and in- ternational agreement (STOW). The number of required persons and their minimum qualification aro usually stipulated through the national regulations or the international agreement (STCW). For Stationary Systems (Power Plants): The superintendent (engineer) must be available. Supervision/contro- ling of the engine and the accompanying supply system through a trained and specially briefed machinist or mechanic. For managing persons in Germany, proof, among other things, must be furnished in accordance with the energy economy law (EnWG) that the technical operation management is guaranteed by qualified and sufti- ciently numbered personnel. in other countries, comparable laws/ guidelines are to be observed, o7.04 TCAGG 19Safety during Maintenance/Repairs 2.3 Qualification of Personnel Performed by machinists or mechanical fitters and their assistants Briefing and supervision of cifficult work tasks through a technical offic- cr or the chief engineer. Use of Cleaning Agents When using cleaning agents the manufacturer's notes for usage, pos- sible dangers and disposal are to be observed. ZX warnine Cleaning agents can be causti Cleaning agents on the skin, in the eyes or being inhaled can lead to serious damage to one’s health o to allergies + Always observe the manufacturer's notes for cleaning agents! + Wear protective clothing whenever required! + Wear protective gloves whenever required! + Wear safety goggles whenever required! + Wear respiratory protection whenever required! + Pay attention that other persons also wear the appropriate | protective equipment whenever required or make these persons | aware thereot! Use of High-pressure Cleaners ‘When working with high-pressure cleaners ensure proper usage. Air fiters, shaft ends (also including such with lipped sealing rings), governors, splash-proof monitoring systems, cable sockets as well as ‘sound and heat insulations under non-watertight coverings, must be covered or exempt from the high-pressure cleaning Opening Pipes/Pressure Tanks Z\ ATTENTION Danger of burns from hot components! Many engine and turbocharger components become very hot during operation and require ample time for cooling down afterwards. cool down sufficiently (1-2 h)! StXeime- Gad 6671 61 2.3-02E 07.04 ToASS 20Z\ ATTENTION Disassembly and Assembly of Pipes: Removal/Disassembly of Heavy Components Danger of burning/scalding from running-out lube The lube oil is under pressure and very hot! + Before opening pipes, tlanges, screwed connections or gauges, free the system of pressure and check that itis pressure-free! + Before opening oil pipes, wait until the lube oil has cooled down sufficiently (1-2 h). + Drain the system and check that ithas been drained completely. + Wear protective clothing! (On turbochargers with emergency and post-lubrication system, the lube oll will continue to drain for up to 1.5 h after shutting down the en- gine system. During any work on the pipe systems, especially for fuel, lubrication oil and air, ensure utmost cleanness in order to avoid foreign objects or debris from entering the system. Therefore, all pipes subject to reas- sembly should be blocked with care upon disassembly. New pipes being installed should be checked for cleanness and flushed, if required. For extended storage, all individual parts are to be preserved. ZX warning SUX enone — haan 6671 C1 23-02 E Danger of injury from suspended loads! Unsuitable or poorly maintained transport equipment as well as unsuitable set-down locations can lead to serious injury of people and to major damage. + Use only transport equipment which is in perfect condition + Cheok i the transport equipment being used has the required carrying capacity. + Choose only set-down locations that have sufficient loading capacity forthe heavy component (this isnot always the case for galleries, ha-Jandings or gric-iron coverings). 07.04 TCAGS a4Spare Parts ‘During operation, very high forces are applied to the components of the turbocharger. Therefore, MAN B&W has developed special materials that can withstand these high forces. The use of these high-quality ma- terials can be guaranteed only when using MAN B&W original spare parts. ZX DANGER Bought-out spare parts can be manufactured from low- quality materials that can not withstand the forces occurring during operation of the turbocharger! This can result in serious damage to the turbocharger, engine room and engine, as well as danger to life for the operating personnel. + Use only MAN B&W original spare parts! + Use bought-out spare parts only after these have been released by MAN B&W & STX Enpaco! SUX emce— Gan) 6671 129-02 ‘STX Enpaco & MAN B&W shall in no way be liable for any damage to ppefsons or material, caused by usage of bought-out spare parts, Furthermore, any and all warranty claims on the turbocharger expire when using foreign spare parts. 07.04 TCASE 22Technical Data Exhaust Gas Turbocharger Classification Turbocharger/Engine 3.1 [Turbocharger Engine [Type | Wore to. | Type [Power | Speed | (kw) fem) | (tenes I ‘Turbocharger Type Plate lo oO type SUX enpaco — faand exhaust gas turbocharger wine, [—z— Amex 3 JAPM maxtemp [=a—)°[5] O _type-tested [—e—] year ° Turbocharger type Works No. (Serial No,) Unit of temperature Type approval Year of ex-works delivery NoQasones Note! The type plate is mounted either on the compressor casing or on the air intake casing (if available). StXeme-GA 6671 C13.1-01E o7.04 Admissible rotor speed, maximum ‘Admissible turbine inlet temperature, maximum TCAGS Fig. 4. Type plate 23,Weights, Classified according to Assemblies (approx. values) 513 517 518 520 540 542 544 545 546 554 595 596 Exhaust gas turbocharger, incl. silencer. approx. 5 500 kg Gas-admission casing, complete o 270k 20° 380 kg Gas outlet casing, complete 4.200 kg Gas outlet cituser. Shroud ring Nozzle ring Bearing casing, complete sens 910 KQ Casing fest, complete 340kg Rotor gear, complete 200 kg Turbine rotor 430 kg Compressor wheel 66 kg Insert. 198 kg Dihucer ee ee 64kg Silencer, complete (i existing)... 800 kg Intake casing, complete (if existing) ...unsenn soon 237 kg Compressor casing single socket, complete .- 800 kg Emergency and post lubrication system, complete so 140 kg ‘Spare parts with box vw @PIOX. 15 kg Tools With BOX .w.snsnsnsnnnsnnnannnnn approx. 80 kg StXcomeo— Gan 6671 Ci 31-01 E 07.04 TCAGS 24Operating Characteristics Speed Temperatures Prossures Lube oil throughput Lubricating Oi! Noise development Operating Life Bearing Turbine rotor Compressor whee! Casing StKemae— GQ 6671 C1atole Admissible speed, max... 16.000 pm Admissible exhaust gas temperature ahead of turbine, max..... 600 °C Admissible inlet temperature of lubricating oil, max... 70°C Lubricating oil: ‘At regular operation and full load of engine 12-22 bar Alarm. <12bar Reduction to half load of engine (stow doWn) ...snennenn< 1.0 bar Motor stop (shut down). -<0.8 bar Admissible lubricating oll pressure, max... soe 2.2 bar External sealing air (optional) Inlet pressure in turbocharger. 1.3-1.5 bar Jet assist (optional): Prossure in starter-air cylinder. 80 bar Admissible inlet pressure in turbocharger, max. 4 bar with SAE 30 at 60 °C and 1.3 bar pressure in operation......7.0 mn Lube oil supply: 2 connections that can be used alternatively. The con- nection not used is plugged with a dummy lid. Emergency and post-ubrication system: 1 connection (filing, relubri= cating), 1 overflow connection, Lube oil outlet: 1 connection up to 110 dB (A) at a distance of 1 m from the turbocharger. Up to 50 000 operating hours. Up to 100 000 operating hours Up to 80 000 operating hours ‘The operating lfe of the compressor wheel depends on the intake air temperature, the charge pressure and the load profile of the engine. It can be considerably reduced by unfavorable conditions. Prat ally unlimited These periods are empirical values and are reached with turbocharg- ers thal operate on engines powered with heavy fuel oil. For operation with diesel oil (Marine Diesel Oil MDO), considerably longer periods can be achieved. Continued use or replacement of components is decided upon at each ‘major overhaul of the turbocharger. Itis imperative that major over- hauls are performed according to the periods specified in the mainte- nance schedule, 07.04 ToASS 25Dimensions and Connections 1 Gas-admission casing 8 Charge air inlet 2 Gas outlet casing 7 Charge air outlet 3 Washing water outlet 8 Jetassist 4 Lube off outlet 9 Lube oil supply 5 Venting x rolor removal size: 570 mm Fig. 5. Main dimensions, TCA66 with 90° gas-admission casing 1. Gas-admission casing 6 Charge air inlet 2 Gas outlet casing 7 Charge air outlet 3 Washing water outlet 8 Jetassist 4. Lube oif outlet 9 Lube oil supply 5 Venting X_rotor removal size: 730 mm Fig. 6. Main dimensions, TCA66 with an axial gas-admission casing StXcr0— Gan 6671 C1 31-01 07.04 ToASS 26Operating Media 3.2 Fuels for the Engine Engine fuel affects exhaust gas ‘The quality or the fuel with which the engine is operated affects the quality composition of the exhaust gas that flows through the turbocharger. Im- purities in the fuel can lead to residues in the exhaust gas, which can effect the turbocharger in an abrasive or corrosive manner. Quality Requirement for MDO js also known as diesel fuel cil, diesel oil, bunker diesel oil or ma- Marine Diesel Oil (MDO) fine diesel fuel. MDO is offered exclusively for shipping as heavy distillate (ISO-F- DMB) or as a mixture of distilate and low amounts of residual oil (|SO- F-DMC). The term "blended MDO" is common for the dark brown to black colored mixture. MDO is produced from crude oll and must be {ree of organic acids, ‘Tho usabilty of the fuel depends on the design of the engine and the cleaning device as well as if the characteristics mentioned below, which are based on the condition at the time of supply, are observed. ‘The charactetistics determined were based on the ISO 8217-1987 and CIMAC-1990 specifications. The characteristics refer to the mentioned testing methods. __ Properties/Characteristic Unit | Testing Method] Parameter 1SO-F specification | DMB [DMC Density fat 15°C kgim® [180.3675 0.900 0.920 _— Kinematic viscosity fat 40°C mm/s =eSt| _ISO.S104 60_ [Sediment content (extraction) —_ “1808735 | <0,07 = [Total sediment content _ ISO CD 10307 = 0,10 Water content - Vol% 180 8733 03 ‘Sulfur content _ Whe 180 8754 2,0 [Ash content Wim 180 6245 20,05 [Carbon residue (MCR) - wi% | IS0.CD 10370 | 20,3 <2,5 [Cetane number =a 180.5165 40, 340, [Copper strip test ~ — = 10.2160, a at ‘Vanadium cont z= z mokg | DINSt790T2 | __0 100 Aluminum and mgkg | ISOCD 10478 0 <5 tent Visual check = — (Other specifications: - British Standard BS MA 100-1987 Glass M2 | Class M3 ASTM D 975 2D 40 ASTM 396 [ie 3| fo. Th go0d fght anal room Temperature, the Tel Should appear clear and Wanapareal—— Table 4: Marine Diesel Oi (MDO) ~ Characteristics to be met StXempc-GO 6671 C13.2-01€ 07.04 ToAss orQuality Requirements for Heavy Fuel Oil (HFO) StXeme- GQ) 6671 C132-018 Important! ‘Mixing fuels can lead to a reduction of quality. This can result in combustion with a high degree of residuals, which can cause ‘heavy contamination of the turbocharger. Extreme contamination can damage the turbocharger. Therefore the following points are to be observed: ‘© In loading plants and during transportation, MDO is treated as residual oil. Mixing with, ¢. ghigh-viscous fuel oil or Interfuel remaining in a bunker vessel is possible and can lead to a considerable reduction in quality. ‘© Different bunker batches of blended MDO (ISO-F DMC) can be incompatible and therefore should not be mixed. For this reason, the respective fuel tank should be emptied to the greatest possible extent before @ new batch is filed up. Important! Ocean water in the fuel aides corrosion in the turbocharger and leads to high-residual combustion. Solid foreign matter increases the mechanical wear in the nozzle ring and the turbine of the turbocharger. Therefore the following is to be observed: ¢ Ifblended MDO (/SO-F DMO) is primarily being used, we recommend instaling a centitugal separator in tront ofthe fuel iter. This widely separates solid particles (sand, rus, catalyst residue, canes) and water, so that the cleaning intervals forthe fite inserts can also be prolonged Operating data: ‘Soparator admission 65 %, with reference to the rated throughput capacity; Separation temperature 40-50 °C. ‘STX Enpaco - MAN turbochargers can be operated on engines that run on crude-cil based heavy fuel oll, when the engine and the processing system are designed accordingly. ‘The fuels used must mest the fuel specifications in accordance with Table 5. Table 5 lists each of the limit values to be observed. The limit values that influence the engine operation are to be specified when ordering fuel, e.g. in the bunker or charter clause, Important! Adding motor oil (waste oll), mineral-oil-oreign materials (e. g. coal oil) and remainders from refining or other processes (e. g. solvent) is prohibited! This ban is specitically to be pointed out in the fuel order, as itis not yet part of the standard fuel specifications. Such additions lead to combustion with high residue and increased \wear and corrosion on components ofthe turbocharger. Adding motor oil (waste/old ol) is particularly citical, as the lube ol additives cause emulsions to form and keep debris, water and catalyst particles finely distributed in poise. This impedes or avoids the required fuel cleaning Important! The heavy fuel oils ISO F-RMK 35/45/55, with a maximum density of 1010 kg/m, can be used only when respectively modern separators are available. 07.04 TCASS 28Fuel Specification GIMAC 1990 AiO | BICIO] DIS | E25 | G35] HAS | HSS | BS MA-100 wa S| _M7_| 8 | Ma | Mol iSO FAM Aio_| BICi0 | 015 | E/F25 | GiH3s | HaS | 55 ‘System Relevant Characteristios Viscosity (at 50°C) _|mmels [max. 40 | 40 | 80 | 160 | 380 | 500 | 700 Viscosiy at 100°C) |{0S0 [max.| 10] 10 7 | 3 | 45 | 55_| Density at 15 °C) gimi |max. | 0375 | 0984 oa Flash point °¢__|min, oO Pour point (gunmen) °C |max._| 6 [24] 30 30 Pour point (winter) °C min. oO 24 30 30, {Engine Relevant Characteristics [Carbon residue (Conrad |We% max] 10] 104] 14] 1800 | 1825] a2] 2B son) [Sulfur Wie as_[ 4 5 5 [ash Wit 0.10 O15 020 Vanadium mark 1507 | 350 | 2007 | S007 300 300 500_| 600 Water Vol% [max | 05 | 05 | 08 | 1 1 7 7 ‘Sediment (potential) We% _[max. 01 ~ Supplementary Characteristics - [Aluminum slicium ——[mgkg [max 30 [Asphaltenes We — max. 27S of the carbon residue (Conradson) Sodium mora Sodium < 178 vanadium, sodium < 100 Getane number of the fiuid mixing component: min. 35 Fucl to be free of mineral-ci-foreign additives such as coal oll or vegetable ol Free of creosol and lubricating oil (waste oil) Table : Fuel specifications and corresponding characteristics StKempae— and 6671 cis2o1€ Important! Thorough processing of heavy fuel oils required for trouble-free engine operation. The following points are to be observed for this. ‘© Heavily abrasive inorganic, solid foreign substances (cattines, rust, sand) must be separated to the greatest possible extent. ‘© With an aluminum content >10 mg/kg, the abrasive wear in the turbocharger increases heavily. ‘© Use only separators of the latest generation which are fully effective over a large density range without any adjustment, and separate ‘water with an HFO density of 1.01 g/ml at 15 °C. The cleaning effect is controlled by the separator itself ‘© The HFO purification is to be designed in such a manner that the characteristics in Table 6 are reached: Characteristic | Pariicle sizo ‘Amount Inorganic, sod Yoreign <5 ym = 20 mghkg substances (inl. catfines) (Alcontent <5 malkg) [Water _= < 0.2 Vol.% Table 6: Achievable foreign matter and water conten aftr separation 07.04 TCASS 29Lubricating oit Base Oil «© With unfavorable vanacium-sodium ratio, the melting temperature of the HFO ash drops tothe range of the exhaust valve temperature, ‘which causes hot corrosion. By pre-cleaning the HFO in the settling tank and inthe centrifugal separators, the water and thus the water- soluble sodium compounds can be removed to the largest extent. With a sodium content exceeding 100 mg/kg, increasing salt doposits in the turbine are to be expected. This jeopardizes the turbocharger operation (by pumping of the turbocharger, among other things). When using PTG, the sodium content must be limited 10 50 mgikg, Under certain conditions, hot corrosion can be avoided with a fuel additive that increases the melting temperature of the HFO ash ‘© Heavy tus! oils with a high ash content in form of foreign substances, €.g. sand, rust, catfnes, increase the mechanical wear in the turbocharger. Heavy fuel oils from catalytic cracking plants can contain catfines. Generally, these are aluminum silicate, which effects high wear in the turbocharger. The determined aluminum content multiplied by 5-8 (depending on catalyst composition) approximately amounts to the content of catalyst material in the HFO. In practice, combined lubricating oils (base oil + additive) are used. ‘These lubricating oils must have the following characteristics: The base oil must fulfill the following limit values, particularly concern: ing the aging stabiity. Properties/Characteristic Unit_| Testing Method Parameter Siructure = = Preferably paraffinbased [Behavior in cold - still fui °C ‘ASTM-D2500 16 Flash point ace. to Cleveland °C ‘ASTM-D92 > 200 ‘Ash content (oxide ash) “ASTM-D4a2 = 0.02 (Carbon residue acc. to Conradson ASTW-D189 in <0.05 [Aging tendency after 100h ofheating | - | MANaging cabinet a 10 195°C | mheptane insoluble “Wi% | ASTM-D4055 resp. <02 DIN 51892 Evaporation loss Wax <2 “Drop test (fter paper) = MAN test Mast not show separation of resin-| | ous and asphaltic aging products Table 7: Lubricating oil - Characteristics o be met Additives StXepe- GO 6671 013.2-01€ ‘Additives must be dissolved in oll and of such a structure that as little lash as possible results during combustion. The ash must have a soft structure. If this is not the case, increased formation of residue in the ‘gas admission casing of the turbocharger must be taken into account, Hard additive ash enables increased mechanical wear. Additives may not aid a clogging ofthe fer inserts, neitherin the active ‘or processed condition, 07.04 TOASS 30Viscosity Alloying Degree Lubricating Oil Additives Compressed Air External Sealing Air det Assist Cleaning Agent for Turbine Dry Cleaning ‘Wet Cleaning SUXtmae— Gand 6671 C1s201£ Turbocharger | SAE class | Viscosity mms at 40 °C resp. | 100°C FEASSt0TCA SS | 80 |Preferredin the upper range of 2 |the SAE class assigned to the tur- bocharger Table 8: Viscosity (SAE class) of lubricating ols We recommend alloyed lubricating oils (HD cils) that meet the interna~ tional specifications MIL-L 2104 D or APCD and have a Total Base Number (TBN) of 12-15 mg KOH/g (NATO-Code 0-278). ‘We urgently advise against the later addition of additives to the lubri- cating oll or mixing different lube oll brands together, as this can de~ stroy the function of the additive package matched for the base oil ‘Such action also annuls the supplier's responsibilty for the lubricating ail, Connection to the compressed air supply of the system"). Connection to starting-air cylinders For dry cleaning of the turbine during operation, commercial granules are used that must meet the following specifications: Granulates of: © Nutshells, ‘© Activated charcoal (sott) Particle size: © 1.0mm (max. 1.5 mm) ‘© Filling capacity of container, approx. 1.51 Fresh water without chemical additives Water pressure: © 2 bar (at 4 washing lances) Important! Use fresh water only. Salt water causes corrosion on the turbocharger components. 4) Pressure, see Chapter 3.1, Operating Characteristics. 07.04 TCASS 31StKtrpco fad 6671 C1 3.2-01E 07.04 TCAG6 32Description 4 Exhaust Gas Turbocharger 41 General Economical operation of madern large-scale engines is not imaginable ‘without exhaust gas turbochargers. The already high requirements for propulsion systems and energy producing units concerning etficiency and longevity are being continuously increased under the aspects of fuel utlization and environmental load. Inthis, the components of exhaust gas turbochargers are subject to ex- treme operating conditions. ‘© Exhaust gases of up to 650°C continuously flow through the turbine and heat up its components, without an own counteractive cooling system, Especially the shaft bearing must withstand the high ‘operating temperatures without the lubricating film ever breaking. © Onthe compressor side, the air is heated to over 200 °C. The high temperatures lead to extreme thermal loads of the material at many locations. ‘© Speeds are extremely high: The STX Enpaco - MAN exhaust gas. turbochargers are operated with speeds ranging from 10 000 to .35 000 rpm, depending on size. In this, circurnfetential velocities of 560 mis and more are reached at the compressor whee, which amounts to 1.7 times the speed of sound or 2 000 kmih, © The centrifugal forces are extremely high: Forces of several hundred kN can easily apply at the foot of the turbine blade. ‘© The complete gas exchange of the engine is performed by the exhaust gas turbocharger. For this machine, the throughput of combustion air can amount to 24 m*s, © Simplified, it can be said that approx. 1/5 of the power produced by the engine is converted on minute space within the exhaust gas turbocharger. These requirements can be fulfilled only with use of the most recent material and manufacturing technologies, introduced into the series by MAN B&W with use of the latest developmental results, and based on decades of experience in building diesel engines and exhaust gas tur- bochargers. Important! Prescribed maintenance must be carried out precisely and in time using the prescribed tools, in order to keep the turbocharger in ‘good condition and not damage it. ‘Maintenance Schedule see Chapter 6.3. SUX emo Gan) 6671 C1 4.1-01E 07.04 TCASS 33‘Subassemblies 1 Stencer 8 Turbine rotor 15 Gas-outet dituser 2 Insert 8 Gas outet casing 16 Outlet, washing water 3 Compressor casing 10. Bearing bush, 17 Thrust bearing 4 Difuser turbine side 18 Compressor wheo! 5 Bearing casing 11 Nozzle ring 19. Discharge, com- 6 Boating bush, 12 Gas-admission casing prossed fresh air 7. Boaring body 14. Casing oot compressor side 13. Turbine blades Fig. 7. Cutaway view, TCA6S ‘Turbochargers consist mainly of a turbine and a compressor, which are seated on the same shaft. The exhaust gas of the engine drives the tur- bine; the compressor draws in fresh air and compresses it SUXereaco— Gand 6671 C1 4.1-01E 07.04 TCAGS 34The turbocharger consists of the following main subassemblies: © Rotating element ‘Turbine wheel and shaft are firmly connected together; the turbine blades are individually set into the turbine wheel. The compressor wheel is mounted on the shaft and can be removed. © Bearing casing The interior bearing of the running equipment consists of two bearing bushes and a thrust bearing. Lubrication of the bearing is carried out via the lube oil circu of the engine. Lubricating oll pipes, lube oil venting and sealing air pipes are integrated in the bearing casing, '* Gas-admission casing: The nozzle ring is built into the gas-admission casing. It enables ‘optimum adaptation of the turbocharger to the engine. © Gas outlet casing: ‘The gas-outlet diffuser in the outlet casing is flow-technically optimized. The outlet casing is fitted with 5 offset connections forthe ‘washing water outlet, Depending on the build-in position of the turbocharger, the connection positioned lowest is used. ‘The outlet casing is designed so that together with the flanged-on gas-admission casing, it olfers optimum burst protection for the turbine wheel. ‘© Silencer or air intake casing ‘© Compressor casing optional with one or two discharge connections. ‘The compressor casing houses the diffuser, which allows for optimum adaptation of the turbocharger to the engine. Additionally, the diffuser functions as burst protection. Functional Description The exhaust gas of the engine flows through the gas-admission casing and the nozzle ring, and runs axially onto the turbine wheel. The ex- hhaust gas drives the turbine wheel; in this process, the energy con- tained in the exhaust gas is transformed into mechanical rotation ener- gy atthe turbine wheel. As the turbine wheel and the compressor wheel are seated on the same shaft, the compressor wheel is driven at the same time. The exhaust gas exits the turbocharger through the gas- outlet diffuser and the gas outlet casing. ‘The compressor wheel draws in fresh air through the silencer or the in take casing and the insert, The fresh air is compressed in the compres sor wheo|, dfuser and compressor casing. The compressed fresh air Js forced into the cylinders of the engine via charge air cooler and charge air pipe. ‘The running equipment of the turbocharger is led radially by two bear ing bushes, which are situated in the bearing casing between turbine wheel and compressor wheel. The thrust bearing positioned on the ‘compressor side not only handles the axial guidance, but also transfers the thrust in axial direction. A bearing body holds the bearing seat and, at the same time is used as insulation against the hot exhaust-gas side of the turbocharger. SEX ema —- Gad 6671 C1 4.1-01E 07.04 ‘TCAG6 35Intended Use Not Intended Use Go 6671 C14tore “The turbocharger is intended for use on diesel and heavy-fuel-oil en- gines. It produces the required amount of air for engine operation and the charge pressure. Any application beyond this must be discussed with and approved by MAN B&W, otherwise MAN B&W will refuse any and all liability. Each turbocharger is specially adapted to the engine with which it will be operated. This means the turbocharger may be operated only on this engine or one that is absolutely comparable (Also see scope of ‘supply, technical specifications and order confirmation). In addition to this, the intended use includes as follows: «The buildin location must aford sucent space for maintenance and assembiy/disassembly ofthe turbocharger. Usage of liting equipment must be possible. + Supply, measuring, contol and regulating systems must enable trouble-free operation (design/lay-out in accordance with MAN B&W recommendation, resp. state of art). «Observing the operating parameters (aiissible exhaust gas temperature, admissible le oll temperature and lube oll pressure, use ofthe spectied operating materials, see Chapter 3) «The turbocharger may be put ito operation only when in perect condition. + Operation may be carried out only by trained personnel which is familar with the system; operation through unauthorized personnel isto be prevented with suitable means, For operation, he operating manuals and the general safety and operational regulations are to be observed. ‘©The operation must be controlled by means of sultable measures. {Malfunctions that could influence the safety are tobe corrected immediately «Performing the service and maintenance in accordance with the maintenance schedule. ‘© For repairs, use original spare part only. The following points specifically do no comply with the intended use. ‘STX Enpaco & MAN B&W shall not be held liable for any or all damages resulting therefrom. Unauthorized changes/alteration on the turbocharger. Installation of foreign (non-original) parts. Operation not within the defined operating parameters. Bridging/shutting off alarm systems, and thereby enabling ‘operation in spite of limiting values being exceeded, © Operation when supply systems have failed (e. g. lubricating oil system), Insufficient maintenance, © Longer-term shut downs without preservation measures. 07.04 TCASS 36Lube Oil System Lube Oil Diagram Level 2 42 10 | detvery scone turbocharger lo max. inclination of system: + 5° 1 Ww | + supp pipe 7 Bearing casing 13. Non-return valve | 21 Pressure reduction 8 Locating bearing wth oypass valve (4-sroke) 8 Bearing bush 14 Bore 22 Onice (2-sroke) 10 Drain pipe 15. Supply/erain pipe 3 Turbocharger supply 11 Service tank or crankcase 16 Orifice Pipe 12 Venting 17 Overiow pipe 4 Non-return valve 18 Emergency and 5 Pressure monitor postlubricaton sys- i 6 Pressure gauge fom 2 Fig. 8. Lube oll dlagram, TCAGS StXtme Gad 6671 142-01 o7.04 ToAss a7Functional Description Lube Ol Circuit Venting Emergency and Post-lubrication System StKerpco— fan) 6671 C142o1€ ‘The lubrication and cooling of the high-stressed bearing bushes in the turbocharger takes place by means of a lube oil system, which is inte~ grated mainly in the bearing casing, ‘The lubricating ol is supplied from the lube oil system of the engine to the lube oil system of the turbocharger via a supply pipe (1). Apressure reduction valve (2.1) (four-stroke engine) respectively an orifice (2.2) (two-stroke engine) adjusts the required lube cil pressure. The lube oil pressure is controlled behind the non-return valve (4) by means of a pressure monitor (5) and a pressure gauge (6). Important! Air bubbles may not be contained in the oil being supplied. This could lead to bearing damage at post lubrication of the turbocharger. ‘The lubrication oil flows through the non-return valve (4) into the turbo- charger casing, from where it reaches the thrust bearing (8) and the bearing bushes (9) via passages in the bearing casing (7) and the bear- ing body. The lubricating oil flows to the gap between bearing and shaft as well as to the face-sided lubrication point of the thrust bearing via boresin the bearing bushes. The lubricating oil eaves the gap between the bearing and the shaft and is splashed against the wall of the bear- ing casing by the rotation of the shaft. The lubricating oil exits the bear- ing casing through the drain pipe (10) and flows back into the lube oil system of the engine (11). Important! The pipe for the lube oil drain must be installed with sufficient large diameter and inclination, 50 that drainage of the lube oil is readily possible without backing up. A backup in the lube oil drain can lead to an oil-flood in the turbo- ‘charger. In the worst case, the oll can come out of the turbine-side and cause a fire in the exhaust pipe. For this reason the lube oil drain must be installed with an inclination, which Is calculated as follows: Inclination a> max. possible system inclination + 5°. Due to constructive measures, this turbocharger does not require a separate venting tank. Lubricating oil and air are separated from each ‘other within the bearing casing. The connection for the venting pipe (12)is attached directly at the bearing casing. ‘The emergency and post-lubrication system (18) above the turbo- charger ensures the lubrication of the bearings after the engine is switched off, as long as the rotating element runs out and the bearings stil must cool down, During operation the non-return valve (19) is shut. The emergency and postlubrication system is filed with lubricating oll via a small bypass bore in the valve plate of the non-retum valve (13). As long as the lube oil level is below the overflow (17), the emergency and postlubrication system is pressure-free. As soon as the lube oil level reaches the over- ‘low pipe (level 2), lubricating oil flows back into the bearing casing through the overfiow pipe. An office (16) is installed in the overflow pipe. Iteffects that less lubricating ol runs off than enters, until the emergency 07.04 TASS 38Shaft Sealing Operating Conditions Lube Oil Quality Lube Oil Fittation Lube Oil Temperature Lube Oil Pressure StKemae— Gan 6671 C142-01€ ‘and post-lubrication system is filled, This leads to compression of the air in the upper part of the tank. I the engine is shutoff, the pressure in the lube oil system is reduced. This causes the non-retum valve (13) to open and the non-return valve (4) to shut. At first the lubricating oil lows under pressure from the emer- gency and postlubrication system back into the turbocharger to the bearing bushes. As soon as the lube oil level sinks below the overflow (level 2), the emergency and post-ubrication system becomes pressure {ee again. The lubrication ol is now fed back to the bearing bushes at reduced flow rate by means of gravity. Once the height of the supply/ drain pipe (15) is reached (level 1), the volume remaining in the tank flows through a small bore (14) in the supply/drain pipe near the bottom passage. The size of the bore is dimensioned in such a manner that due tothe geodetic pressure, only the bearing bush (9) on the turbine side is post-lubricated, ‘The bearing casing is sealed with labyrinth sealings on the rotor shatt, both on the turbine and compressor side. The radial labyrinth clearance is dimensioned so that during the first operating phase, the rotating lab- yinth tips ightly embed into the softer layer of the cover seal. At higher speeds, the running equipment is lightly elevated according to the thickness of the lubricating film. The labyrinth tips run freely then. When standing still, the running equipment is lowered again. The labyrinth tips embed into the grooves of the cover seal, through which a better sealing effect is achieved during pre and post lubrication. Run-in grooves at the circumference of the sealing cover bores are thus inten- tional and not a reason for replacement of the parts. (On the turbine side, the shaftis additionally sealed by means of sealing air (see Chapter 4.3). Commercial engine lubricating oils SAE 30 and SAE 40. High-alkaline cylinder oils are not suitable (see Chapter 3.1) The turbocharger does not require any separate lube oil fiters, The fi tration and processing of the lubrication oil through the engine system is generally sufficient, The following values must be observed: © Lube oi fiter = 0.050 mm, ‘© Accumulation with water < 0.2% amount of weight, ‘© No accumulation with residue > 0.020 mm. Inlet temperature in the turbocharger: max. 70 °C. For engine lube oil pressures > 2.2 bar, we recommend installing a pressure reduction valve with outlet control. The lube oil pressure is controlled via the measuring connection behind, the non-retum valve. Important! Level differences between indication instrument and center turbocharger are to be taken into account with + 0.1 bar per 1m level difference. (Indicator positioned higher - lower pressure; indicator positioned lower — higher pressure) 07.04 TOAGS 39Lube Oil Consumption Pre-lubrication Post Lubrication StXKemae—- Gd 6671 C142-01€ Lube oil pressure at full load of engine and lubrication oil at operating temperature: Phin = 1-2bar Png = 2.2 bar Lube oil pressure at engine start and cold lube oil: For a short time up to A bar. Limit values for alarm in case of too low lube oll pressure’ At <1.2 bar: Alarm, at <1.0 bar Engine power at half load and at <0.8 bar: Engine stop. Important! When reaching the limit values, both the alarm and the reaction of the engine control must go off at the same time (without delay), in order to avoid damage to the turbocharger. The required lube oil throughput depends on the viscosity and temper- ature of the lubrication oil. At 60 °C~65 °C, the lube oil throughput is approx. 9m. Before starting the engine, the bearing points of the turbocharger must be pre-lubricated. This is done automatically together with the pro-Iu- brication of the engine, as the lube oil system of the turbocharger is. connected to that of the engine. Depending on the engine system, pre- lubrication ocours directly before starting, either through interval of con- tinuous pre-lubrication. Pre-lubrication before start ‘# 10-30 minutes max. at an oil pressure of 0.6 - 2.2 bar. Interval presubrication: © 10 minutes max. per 2 h, oll pressure of 0.6 - 2.2 bar. Continuous pre-lubrication: ‘¢ Atul oll pressure only in conjunction with external sealing air (option). ‘© With oll pressure at maximum 0.2 - 0.6 bar possible only without flue. Occurs automatically via the emergency and post-ubrication system; otherwise at an oil pressure of 0.2 - 0.6 bar for a periad of 10-30 minutes. 07.04 TCAGS 40Connecting Several Turbochargers to the Engine Lube Oil System It an engine operates with several turbochargers, then these are con- nected paraliol othe lube ol system ofthe engine (sce Fig. ©). 1 Supply pipe 2.1 Pressure reduction valve 3 Turbocharger supply valve 4 Non-return valve 5 Pressure monitor 6 Pressure gauge 7 Bearing casing 0. Drain pipe 11 Service tank or crankcase 12 Venting 18. Emergency and post- lubrication system @ Maximum inelination of system: +.5° SUX ema —Gan 6671 C1 4.2-01E 07.04 TCAs aSealing Air System 4.3 ‘sealing Air Diagram . ° i? —. 5 H Ishs | " Sy} o 1 Compressor casing 6 Compensation pipe 12. Gas outlet casing 2 Ring duct, compres- 7 Non-return valve © Compressor whee! sorside 8 Pipe bend T Turbine wheel 3 Oriice 9 Bearing bush 4 Seating air pipe 10 Locating bearing 5 Ring duet, turbine-side 11 Bearing casing Fig. 10. Sealing air diagram, TCAG6 StKemo-G 6671 C14.3-01E 07.04 TCASS 42Functional Description Sealing Ar System Measures in Case of Vacuum External Sealing Air ‘Sealing Air System with External Air Connection’ SUXcme— Ga 6671 C1 4.3-01E ‘The sealing air prevents hot exhaust gas from entering the bearing cas- ing and the lubricating oll from seeping into the turbine (oll coke). Adt tionally, undesirable axial thrust on the bearing bushes is reduced. ‘The sealing air system is fully integrated in the bearing casing (11). A part of the air compressed by the compressor wheel (C) is diverted and flows out of the campressor casing (1) into a ring duct (2) in the bearing ‘casing. From there, the air is led into the sealing air pipe (4), whereby an office (3) reduces the pressure to the required sealing air pressure, ‘The airis led to a ring duct (5) on the turbine side of the bearing casing. ‘There, the sealing air emerges between shaft and turbine labyrinth, ‘© Asmall amount of the sealing air flows back into the bearing casing, presses against the turbine-sided bearing bush (9), and thus holds back the lubricating oil. ‘* The other part of the sealing air is led past the rotor shatt, through the labyrinth seal on the turbine side, and into the gas outlet casing (12), This develops a thrust-compensating piston between the labyrinths on the turbine disc and bearing casing. The sealing air pressure is factory set via the orifice (3) and must not, be controlled or readjusted by the user. With four-stroke engines, a vacuum can develop on the compressor side at reduced partial load (suction operation). In this case, a compensation pipe (6) between sealing air pipe and ambient air prevents lubricating oil and exhaust gas from being drawn into the compressor casing. ‘Anon-return valve (7) blocks the compensation pipe during regular ‘operation. In case of a vacuum in the sealing air system, the spring-free non-return valve opens and outside air is drawn In through the ‘compensation pipe. Optionally, the turbocharger can also be operated with external sealing alr. This Is necessary, when a seal is required through sealing air be- fore the engine and turbocharger star, e. g. when the bearings are pre- lubricated for an extended period (see Chapter 4.2). For long standstils of the engine with the lube oll pump running or for ‘operation with extreme low load, it can be required to supply exterior ‘sealing air in order to avoid oil leakage. For this, a compressed-air 07.04 TCAGS 43supply line with orfice is connected to the non-return valve of the compensation pipe instead of the pipe bend (see Fig. @). 7 Non-return valve 11. Bearing casing 13 Compressed-air sup- ply ine 14 Orifice 15 Pressure gauge 16 Venting Fig. 11. External sealing air Functional Description External Sealing Air Compressed ait from an external compressed-air source flows through the supply line (13) to the turbocharger, whereby an orifice (14) en- sures the required external sealing air pressure of 1.3 bar to maximum 1.5 bar. Before starting operation of the engine and turbocharger, the compressed ar flows through the non-return valve (7) and the compen- sation pipe into the intemal sealing air system of the turbocharger (15), thus providing the required seal. Important! The compressed air must be free of debris and condensate. Provide for a filter and water separator in the compressed-air supply line (13) as required. When starting the engine and turbocharger, the internal sealing air sys tem begins to operate (see above). As soon as the pressure of the in- ternal sealing air is higher than the external sealing air pressure, the ‘non-return valve in the compensation pipe shuts. The turbocharger now operates only with internal sealing air. a vacuum should ocour in the sealing air system during operation, the non-return valve opens. again and extemal sealing air flows in via the compensation pipe. In normal engine operation the amount of available sealing alr is always sufficient. For longer standstils of the engine with the lube oil Pump in operation or for operation with extreme low load, it can be necessary to supply external auxiliary sealing air in order to avoid oil leakage. StXem0- Ga 6671 6143-01 07.04 ‘TCAGS 44Acceleration System 44 “Jet Assist” (Auxiliary Air Drive) Diagram “Jet Assist” delivery scope turbocharger 1 Pressure reducing sta- 4. Ring duct A. Starting-air oytinder tion or orifice 5 Insert (80 bar) 2 Solenoid valve 6 Bore © Compressor wheel 3. Non-return valve 7 Compressor casing Fig. 12. Jet assist diagram, TCA66 StKerp0— Gal 6671 C1 44-01 E 07.04 TCAGG 45Functional Description ‘et Assist” StXepe Gm 6671 0144-01 € ‘The “Jet Assist” acceleration system is used when special require- ments are made towards swift and possibly soot-ree acceleration, and/or towards the load applications of the engine. ‘Tho engine control actvates the solenoid valve (2). Compressed air of 30 bar now flows from the starting-air cylinder through the pressure ro- ducing station or orifice (1), where itis reduced to a maximum of 4 bar. ‘The compressed air reaches the compressor casing (7) via a non-re~ turn valve (8) at a maximum of 4 bar, from where itis led to the insert (6) via the ring duct (4). The compressed airs blown onto the compres- ‘sor wheel (C) through several inclined bores in the insert. On the one hand this provides adcitional air to the compressor, while on the other hand the compressor wheel is accelerated, thus increasing the charge air pressure. 07.04 TOAGG 46Cleaning System — Dry Cleaning Diagram Dry cleaning of the turbine 45 Compressed air pipe (6-8 bar) Screw plug Granulate container Pipes (25x20mm) Connection flange Adapter Gas-admission casing Gas-outet casing Turbine wheel Nozzle ring Stop cook (compressed air) ‘Stop cock (exhaust gas) Fig. 13. Diagram, turbine dry cleaning Gam 6671 C145-01E 07.04 TCAs a7Functional Description Operating Conditions Stepe-GQ 6671 C14S-O1E The dry cleaning of the turbine is performed during operation at normal load of the engine. The gtanulate container (3) is equipped with a filing opening, a com- pressed-air pipe (1) and a pipe (4) leading to the gas-admission casing (7). The pipes for compressed air are fitted with stop cocks (A) and (B). The granulate container is filed with cleaning granulates and shut tight. The stop cock (A) in the compressed-air supply pipe is opened and compressed air flows into the granulate container. Afterwards, the stop ‘cock (B) in the pipe leading to the gas-admission casing is opened. The compressed air blows the granulates out of the granulate container into the gas-admission casing, trom where the exhaust gas flow transports the granulates to the turbine wheel. The granulates bounce against the nozzle ting and turbine wheel, thus removing deposits and contamina- tion. The exhaust gas flow carries the granulates and contamination parlicles out of the system. Important! Cleaning the turbine with granulates on ship systems can lead to downfall on deck. Note! Maintenance intorval, see Chapter 6.3.1 ~ Maintenance Schedule ‘© The granulate container (3) must be fastened at a suitable location. Itmay not be not be positioned lower than 1m below the connection flange (6). ‘© The pipe (4) may not be longer than 6 m and must be supported against vibrations. Ensure unobstructed flow. ‘© Maximum operating temperature of the stop cock (B) (exhaust gas): 150°C. ‘® The conneotion flange (5) can be attached either at the adapter (6) of the exhaust gas pipe or directly at the gas-admission casing (7). Important! ‘Store and mark granulates in such a manner that they can not be mistaken for other materials (salt, sand, etc.). Note! Granulates to be used for cleaning: See Chapter 3.2/ Technical Data ~ Operating Media 07.04 ToASS 48Clea ig System — Wet Cleaning of the Turbine 46 Diagram Wet cleaning of the turbine 1 Washing water 6 Turbine whee! 2 Prossure gauge 7. Drain, washing water 3 Nozzles 8 Drain funnel 4. Gas-admission casing B Drain valve 5 Nozzle ring E Shut off valve water supply Fig. 14. Diagram, turbine wet cleaning StXKewae—-Gd 6671 C14.6-01E 07.04 ‘TCAG6 49Functional Description StXtme- GQ 6671 C146-01E ‘The wet cleaning is performed during operation with heavily reduced engine load, in order to avoid overload of the turbine blades (ther- moshack), Note! Wet cleaning, see work card [500.21] in section C2. ‘The advantages of wet cleaning in comparison to dry cleaning are: ‘© The better cleaning effect and thus longer cleaning intervals, ‘© Control of the cleaning effect via the contamination degree of the drained washing water. The washing water flows through the stop cock (E). ‘The washing lances spray the washing water in the exhaust gas pipe -” in front ofthe turbine. The washing water droplets bounce against the nozzle ring andthe turbine, where they wear ofthe contamination. The ‘washing water collects in the turbine casing and runs off through the ‘washing water drain (7) and the drain valve (B). The washing water is led via a funnel (8) to a sediment tank, where itis collected. ‘The funnel enables visual control of the washing water. The cleaning process is finished when the washing water remains clean. Note! Maintenance interval, see Chapter 6.3.1 ~ Maintenance Schedule 07.04 TOASG 50Cleaning System — Wet Cleaning, Compressor 47 Wet Cleaning System of the Compressor with Pressure Sprayer 1 Handle 4 5 2 Pressure sprayer 3 Relief Valve 4) Hand valve 5 Turbocharger (compressor) Fig. 15. Wet cleaning system (pressure sprayer), compressor ‘The wet cleaning of the compressor is performed during operation at full load, ‘The water container of the pressure sprayer (2) is filled with freshwater. ‘An overpressure is created in the water container by means of the pump. By actuating the pushbutton on the hand valve (4), water is sprayed into the compressor casing (5) ahead of the compressor wheel. The water drops bounce against the compressor wheel where they wear off contamination. SUXemno— Ga 6671 C14.7-02E 07.04 TCASS stStKérmco Gad 6671 C1 4.7-02E 07.04 TCAG6 52Cooling System — Turbine Disc Turbocharger on the Four-stroke Engine 48 Cooling System of the Turbine Disc 1 Charge air cooler 2° Supply pipe, cooling air 3 Measuring lead to the pressure transmitter 4 Pressure transmitter 5 — Motor control 6° Screw connection 7 Gas-admission casing &* Pipe with flange 9° Nozzle ring 10" Turbine ise 11° Turbine rotor 12" Gas outlet casing Pax Pressure control cooling air Tu Exhaust gas tempera- ture ahead of turbine Mi, Rotor speed * delivery scope turbocharger _ a J} Fig. 16. Diagram, turbine-disc cooling with contro! Supercharged four-stroke diesel engines have very high exhaust gas temperatures. The turbine in particular is subject to these high temper- atures. To react against overheating of the TCA turbocharger turbine, the turbine disc (10) is cooled by means of charge air. 3 This new development enables additional potential for future applica- i tion beth on supercharged four-stroke diesel engines and gas engines 3 with iereased exhaust gas temperatures for maximum thermodynam- i ical efiency retes, StKtime Gd 6671 C14.8-01€ o7.04 Tease 53Note! The following functional description applies only for TCA turbochargers on four-stroke engines. On two-stroke engines, turbine-disc cooling is not necessary or does not apply. Functional Description Charge air is drawn from out of the charge air cooler (1). Charge air is conducted via the cooling air supply pipe (2) to the gas-admission cas- ing (7) and from there via pipe (88) to the hot side of the turbine. ‘The escaping flow of cooling air has an insulating effect between the hot exhaust gas and the turbine disc of the turbocharger. This reduces the charge of heat into the turbine disc. ‘The turbine disc cooling system works maintenance-free during opera~ tion. The pressure in the cooling air supply pipe (2) to the turbocharger depends on the load condition of the engine andis controlled by means of the pressure transmitter (4). If the pressure in the supply pipe is not within a defined tolerance range (reference value +/-), an alarm is sent ut from the engine control system with a request for load reduction. Parameters for control of the turbine disc cooling system: © Rotor speed of the turbocharger nin © Exhaust gas temperature ahead of turbine Ti © Pressure in the cooling alr pipe Pux Important! Without turbine-dise cooling, engine operation with an engine load exceeding 50% is not permitted (four-stroke engine) SWXemice GQ 6671 C1 4.8-01 07.04 ‘TCAGS 54Operation Starting Operation/Putting Out of Operation 5.1 Initial Starting of Operation 41. Unpack the turbocharger 2. Remove closing covers on gas-admission casing, gas outlet cas- ing and compressor casing. 3. Remove preservation agents on the exhaust gas flange of the tur- bine casing as wel as on the pressure neck ofthe compressor casing with suitable scraper and cold cleaner. Z\ warning Danger of poisoning from toxic vapours! The vapour-phase corrosion agent (increased corrosion protection) with which the openings of the turbocharger are treated sets toxic vapours free upon heating. + Thoroughly biow out the turbocharger casing before assembling the turbocharger. + Upon initial putting into operation, check if any corrosion protection agent is on the turbocharger. Work prior to Starting the Engine Starting Operation StXtmpae— Gan 6671 C15.1-01€ Important! The indication of the pending alarm and the reaction from the engine control system must occur at the same time. Therefore, the engine control system must at least correspond with category 3 according fo DIN EN 954-1. Note! For assembly of the turbocharger to the engine, see Technical Documentation/Section C2, 1. Pre-lubricate engine and bearing points of the turbocharger (en- {gine control system). Switch on exterior sealing air. 2. Sot all shut-off devices of the engine system to the operating po- sition. 3. Check the lube oil pressure in front of the turbocharger. Start the engine. The engine exhaust gases drive the turbocharger and thus begin to start the operation. If available, the “Jet assist” accelera- tion system is put into operation via the control system. 07.04 TOSS 55Checks during Operation General Continuous Checks on the Turbocharger ‘Smooth Running Speed StXee— Gan 6671 C15.1-01€ Despite automatic activation and control of the engine system, regular checks of the turbocharger are required so that possible malfunctions are detected as early as possible and the causes can be corrected in time. Important! The following listed checks are at the operators duty of care. Results, observations and activities of such control measures are to be recorded in an engine log book. Reference values are to be defined in order to enable an objective evaluation of the results. Turbocharger speed Lube oil pressure in front of turbocharger Lube oil temperature in front of turbocharger Lube oil temperature behind turbocharger Exhaust gas pressure in front of turbine Exhaust gas temperature in front of turbine Charge air pressure behind compressor Charge air temperature behind compressor Leakage of exhaust gas, charge air and ol pipes Contamination/saturation of air fiter mat at silencer ‘Smooth running of turbocharger Damage to the rotating element and bearings usually gives notice of appearance by unsmooth running, owing to imbalance or grazing of ro- tating parts. By auscultating the turbocharger (listening with e.g., a stethoscope), unsmooth running can often be detected at an early stage. For clean air ducts of the compressor, a certain charge air pressure is assigned to each speed of the turbocharger. Thus, the charge pressure gives information about the speed and can be used for approximate speed control 07.04 TOAGS 56What to do in Case of Operating Faults Z\ WARNING | Ignoring or suppressing alarms and putting reduction and stop signals out of operation can lead to operational malfunctions which can result in serious personal injury and damage to property! ‘Turbocharger and engine are fitted with an alarm system which sounds an alarm in case of technical problems or malfunctions. Therefore, an alarm always has a cause which must be rectified! + Do not ignore or suppress any alarm, reduction or stop signais! + Investigate the cause of or report every alarm, reduction or stop signal + AS far as possible, provide for swift rectification ofthe cause of alarms and signals! + Ignore or suppress alarms, reduction and stop signals only in cases of force majeure or when ordered by management! 1. Ether reduce the engine load or shut off engine, depending onthe sitvaion 2. Determine and corect the cause ofthe malfunction (see Chapter 5 3} Important! All malfunctions are to be corrected as soon as possible, as minor malfunctions can also lead to increased subsequent damage of the turbocharger or engine. 8. If the damage can not be corrected immediately, emergency op- eration is possible (see Chapter 5.2). 4, When the damage has been corrected, start the engine operation again as usual, Putting Out of Operation 1. Shut off engine, The turbocharger gradually comes to a stop. Important! The run-down time of the turbocharger permits to draw conclusions about its mechanical condition. Sudden stopping is an indicator for mechanical damage to the bearing, grazing of the ‘compressor or turbine wheel, foreign objects that have become obstructed or heavy contamination. 2. The lubrication oll runs out of the emergency and post-ubrication system to the turbocharger bearings so that these are still contin- ously lubricated for several minutes (post lubrication). SUXcme— GQ 6671 C1 5.1-01E 07.04 ‘TCAGE 87Emergency Operation of the Engine 5.2 on Failure of a Turbocharger lf damage ocours to a turbocharger which can not be corrected imme- diately, emergency operation is stil possible. Available Appliances Turbocharger (see work card [500.11] and [500.12}) ‘© Securing fixture for blocking of the rotating element from the ‘compressor side (intake cross-section remains open), © End cover, for closing of he compressor and turbine back side when the rotating element is disassembled. All appliances are designed in such a manner that continuous flow through the air and exhaust gas side of the turbocharger is possible. Appliances for use on the engine: © Screen (grid) forthe side ofthe charge air pipe that faces away from the turbocharger. The screen is supposed to ease the suction operation of the engine. ‘Blind flange’s for blocking of the partially mounted charge-air bypass pipe (i given). Achievable Outputs/Speeds for Four-stroke Engines The following criteria restrict the achievable engine load in engine- ‘emergency operation ‘© Maximum exhaust gas temperature after cylinder, ‘© Maximum exhaust gas temperature before turbocharger, © Density of exhaust gas. ‘The following rating data apply only as reference values: Turbocharger failed L-Engine | V-Engine Engine operation with variable speed 15% 15% Engine operation with constant speed | 20% 20% Tabla. 9: Emergency operation or talure of one turbocharger ~ Achiovablo outputs Step GA 6671 01 5.2-01E 07.04 TOASS 58Emergency Operation on Failure of One Turbocharger, | ZN Warning Despite compliance of the following measures, the danger of ) turbocharger destruction is still given! For this case, there is imminent danger of personal injury or damage to property! + Limit the duration of emergency operation to the absolute necessary minimum, + Use the securing fixture (measure A) for emergency operation only when removal of the running equipment is not possible! + Persons are by no means allowed to stay in the vicinity of the turbocharger during emergency operation unless absolutely necessary. Emergency Measures = ‘Supplementary Measures/ Precautions ___| (628 code number) Engine may not be stopped for reasons of urgency Turbocharger remains unchanged 7 _ 0-3 | Engine may be stopped (short-term) | important! | carry out measure A only when measure B can not be carried out for reasons | of time. Subsequent damages possible. Measure A: | Block rotor from the compressor side using securing fixture (intake cross-section re- os mains open). Afterwards, mount intake silencer again. (See work card (500.11) Measure B: Disassemble rotating element including bearings; shut bearing casing on compres- os sor and turbine side with end covers. Rleassemble silencer/intake casing and gas- admission casing again. (See work card [500.12)) _ Table 10: Emergency operation for fluro of one turbocharger Legend CodeNumber ‘Supplementary Measures/Precautions © Observe instructions of engine manufacturer! 1 Reduce engine power. The maximum exhaust gas temperatures behind cylinder and in front of turbocharger, and (for engines with two or more tur- bochargers) the maximum admissible turbocharger speed must not be ex ceeded. Pay atlention to density of exhaust gas. 2 Asa precaution prepare fire-extinguishing measures! 3 When the rotating elementis blocked or disassembled, stop lube oll supply ‘because of danger of contamination or fire. ; 4 For suction operation (or with two or more turbochargers), the engine must i be driven with reduced charge. } 5 Engines with two or more turbochargers: Separate the exhaust gas intake side of the defective turbocharger from the gas flow of the second turbocharger with blind flange. StKemace Gad 6671 C15.2-01E 07.04 TCA66 59Malfunctions/Faults 5.3 and their Causes (Trouble Shooting) Important! Incase of turbocharger irregularities upon or during engine ‘operation, determine and correct the cause of the malfunction as soon as possible. Otherwise the danger is given that minor ‘malfunctions can lead to increased subsequent damage on the turbocharger or engine. Ze Possible cause Corrective Action Work = Card 1 Exhaust gas temperature | Siencer contaminated Gleanireplace 500.24 in front of turbine too high | 500.22 ‘Compressor contaminated __|Clean 500.25 | Turbine wheel and/or nozzle | Clean 500.21 fing heavily contaminated — | 500.22 7 | 500.52 Rotating element grazes | Contact STX Enpaco T/C Plant, [MAN Baw Service Freign objects in front ofin tre |Check turbinelcompressor for | 50043 bine or compressor damage; contact STX Enpaco | 500.53 “TIC Plant, MAN B&W Service, if required _ Turbine wheel, shroud fing, | Exchange defective compo: | 600.43 nozzle ring or compressor’ —_[nents; contact STX Enpaco | 500.52 wheel damaged or eroded —_|T/C Plant, MAN B&W Service, | 500.53, if required | 500'54_ [High alrintake temperature | Reduce output Engine | Charge air cooler contaminated] Clean, measure pressure difler | Engine | : ential [Charge air pipe leaks Seal charge air pipe Engine ‘Charge air temperature too high aie Tnlet/exhaust valves, valve slots of engine contaminated Exhaust gas pipe leaks Seal exhaust gas pipe Engine ‘Exhaust-gas back-pressure be- | Clean boiler Plant | hind turbine too high — | Fue injection at engine fauly | Repair fel injection Engine Table 11: Trouble Shooting StX twice fea 6671 C15.3-01E 07.04 TCAGS 60oi] Martanction Possible Cause Corrective Aetion Work Card 2| Charge air pressure too | Turbine speed too low See malfuncion No.4 — |low ‘Silencer contaminated ‘Clean/replace 500.24 - 500.32 | Compressor contaminated | ean 500.25, “Turbine wheel and/ornozzie | Ciean 500.31 | ring heavily contaminated 500.22 : 500.52 Defective bearings, balance | Beaing nepection (nose and | 60043 of rotating element vibrations); contact STX Enpaco | 500.48 TiC Plant, MAN B&W Service, | 500.53 it required | 500.56 Fotaing element grazes |Check paris contact STX |" 500.89 Enpaco T/C Plant, MAN B&W | 500.54 Service, it required 500.56 Foreign abjecisn onlin tr- | Check turbine/eompressor or | 50043 bine or compressor damage; contact STX Enpaco | 500.53 [TiC Plant, MAN B&W Service, ifrequired | Turbine whe, Shroud ing, | Replace defective components; | 800.43 nozzle ing or compressor’ contact STX Enpaco TIC Ptant, | 500.52 ‘wheel damaged or eroded | MAN BAW Service, f required | 500.53 \ | - 500.54 | Tigh airintake temperature | leduce output Engine | | [Charge air cooler contaminated] Clean — [engine Sarge air pipe leaks Seal charge airpipe Engine inlet/exhaust valves, valveaiols | Clean, measure pressure afer | Engine |of engine contaminated ential [Exhaust gas pipe leaks ‘Seal exhaust gas pipe Engine Exhaust gas pressure affetur [Clean turbine; check for dam] $0021 bine too high age, if required 500.22 : 500.53, Fuel injection at engine faulty | Repair fuel injection Engine 3] Charge air pressure too —|Nozze ring lightly (Giean 500.52 high contaminated/resticted . Tow ar intake temperature [Reduce output Engine Table 11: Trouble Shooting StXtme—-Gr 6671 C15.3-01E 07.04 TCAGE 6tNo, |Malunetion Possible Cause [Conective Action Work Card, 4] Speed too low ‘Silencer or ai fitr contaminat- |Clean/replace 500.24 ed 500.32 Compressor contaminated | Clean 500.23 [Turbine wheel and/or nozzle [Clean —— 50021 fing heavily contaminated 500.22 | 500.52 [Defective bearings, imbalance | Bearing inepedlion, contact | 500.46 of rotating element STX Enpaco TIC Plant, MAN. | 500.58 | | __ [Baw Senvice, if required | [Rotating element grazes | Contact STX Enpaco T/C Piant| [MAN B&W Service, it required [Foreign abjacis in roni/in. | Check turbine/eompressor for | 500.43 | Turbine or compressor \amage; contact TX Enpaco | 500.53 “TiC Plant, MAN B&W Servica, __ required Turbine wheel, shrouding, [Replace defective components; | 500.43 nozzle ring or compressor contact STX Enpaco T/C Plant, | 500.52 wheel damaged or eroded | MAN B&W Serica, if required | 500.53 500.54 High air intake temperature | Reduce output Engine Charge air cooler contaminated | Clean Engine Charge air pipe leaks Seal charge air pipe Engine Jinlet/exhaust valves, valve slats [Clean Engine of engine contaminated Exhaust gas pipe leaks Seal exhaust gas pipe Engine Exhaust-gas backpressure |Clean turbine; check for 50021 behind turbine too high damage as required | s0022 : 500.53 Engine fuel injection faulty | Repair fuel injection [Engine '5| Speed too high ‘Nozzle ring lightly ‘Clean | 500.52) contaminated/restricted | [Low air intake temperature [Reduce output | Enaine | | Lube oil pressure too low |Fiow temperature of lube of 60 | Engine high Lube ol fiter contaminated | Replace ube ol filer Engine Lube oll manometer defective [Replace lube oll manometer —| Engine 7 | Labs oifioss Thrust ring, labyrinth ring dam | Check pats; contact STX | 500.45 Enpaco TIC Plant, MAN Baw | 500.53 aged Sonics, i required Detective labyrinth seal Checkpars; contact ST | s00ae Enpaco T/C Plant, MAN B&W | 500.55 Service, it required ‘Seals damaged, connections | Check parts; contact STX untight Enpaco TIC Plant, MAN B&W. Service, if required [Sealing air ineffective, oil coke | Check parts; contact ST | behind turbine whee! Enpaco TIC Plant, MAN B&W L _|Senvice,ifrequired [lube ollpressure too high | Reduce oil pressure Engine! Plant ‘Overpressure in oll drain or in [Drain oll as described in crankcase Chapter 4.2 Table 11: Trouble Shooting StKema-Gan 6671 C15.3-01E 07.04 TCASS 62{Noi [ Malfunction Possible Cause Convective Action Work I 2 Card _| | 8|Hesitant staring, short [Compressor contaminated | Clean - 500.23 |run-down time Turbine wheel and/or nozzle {Clean 500.21 | ring heavily contaminated 500.22 500.52 “Thrust ring, labyrinth ring dars- | Check paris; contact STX | 600.45, aged Enpaco T/C Plant, MAN B&W | 500.83 Service, if required \ Defective Bearings, imbalance |Bearing inspection; contact | 500.43 of rotating element STX Enpaco TIC Plant, MAN. | 500.46 | BAW Senice, if required 500.53 500.56 Rotating clement grazes Contact STX Enpaco T/C Plant, MAN B&W Service Foreign objects in fronivin | Check turbine/compressor for | 500-48 turbine or compressor damage; contact STX Enpaco, | 500.53 ‘T/C plant, MAN B&W Service, _ itrequired FFurbine whee), shroud ing, | Replace defective components; | 600.43, nozzle ring or compressor _| contact STX Enpaco T/C Plant, | 500.52 wheel damaged MAN B&W Service, if required '| 500.53 | 500.54 | Sealing air ineffecive, ol coke |Gheckparts;contactSTX | 00.83 behind turbine wheel Enpaco T/C Plant, MAN B&W — __| Service, itrequirod | Unusual strong noise | Thrust ring, labyrinth ring dam- | Check parts; contact STX 50046 aged Enpaco TIC Plant, MAN B&W | 500.53 a Service, if required | Detective bearings, imbalance [Bearing inspection; contact | 600.4 | of rotating element ‘STX Enpaco T/C Plant, MAN | 500.46 | BBW Senice, it required 500.53 | 500.56 Rotating element grazes | Checkparts;contactSTX | 00.53 Enpaco T/C Plant, MAN B&W | 500.54 Service, f required 500.56 Foreign objects in fronivin | Check turbine/compressor for | 00.43 turbine or compressor damage; contact STX Enpaco | 500.53, | ‘T/C Plant, MAN B&W Service, | | itrequired | FFurbine wheel, shroud ring, [Replace defective components; | 500.43, nozzle ring or compressor _| contact STX Enpaco TIC Plant, | 600.52 wheel damaged MAN B&W Service, if required | 600.53 500.54 Table 11: Trouble Shooting StXemae Gad 6671 C15.3-01E 07.04 TCAG6 63No. | Malfunction Possible Cause Corrective Action Work Card 10) Turbocharger vibrates | Turbine wheel heavily contami- | Clean 500.24 nated i 500.22 Thrust ring, labyrinth ring dam | Check parts; contact STX 500.45, aged Enpaco T/C Plant, MANB&W | 500.53, Service, if required Defective bearings, imbalance |Bearing inspection; contact | 500.43 of rotating element STX Enpaco TIG Plant, MAN | 500.46 BBW Service, itrequired | 500.53, 500.56 Rotating element grazes (Checkparts;contactsTX | 500.53 Enpaco TIC Plant, MAN B&W | 500.54 Senvice, it required 500.56 Foreign objects in front/in tur- | Check turbine/compressor for | 500-43, bine or compressor damage; contact STX Enpaco | 500.63 TIC Plant, MAN B&W Service, if required | Turbine wheel, shroud ring, | Replace defective components; | 500.43 nozzle ring or compressor | contact STX Enpaco T/C Plant, | 500.52 whee! damaged MAN B&W Service, it required’ | 500.53, | 500.54 T1|Compressor pumps | Turbine wheel and/or nozzle | Clean 500.21 | ring heavily contaminated 500.22 500.52 Foreign objects in front/in tur- | heck turbine/compressor for | 500.43, bine or compressor damage; contact STX Enpaco | 500.53 ‘T/C Plant, MAN B&W Service, if required Low airintake temperature [Reduce output Engine Charge air cooler contaminated] Clean Engine Charge air temperature too high|Reduce output Engine Iniet/exhaust valves, vaive slots [Clean Engine of engine contaminated ‘Exhaust-gas back pressure be- | Check exhaust gas pipe Engine? [hind turbine too high _ Plant Repair fuel injection Engine Table 11: Trouble Shooting ' hom 6671 C1S.-01E o7.04 ‘ToA6S 64Maintenance 6 General Remarks 6.1 Maintenance Work ‘Maintenance work belongs to the duties of the user, just as regular checks do. Their purpose is to retain operational readiness and opera- tional safety of the system. They are to be carried out by competent personnel in accordance with the time schedule for maintenance. Maintenance work supports the operating personnel in their effort to detect arising malfunctions‘fallures in time. They deliver hints towards necessary maintenance work or repairs to the persons responsible, and influence the planning of downtimes. Maintenance and repair work can be carried out properly only when the required spare parts are available. In addition to these spare parts, itis, advisable to stock a certain quantity of spares for unexpected outages. Maintenance Schedule The required tasks are listed in the maintenance schedule. (Chapter 6.3.1/6.3.2). contains a brief description of the work, the repeat intervals, the personnel and time requirements, references to the respective work cards/working instructions. Work Cards ‘The work cards are comprised in Part C2 of the technical documienta- tion. They describe the aim and object of the work ‘and contain information about the required tools/appliances and ‘© dotailed descriptions and graphical depictions of the necessary ‘work sequences and work steps. SUX ema — Gd 6671 C16.1-01E 07.04 TCAGS 65Spare Parts ‘Special Services/Repair Work SiXema-GQ 6671 C16.1-01E Ordinal numbers for spare parts ‘© Turbocharger: In the spare parts catalog in Part C3 of the technical documentation © Tools: Table of contents for tools ‘© can be found on the respective work cards in Part C2 of the technical documentation. Ordinal numbers consist of the 3-digit assemblies number, a dot, and a 3-digit position number. ‘STX Enpaco offers the following special services: Delivery of spare parts Consultation and support on questions concerning operation, maintenance and repalts Field-experienced training for operating personnel of STX Enpaco - MAN exhaust gas turbochargers ‘Assessment and clarification of damage cases Dispatch of fitters and engineers In case of requests please contact us at STX Enpaco T/C Plant MAN B&W Diesel AG, Augsburg Works MAN B&W Diesel AG, Service Center Hamburg MAN B&W Diesel Pte. Ltd., Service Center Singapore Other Service Centers and authorized repair shops ‘Addresses in Chapter 1.3. 07.04 TCASS 66Tools/Special Tools 6.2 Inventory tools Conventional tools, usually included in the inventory of the engine sys tem, Inventory tools are not contained in the turbocharger’s scope of supply. Standard Tools Included as standard in the turbocharger’s scope of supply. Normally, one set of standard tools is sufficient for a system with sev- eral turbochargers. The usual maintenance work can be carried out with these standard tools and the inventory tools. ‘The standard too! kit for the turbocharger(s) is combinedin one or more boxes and supplied with a table of contents. The ordinal numbers of the individual tools can also be taken from the table of contents, Tools Requested by the Customer Additional tools and appliances can be ordered at the STX Enpaco, as required. Special Tools Available only at the Service Centers; these tools are not required by the user of the turbocharger. ‘Some jobs, - more repair work than maintenance-, require special knowledge, experience and auxiliary equipment/appliances. For jobs like this, adcitional specialty tools are available to our Service Centers and possibly to some authorized repair shops. Therefore, we recom- mend that you always consult these Partners or commission work to ther when your own time schedule, or the professional or personnel capacities are not sufficient. SUXcomo— Gan) 6671 01 6.2-01E 07.04 TCAS6 67Maintenance Schedule 6.3 Reliability and Adaptability Validity of the Maintenance The maintenance schedule contains a summary of the maintenance Schedule and inspection work, down to the major overhaul of the turbocharger. ‘A major overhaul of the turbocharger must be carried out latest after '* 12.000-18 000 operating hours with four-stroke engines or #24 .000-20 000 operating hours with two-stroke engines. After each major overhaul, which best is carried out with a due engine service, the maintenance schedule starts from the beginning again. ‘A major overhaul includes the disassembly of the complete turbocharg- er for inspection of the actual condition, thorough cleaning and a check of all parts/components, Important! The maintenance must be scheduled ahead of time, meaning that . g. ship timetables or auditioning periods of power plants must ‘be planned. In order to ensure the operational safety of the turbocharger and the engine, maintenance work is to be performed as far as possible on schedule or beforehand. ‘Adaptation of the Maintenance The maintenance schedule takes the following operating conditions Schedule and an annual operating petiod of approx. 6000 h into account: ‘© Uniform loading within a range of 60 to 90% of the rated power, '® Observation of the specified operating media temperatures and pressures, © Usage of the specified lube oil and fuel qualities, ‘© Attentive separation of fuel and lubrication oi ‘The maintenance intervals must be shortened when the following op- erating conditions are given: ‘© Longer-term operation with peak loads or low loads, long idle periods, frequent heavy load cycles, ‘© Frequent engine starts and repeated run-up phases without sufficient warming-up, ‘¢ High stress on the engine before reaching the specified operating media temperatures, ‘© Too low lube cil, cooling water and charge air temperatures, © Use of problematic fuel qualities and insufficient separation, ‘© Insutfcient filtration of the intake air (particularly with stationary engines). 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Inspection Report For a major overhaul of the turbocharger or for repair work concerning ‘major components, itis recommended to record the condition of indi- vidual subassemblies and make entries into the operating log. Inspec tion report form, see Chapter 6.6. Important! For disassembly work, mark the position of the components to each other using a felf pen. required, document the disassembly/assembly with a camera. Exchanging Components. ‘Components with traces of wear or damage that influence especially the strength and the balancing precision and thus the smooth running of rotating parts, must be exchanged with original spare parts or re- paired by an authorized repair facility or the manufacturer. For dispatch, components must be packed and protected against cor- rosion in such a manner that they are not further damaged during trans- portation. Screw Connections Loosening Seized or Snug Important! Connections Never attempt to loosen seized or snug screw connections with overly force. This can lead to screws being torn off or parts being 0 heavily damaged that they must be replaced. Torn off screws ‘must be drilled out; the threads must be reworked. Apply plenty of diesel fue! or special dissolver (e. g. Caramba, Omnig- liss, WD 40) to the screw connection and allow to penetrate for atleast 1/2 hour, so that the dissolver can work its way through the threads. Observe the applicational tips of the dissolver manufacturer. After- wards, apply light hammer blows to the scraw/bolt head so that the threads run freely. Tightening Screw Connections All screw connections on the turbocharger must be in perfect condition Upon assembly or be renewed. When assembling lock washer pairs (1 pair consists of 2 equal washers), the long wedge surfaces (inside) must face each other, otherwise there will be no secuting effect. SUG) 6671 C1 6.4-01E 07.04 TCAGS 73— Screw Connections on the Turbine Side StKerp0— and 6671 C164-01€ Fig. 17. Assembly of wedge lock washers Important! Always tighten screws/botts with the specified tightening torque! (see Technical Documentation Section C2 Work Cards) Improper tightened and secured screws/bolts and nuts can become loose due to vibrations and then be driven into the turbocharger by the air or exhaust gas flow, and cause severe damage. Due to the high temperatures on the turbine side, screws/bolts, nuts and tab washers of non-scaling materials are used. These are marked (on the face side (SM, VM or 4923, Z1 or 4828), to avoid them from be- ing mistaken with regular parts. When disassembling, the fastenors marked in this manner are to be stored separately until being assem- bled, All lock washer pairs on the turbocharger are made of non-scaling ma- terial and are not marked. In order to avoid the screws/bolts and nuts on the turbine side from heating together, they must be treated with high-temperature lubricant (e. g. Molykote HSC) prior to each new assembly. Before treating with lubricant, the threads must be cleaned thoroughly. Screw-in threads. from studs are not treated, 07.04 TCASS 74Inspection of Individual Components 6.5 The following remarks and questions are intended as a guide, e. 9. for Assessment of the turbocharger condition, ‘© Operating log and inspection report, © Checking, reusing, repair and replacement of individual ‘components. Gaps and Clearances Admissible values, see C2 Chapter 3.2. Crack Test Crack test on turbine blades (turbine rotor, compressor wheel) via acoustic testing or penetration testing with fluorescent color. ‘Streaks Streaks all around the circumference of the turbine rotor, compressor ‘wheel, insert: Check gaps and clearances, see C2 Chapter 3.2. Streaks, locally on circumference of turbine rotor, compressor wheel, inser: Indication of imbalance. il Coke behind Turbine Wheel Sealing air not effective (e. g., pipe clogged), shalt seal on turbine side damaged or pre-lubrication pressure too high. Erosion during HFO Operation During HFO operation, small, hard particles (e.g. “catfines") are con- tained in the exhaust gas. These act particularly erosive where high {gas velocities and high concentrations of such particles occur. The highest flow rates are effective at the outlet of the turbine nozzle ring. Here, the flow is strongly deflected towards the direction of the circum- ference, Besides this, the particles contained in the exhaust gas are hurled towards the outside. For this reason erosions can be noticed at the discharge of the nozzle ing, at the interior diameter of the shroud ring and at the exterior of the turbine blades. “Catfines” ‘As a result of the refinery process and the achieved quality, “catfines", a fine grained powder with great hardness (recognizable through the Al and Si content) as well as other abrasive contaminants, are contained in the heavy fuel ol. Their amount can be reduced by means of well di- ‘mensioned, heated settling tanks and through sufficient separation. Additions ‘Adding used engine lube oll is of particular disadvantage, recognizable through the increased amounts of Ca and Fe. Used engine oil not only ins residues of wear, but above all “Detergant dispersing addi tives’, which bind fine particles and prevent “caifines” and other impu- ities from being eliminated through separation. For operation with waste oil’ added, a sharp increase of erosion damage is noticed. ‘Combustion residue caused by incomplete combustion can also have erosive effects. Therefore, ensure clean combustion. Silencer, i available How is the condition ofthe air filter mat? How is the condition of the ab- sorption plates? Are cracks on any of the components? Insert Are there any traces of streaks? Control Unit for Speed Is the speed transmitter or the speed indicator defective? SUX ema — Gar 6671 C1 6.5-01E 07.04 TCAGS 75Casing Compressor Wheel Turbine Rotor ‘Shroud Ring Turbine Nozzle Ring Thrust Ring Bearings Labyrinth Disk, End Cover SWXemae—-Gar 6671 C1 6.5-01E Which casings are strongly contaminated from soot, oil or oil coke? Were the casings tight, particularly atthe parting lines and the connec- tion flanges? Do the casings show signs of cracks? Were screws/bolts torn? Were all screws/bolts and nuts firmly tight- ened and secured? Was the seal air or were oil bores in the bearing casing clogged? ‘Are all seals O.K.? How is the seat of the compressor wheel and the carrier? Are the seat faces bright or are there signs of freting? Do the turbine blades show signs of cracks or heavy wear? Are there traces of streaks? Do the leading edges ofthe turbine blades show puncture notches: caused by drawn-in foreign objects? How is the run-out of the shaft? How is the condition of the bearing points? ‘Are the labyrinth rings strongly worn? Are the seating faces bright or are there signs of fretting? Are the blades damaged or is heavy wear or erosion at the edges de- tectable? Do the blades have signs of cracks? Do the blades, disc or shaft show any traces of streaks? ‘Are the fastenings at the foot of the blade 0.K.? Note! Innew condition, the blades are not fastened but inserted into the disc with clearance. At the blade end, they can be moved several milimeters both in axial and in radial direction. Due to deposits, this ‘movabilty is limited after extended periods of operation. Are there any traces of streaks from the turbine blades? ‘The radial gap between shroud ring and turbine blade may not fall be- low the minimum value at any position, in order to avoid grazing during operation. The gap can become larger due to erosion. This consider- ably influences the efficiency. Therefore, the gap is measured at 4 lo- cations around the circumference (every 90°) during checking. Admis- sible values, see work card [500.54] ‘Are the blades bent? Are the blades heavily worn due to erosion? ‘Are foreign objects obstructed in the ducts? Can traces be detected that point out to foreign objects? Can any cracks be detected at the biades? ‘Are the die seating faces bright or are there signs of fretting? ‘Are there any signs of scoring or heavy wear? For checking of the bearings and bearing bushes, see work card [500.46] and [500.56]. Any wear across comers on both bearingsis an indicator for imbalance of the running equipment. How is the seat of the bearing in the casing bore? Is the axial clearance of the running equipment and the bearing clear- ance within the admissible range? Note! When the axial bearing clearance is determined by axial displacement of the running equipment, then the running equipment is to be lited lightly so that the labyrinth tips come free, out of the grooves in the cover seal. Is the run-in pattern of the labyrinth tips normal?” 07.04 TOASS 76Inspection Report 6.6 ‘Accompanying the installer report ... Name of customer Address. Site Name of vessel Reason... Last inspection/Overhauled on. Operating hours since start @ checked DIntake casing, i available . 1D contaminated O Silencer, if available D Airfiter mat Ci contaminated 0 cleaned 1 Speed transmitter, if available Oi defective 1 Insert Clutiized replaced Ccontaminated 1 traces of streaks Daxial CO radial 1 all around the circumfer- ence 1 Locally on the circumfer- | ence | Location 1D Compressor housing 1D cracks 1D damage from foreign ob- jects ‘Turbocharger inspected/overhauled on. . Dutlized replaced | D contaminated... og Operating hours since last inspection/overhaul B Please mark where applicable 0 Diffuser D utilized replaced 1 contaminated. blades bent tom damage trom foreign ob- jects Compressor wheel 0 utilized replaced Reason 1D contaminated 1 traces of streaks Davial 0 radial 1D all around the circumfer- ence 1D locally on the circumfer- ence Location O blades OI bent tom damage trom foreign ob- jects O bore signs of fretting Thrust ring Dutiized replaced 1 signs of scoring Owear 1D signs of fretting Date “Turbocharger Works No... Engine type Works No. by by 1D Turbine rotor D utized replaced reason Ui balanced Oi contaminated. 1 traces of streaks OT axial 0 radial all around the circumference 1D locally on the circumference Location. 1 blades 1 bent tom Oi blade 1 foot plate D foot damage from foreign objects erosion coverings O light heavy Oi one-sided 1 Bearing points signs of scoring wear O seatings 1D signs of fretting Location. 1 labyrinth tips D ollcoke O wear oo SUXtme— Gr 6671 C1 66-01 07.04 TCAGG 71 Bearing casing © Labyrinth disk, compressor Shroud ring ne side(sealing cover) 1D Cracks D utiized replaced 0 utilized replaced reason. 1 Sealing air bores 1 abnormal run-in pattern 1 Contaminated i clogged 1 cleaned O wear : ion ees Di traces of streaks 1 Erosion 1 clogged O cleaned ‘1 End cover, turbine side 1D Traces of streaks 1D all around the O Seals O utlized replaced Leki O replaced 1D abnormal run-in patter 1D locally on the O Sealing air valve, if available wear circumference 1 Valve plater Ee ee ents Location. 0 Labyrinth disk, turbine side moves easily 1 Gas-admission casing Direplaced ES oneestlh es Clepleced a ar rere G Bearing disk O wear 0 Cracks D utilized O replaced oleh Cea O Erosion Di signs of scoring Turbine nozzle ring 1 Damage from foreign objects| aes Ovized replaced Serewconnectons 0 blades aes oe length ()- compressor side Dados, replace Taperfece sul Fy damage rom frsign objets G88 outlet casing 1 length (i) - turbine side Gi puncture notches 1 contaminated Taperface. mm eee Cracks C Counter-thrust bearing O coverings. . 7 1D Damage from foreign objects} D ight 1 Serew connections 1D ullized 1 replaced O heavy 1 toose CI torn off 1D signs of scoring 1D one-sided 1 replaced 0 wear 1 length (0), taperface.....mm Gaps and clearances (admissible values, see C2 Chapter 3.2) Pos. 6 Turbine blade/shroud ring (Radial gap) .. mm Pos. 10 ‘Compressor wheel/insert (Axial clearance) mm Pos. 11 Compressor wheel/insert (Radial gap) mm Remarks: Date Signature StXemica Gan 6671 C1 6.6-01E 07.04 TCAGS 78Technical Documentation Exhaust Gas Turbocharger Work Cards C2 Exhaust Gas Turbocharger. TCA6E D36 6671-1 E SOK Enpaco co, Ltd. 452-7, Nae-dong, Changwon, Gyunsangnam-do, 641-050 Korea « Phone +482 55 280 0770 «Fax ++82 55 282 1938 E-mail: sdlee285e@stxenpaco.cokr + httpy/www.stxenpaco.co.ke StKemae—Gand 6671 C2-01E 05.05 TCAG6 79Table of contents c2 1 Introduction BA Preface nnn 81 1.2 Layout and Usage of the Work Cards. 82 2 Safety Instructions 2.1 Symbols and Designations ve 85 22 Safety Instruction Sign Engine Room. - 86 3 Setting Data 8.1 Bolted Connections and Tightening Torques. 89 82 Gaps and Clearances... 93 4 Work Cards. 44 Emergency Operation 97 500-11 Operation wih Holding Device » a so sn 99 500.12 Operation without Rotating Element “103 42 Cleaninginnn 107 500.21 Cleaning the Turbine (Wet Cleaning) 409 00.22 Cleaning the Turbine (Dry Cleaning) 413 50023 Gleaing the Compressor (Presture Sprayer) svn : 115 500.24 Cleaning the Alt FiROF nun 117 4.9 Assembly of the Turbocharger and Auxliary Equipment 119 $00.91 Turbochargr 0 Engine wn sme 2A 500.32 Silencer : Sree 129 500.33. Air intake Casing . snnnenn 183 500.34 Emergency and Postlubrication System 137 44 Assembly and Maintenance - Compressor Side... : 141 500.41 Speed Transmitter and Insert 143 500.42 Compressor Casing and Dittuser 149 500.43 Compressor Wheel 153 500.44 Labyrinth Disk : . : ene i63 500.45 Ring Nut and Labyrinth Fing sn 187 500.46 Thrust Bearing, Counter-Thrust Bearing 71 4.5 Assembly and Maintenance - Turbine Sid@ 0. 7 500.51 Gas-admission Casing : sennnnnnsnnnnnne VI 500.52 Turbine Nozzle Ring nnn 183 500.53. Turbine ROtOr nnn 187 500.54 Shroud Ring sven 191 500.55 End COVE onnnnnn 195 500.56 Bearing Bushes 197 500.57 Gas Outlet Difuser 208 Index I .. StKewo- Gad 6671 62-01 05.05 ‘TCASE 80Introduction Preface 14 Work Cards and Maintenance Schedule ‘The work cards supplement the maintenance schedule of the turbo- charger in Volume C1 (operating manual) of the technical docurnenta- tion. There, the required maintenance work is listed only in key words, ‘whereas in the work cards the required work sequences are described step by step. AAtfirst the aim and object of the work is described. Then, among other things, information is given on the required tools and appliances, For most jobs several work cards must be observed. Z\ ATTENTION Danger of burning from hot components! Many engine and turbocharger components become very hot during operation and require ample time for cooling down afterwards. + Prior to taking any action, allow the engine and turbocharger to cool down sufficient! + Wear protective clothing! Z\ WARNING § StXtavoe GQ) 6671 C21.-01E Danger of crush injuries or from blows! When the engine is running during disassembly or assembly work, there is danger of becoming entangled in or coming against rotating components. + Carry out all disassembly or assembly work while the turbocharger is shut down! + During the work, secure the engine against starting! + Set up danger signs! 07.04 CASS 81Layout and Usage of the Work Cards 1.2 Numbering ‘The ordinal number of the work cards is located in the top right of the tile. It consists of a 3-digit subassembly group number and a 2-digit ‘counting number. The subassembly group number 500 hereby repre- sents the collective subassembly group number for turbochargers. Example: ‘Turbocharger on engine......- 1 ‘Subassembly group number (500 for turbocharger ‘Counting number (work card No. 31) (On the work cards, cross-references to afliated work cards are printed in square brackets. Example: Cross-reference to work card 500.43. -1500.43] In work card 500.44 (labyrinth disk) reference is made to work card £500.43 (compressor wheel), Layout of the Work Cards, ‘Work cards generally contain the following information: © Required personnel and time, « afiliated work cards, meaning work cards that contain additional necessary or other Useful information, ‘© required tools and appliances, possibly additional information/technical data and the individual work sequences, always beginning with the initial position, and followed by the individual work steps. Parts and tools in the figures and text are each designated with their stock number. Example: Non-return valve in bearing casing ..... 17.142 Subecsemtly foun number (547 for beeing casing) Position number $$$] All assemblies and subassembly group numbers are listed in Section C3 Chapter 2. ‘Stock numbers for tools are (generally) identical with the too! number affixed on the tool Required Personnel and Time The required time is mentioned in hours, both for the amount and qual- ification of the required personnel. The higher hour rate covers the time requirement for the complete scope of the respective work card. Per- Gad 6671 C21.2-01E 07.04 ‘TCAG6 a2Tools/Appliances Standard Option Inventory Spocial Tools SUX cane — Gan) 6671 C2 1.2-01E sonnel with lower hour rate is required only at times, 6. g., for operation of a lifting tackle, Numbers mentioned under the Designation column represent span- ner widths in mm, e. g. socket wrench 22 = socket wrench, size 22 mm, Availability-codes under the Status coltimn have the following mean- ing: Standard tools (with tool number) If included in the scope of supply, turbochargers are equipped with a set of standard tools. Tools requested by the customer (with tool number) Commercially available tools/appliances ‘These are not included in the supply scope of the turbocharger. Itis assumed that these tools/appliances are included in the inventory of the engine system. Spocial tools, e. g. for service centers 07.04 TOAGG 83SW Ga) 6671 C21.2-01€ 07.04 TCAGGSafety Instructions 2 Symbols and Designations 21 Inthe work cards, the safety instructions are indicated by means of the following symbols and designations: Z\ DANGER When the respective caution measures are not complied with, there is imminent danger which will result in A «Death or serious iy, ‘© Total damage to property or ©. Serious environmental damage. ~ 7X wanna ‘When the respective caution measures are not complied with, a poten | A tially hazardous situation will be caused which can lead to: © Death or serious injury, © Serious damage to property or ©. Serious environmental damage. Z\ ATTENTION Vihen the respective caution measures are not complied with, a haz: | ardous situation could be caused which can load to: © Personal injur © Possible damage to property. A safely or danger symbol appropriate to the hazard is always depicted in the marginal column (see C1-Operating Manual, Section 2.1 - Gen- eral Safety Instructions), Important! For pointing out fault sources/handling errors; material damage can occur. Note! ‘Additional notes, information and tips. ‘The instructions “Lubricate contact surfaces and threads”, “Observe tightening torques" and “Use lock washer pairs’ are adulitionally indicat- ed by means of symbols in the marginal column: ‘A @ — Grease, lubricate Use lock washers Observe tightening and oil torques SUX ema — Gan 6671 C22.1-02 E 07.04 TCAGS 85Safety Instruction Sign Engine Room 2.2 Important! To point out the most important regulations, bans and hazards during operation and maintenance the following safety instruction sign must be posted at the entry of the engine room: Fig. 1. Safety Instruction Sign — Engine Room Persons, who for operational reasons are to be within the danger area of 2.5 m around the engine, are to be instructed of the predominant hazards. Access to the danger area is permitted when the turbocharger is in proper operating condition and only when wearing suitable protec- tive equipment. It is prohibited to stay within the danger area without reason. SXeme- Gr 6671 C22.2-02 07.04 TCAGS 86Explanations to the Safety Instruction Sign Important! The regulations, bans and hazards on the safety instruction sign apply at all times and therefore especially for the maintenance work described in the work cards. Wear gloves Wear Wear Wear hard Wear safety protective hearing hat gloves goggles protection 0 @ Safety Symbols Wear Read protective manual clothing Danger Symbols AA AAA Wamingofa Dangerof Tripping Dangerof Corrosive hazard slipping hazard -—selectric. «== materials location ‘shock Crush Inflammable Hot surface Danger of Rotating hazard materials suspended gear hazard Toads Bans Fite, open No access flames and for smoking are unauthorize prohibited! d persons! SUX emo G 6671 022.202 E o7.04 TOAGS a7StKereie— Gan 6671 222-02 07.04 TCAGS 88StXex0— Gad 6671 Setting Data Bolted Connections and Tightening Torques 3.1 Short Version Tighter Tightening of Bolted Connections by Torque C231-01£ Tightening values forall important bolted connections/tightening torques for various friction coefficients p. 19 Torques for Bolted Connections Whenever possible, bolted connections should be tightened with torque wrenches. Particularly important bolted connections on the turbocharger are spec ified in Table 3 and additionally on the respective work cards. For all other bolted connections that are to be tightened with torque wrenches, the approximate values for the tightening torques are spec- ified in Table 2. When tightening bolted connections observe as follows: '* Apart from the applied tightening torque, the tension force of a bolted connection depends on the lubricant being used, the surface condition of support and thread, as well as on the material combination. Itis therefore very important that these conditions are completely observed, ‘© The tightening torques for the various threads, depending on their costficient of friction p (meaning depending on the selected lubricant), are listed in Table 2. The tightening torques apply for bolt ‘materials of the 8.8 property class under utilization of approx. 70 % of their yield strength, For other property classes, conversion factors are to be used and multiplied with the tightening torques from Table 2. The property class is impressed on the bolt head. Properly class] 56 | 68 | a8 | 709 | 729 | Conversion factorx | 047 | 075 | 1.0 | 1.40 | 1.70 Table 1. Conversion factors for tightening torques depending on the property lass ofthe bolts 07.04 TCAS6 89Friction coefficient Tightening Torques in General StXemne = oan) 6671 C23.1-01€ For the friction coefficient y use approximately: .08 for lubricants at temperatures ‘= 200°C, €. g. Molykote G-n or Molykote P40 = 200°C, €. g. Molykote HSC }.=0.14 for lightly oiled surfaces without refinishing Tightening torque Thread, nominal size | in Nm with friction coefficient pw 008 oid Ms 4 é M6 7 10 Me 7 25 M10 34 50 Miz © 5 14 5 135 IM 1axi.5 100 145 M16 140 205 Mi 16x15 150 220 M18 200 280 i 18x15 215 320 Mie 205 300 M20 275 400 M20x1.5 295 50 M202 285 25 M22 370 540 M22x15 385 595 M222 380 565 M24 475 690 Mae 500 750 M27 700 1020 Mane 730 1100 ™30 350 1380 M302 i015 1540 M33 1270 1870 M3a2 1350 2060, 36 1640 2400 i 36x83 1710 2550 M39 2115 3120, M303 2190 3300 Maz 2630 3860 Maas 2760 470 a5 3260 820 M453 a5 5180 a8 3850 5820 Max 185, 6370 Table 2. Tightening torques tor bolts, property class 8.8 07.04 TOASG iTightening Torques, Turbocharger StXemae— Gn 6671 C28t-O1€ Important! The tightening torques in Table 3 apply to a friction coefficient 0.08; Work | Description Tightening Card Torque [Nm] "500.11 | Undercut bolt (646.073) 100 Cylindrical screw (696.028) for hub a '500.12 | Closing device (emergency operation): Hexagon bolt (517.093)/Hexagon nut 60 (596.082) '500.82 | Silencer at compressor casing: | Hexagon nut (644.182) 140 JAirintake casing at compressor casing: Hexagon nut (645.427) 140 500.34 | Emergency and p Hexagon bots fr fan Hexagon bolt (554.048) i-lubrication system: s/oll hoses Hexagon bolt (554.056) 500.41 Insert: Undercut bolt (646.078) 500.42 | Diffuser: Countersunk bolt (546.045) |Compressor casing: Hexagon nut (606.104) Thrust screw for superboli-tension nut 300.44 | Labyrinth disk: Hexagon bot (617.003) 500.46 | Thrust bearing: Hexagon nut (817.102) (Counter thrust bearing Hexagon bolt (517.187) 7 300.57 | Gas-admission easing Hexagon bolt (506.106) 165 500.52 [Nozzle ing/clamp ring: ~ Hexagon bolt (513.013) 7 300.54 | Shroud ring: Hexagon bolt (608.072) 70 500.55 | Stud serews: Lock nut (617.094) 0 500.56 | Cover/counter thrust bearing: Hexagon bolt (517.187) 7 Locating disc: Countersunk screw (617.067) 64 500.57 | Gas outlet diffuser: — _ Hexagon nut (506.108) | 165 Table 3 Special ohtening torques at urbocharger contac suraces and thveads lubricated with Molykote HSC) 07.04 TCAGS a1StXtmua—(an 6671 C23.1-01€ 07.04 TOAS6 92Gaps and Clearances 3.2 Short Version Gaps and clearances are to be measured and compared with the spec- ified tolerances; the results are to be recorded and appropriate action is to be taken. Required Tools/Appliances [Amount] Designation | Number | Status i 1 | Feeler gauge = __[Taventory ting caliper = Haventory i [Dial gauge = [inventory Introductory Remarks Important! When tolerances are not met, the causes must be corrected, ©. 9., imbalance, malfunctions with the lube oil system (debris, pressure, volume, temperature, pre-lubrication and post lubrication). SUX — Ga 6671 023.2 02E 05,05 TCASS 93s Measuring "Work Point Card 00s | 009 12 | S005 500.56 Radial Clearance Bearing Body/Bearing Bush: Turbine Side 3b} - | 025 | ozs 033. | 50056 517.161 Clearance Bearing Body/Bearing Bush: Compressor Side ab | - | 025 | 029 033 | 500.56 ‘Axial Clearance Bearing Bush/Bearing Body: Turbine Side ae] - | 026 | 024 050 | 500.56 517.161 StXewico— Gan 6671 23.2 02E 05.05 TCASS 94Gaps and Clearances Manufactured [men] Axial Clearance Bearing Bush/Bearing Body: Compressor Side Condition as Replace Parts [mm] | Max. [rm] Work Card] 517.162 se} - | 026 | 024 oso | 50086 520,001 6a?| + 0.90 1.10 | (0.60)? 1.40 | 500.54 509,008 “). Seng specication fo ebro ing, see Work card 60064) 2, The minum value may not be fan shor of a ny clon on the crcumference, Axial Gap (10) and Radial Gap (11) Compressor Wheel/Insert to} + | 200 | 290 | - 250 | s00.41 ie) lene 1.20 130 | (1.00) | 1.50 | 500.41 | | | | 20.044 | | 1) Set olor towards system in dracon (A). Measure the ial gap at 3 locations onthe ércunference via soR-metal marking, and caleulate the mean value (determined value catesponds with the largest given (max) axial gap). 2) Take measurement at 4 locations of te cheumference wth afebler gauge and calculate the average value. 3) The minimum value may not be falen short fat any location on the circumference, Important! StKtme— Gan) 6671 023.2 OE 05.05, TCASS Gaps and clearances marked with (*) are to be recorded in the inspection report (see Section C1, Page 77). 95SEX epaco— Gan) 6671 0232 02E 05.05 ToASs 96Work Cards Emergency Operation StXtme— God 6671 02.4.1-01€ 07.04 TCAGS 7SW Gd 6671 02 4.1-01E 07.04 ToAEs 98Operation with Holding Device Short Version Required Personnel and Time Required Tools/ Appliances Corresponding Work Cards StKemace—GO 6671 C2500.11-01 E Enable emergency operation by blocking the rotating element, 500.11 07.04 TOAG6 ‘Amouni| Qualification | Rear 1 [Qualified mechanic 1 Assistant Designation Number | Status ‘Open-jaw wrench 36 =| Taventory ‘Open-jaw wrench 19 =| _ Inventory 7 | Hex key 14 ~ [inventory T | Rotaing device SOEETT | Standard 1] Amesting wrench 596.018 | Standard 7] Hub '596.023_| Standard ~~ 4] Cylindrical screw 596.023 | Standard T[_Lockwasherpair | 806024 | Standard Work Card Work Card Work Card + 800.12 500-82 30035 “500.41 99Introductory Remarks ‘The damaged turbocharger can be shut down either with the holding device [500.11] or with the closing mechanism [500.12] Use the holding device (596.511) only when removal of the rotating el ement is not possible. Note! By using the closing mechanism (see work card [500.12] Operation without Rotating Element) further damage of the rotating element can be avoided. ‘Work Sequence ~ Assembly of the Holding Device Starting Condition 596.018 596.018 Arresting wrench 596.022 Hub Fig. 2. Special tools for operation with holding device Silencer [500.32Vair intake casing [500.33], insert [500.41] and bal- ance ring (540.030) disassembled, ZN DANGER Work Stops: StKerae—Gan\ 6671 A A 2 800.11-01 E Danger to life from crush injuries or blows! When the engine starts during assembly of the securing fixtures, there is danger of becoming entangled in or coming against rotating components and being seriously injured. + Shut down the engine before installing the securing fixture in the turbocharger. + During the work, secure the engine against starting, + Sot up danger signs! 1. Unscrew spinner from compressor wheel. 2. Fasten hub (596.022) on compressor whee! with four cylindrical screws (596.023) and lock washer pair (596.024), Note! The hub is formed accordingly so that the tension nut does not have to be loosened. 3. Attach arresting wrench (696.018) on hub and tighten with two un- dercut bolts (546.073) of the insert. 07.04 TAGS 100Important! Use Lock washer pairs (546.074)! 4, Mount the silencer of air intake casing again y Important! ‘a Lubricate contact surfaces and thread (e. g. Molykote HSC)! Z\ warnine ger of fire caused by lube oil! AY During emergency operation with the securing fixture, the danger of fie is given when lube oil gets into the turbocharger. + Inemergency operation, always shut the ol supply pipe to the turbocharger. Note! Additional emergency operation notes, see Section C1 - Chapter 5.2. Important! (Observe tightening torques upon installation! Undercut bott (646.073): 400 Nm Cylindrical screw (596.023) for hub: 34Nm SEX emace GQ 6671 C2 500.11-01 E 07.04 TCAS 101StKemio—Gan 6671 C2.500.11-01 E 07.04 TCAGS 102Operation without Rotating Element 500.12 Short Version Enabling emergency operation by disassembling the rotating element and closing the bearing casing with closing covers. Required Personne! and Time ‘Amount| Qualification Required Time [h] 1 | Qualified mechanic T 35 (Assistant a5 Required Tools/Appliances | Amount] Designation ~ Number | Status’ 7 | Open-jaw wrench 79 = awentory 4] Closing mechanism 396.572 | Standard 7] Closing cover (compressorside)| 506.027 | Standard “ifr Ciosing cover (urine side) | 596.028 | Standard 7] Gasket (compressor side) | 596.029 | Standard 7] Gasket (urbine side) 596.080_| Standard i) Stud screw 396.081 | Standard 2) Hexagon nat 306.082 | Standard 3 Feragon bot 396.089 | Standard Work Card Work Card Work Card 500.17 800.82 500.38 B004T 50043 800.44 500.51 500.58 - Technical Data ¢ [Designation ‘Specification 3 (Closing device eI) (Closing cover (compressor side) Bt kg | (Glosing cover (turbine side) oka StXemawe Gary 6671 C2 500.12-01 E 07.04 ‘CASS 103Introductory Remarks, ‘The damaged turbocharger can be shut down either with the holding device [500.11] or with the closing mechanism [500.12] Use the holding deviee only when removal ofthe rotating elements not possible, Note! By using the closing mechanism (596.512) further damage of the rotating element can be avoided. Work Sequence ~ Assembly of the Closing Covers 596,033 596.032 | 596.083 AAS, 517099 (00-QSS//) sass 517.095 (8x) — ~~ 13. 6.931 596.929 517.001 i r™~ N. 596.027 Nf 596.030 | 596.028 A | 596.083 f Co 596,032 517.001 Bearing casing 596.029 Gasket (compressor side) 517.093 Hexagon bolt 596.030 Gasket (turbine side) 517.095 Lock washer pair 596.031 Stud screw 596.027 Closing cover (compressor side) 596.032 Hexagon nut 596.028 Closing cover (turbine side) 596.033 Hexagon bolt Fig. 3. Closing mechanism at emergency operation without rotating element Step Gad 6671 C2 500.12-01& 07.04 TCAS6 104Z\ DANGER Danger to life from crush injuries or blows! | A When the engine starts during removal of the running gear or during assembly of the closing mechanism, there is danger of becoming entangled in or coming against rotating components. + Shut down the engine before removal of the running gear as well a before installing the closing mechanism in the turbocharger. + During the work, secure the engine against starting! + Set up danger signs! Starting Condition Silencer [500.32Jair intake casing [500.33], insert [500.41] and gas- admission casing [500.51] disassembled, Compressor whee! [500.43], labyrinth disk [500.44] and turbine rotor [500.53] disassembled. Note! Bearing bushes and counter-thrust bearing can remain assembled, Work Steps 1. Fasten stud (596.031) to closing cover (596.027) with to nuts (696.032). 2. Fasten closing cover and seal (596.029) to the bearing casing (617.000) with eight hexagon bolts (517.093) and lock washer pairs (517.095) of the disassembled labyrinth disk (517.089). 3. Mount closing cover (596.028) and sealing (598.030) on turbine side and fasten to stud with nut (596.032). Note! For easier installing, screw two hexagon bolts (596.033) each into the closing cover. Fig. 4. Installed closing cover (compressor side and turbine side) 4, Mount gas-admission casing. 5. Mount silencer or air intake casing | Z\ Warnine Danger of fire caused by lube oil As During emergency operation without running equipment, the danger of fire Is given when lube oll gets into the turbocharger. + Inemergency operation, always shut the oil supply pipe to the turbocharger. & SUXcmco— Gan 6671 62 500.12-01 E 07.04 TCAGB 105,Important! Lubricate contact surfaces of thread (e. g. with Molykote HSC)! Note! ‘Additional emergency operation notes, see Section Ct - Chapter 5.2. Important! — Observe tightening torques upon installation! Hexagon nut (596.092) oN Hexagon bolt (517.093): 60Nm SUeme-Ga 6671 62 500.12-01 07.04 TCAGS 108Cleaning Steep — Ga 6671 c24.2-01£ TCAGS 4.2 107StKewo- Ga 6671 C24.2-01E 07.04 TCAG6 108Cleaning the Turbine (Wet Cleaning) 500.21 Short Version Carry out the wet cleaning in time according to the maintenance plan; clean components from debrisiresidue. Required Personnel and Time “Amount| Qualification ponies Time [a] i|Qualiiedmechanic ~S~=~=S=“‘“COS: Introductory Remarks General Amount and layout of the washing lances (4) depends on the engine type and can vary from the illustration. Cleaning Agent Use only fresh water for cleaning, Cleaning Interval Every 250 operating hours (depending on the operating conditions the intervals can be shorter). Also see the plate on the engine with the cleaning specification. Note! In order to save time, carry out the cleaning briefly after putting the ‘engine into operation, as jong as the components subject to cleaning are not 100 hot yet. In this case, work step 2 of work sequence can be skipped. Technical Data [Washingiances—————SCSC~dSSCSCSCSC~SCSC [Water pressure 23 bat Exhaust gas temperature at tubing 320°C Turbocharger speed 7 = 9500 rpm StKemace Gd 6671 C2 500.21-01E 02.05 TCAGS 1091 Washing water 6 Turbine wheel 2 Pressure gauge 7 Washing water outlet 3. Nozzles 8 Drain funnel 4 Gas-admission casing B Drainage cock | Nozzle ring E Stop cock water supply Fig. 5. Diagram for water washing of turbine StXee— Ga 6671 C2 500.21-01E 02.05 TCAGS 110Work Sequence ~ Water Washing of Turbine (during Operation) General ‘Water washing of the turbine is carried out at reduced engine power. ‘Washing is carried outin “intervals", otherwise the turbine could graze. ‘The size of the nozzle slot and the water pressure are matched fo the exhaust amount and temperature (quantity of heat) of the charger. Work Steps 1. Run the engine at reduced engine power (1/4 load) for approx. 10 minutes (cooling down to the stabilizing condition) 2. Check the operating parameters for the washing of the turbine: © Exhaust gas temperature < 320 °C ‘* Turbocharger speed < 9500 rpm ‘* Water pressure 2-3 bar Important! The exhaust gas temperature of 320 °C must not be exceeded under any circumstances, otherwise the turbine can graze during washing. 3. Open drainage cock (B). Check the outflow of exhaust gas at the opened cock; free opening, if required. 4, Open stop cock (E): Water is sprayed through the nozzles (3). 5. Washing duration 2 minutes. Note! The water running out of the washing water outlet (7) gives information about the washing effect or about the contamination degree of the turbine. The water can be checked at the drain funnel (8). ‘Shut the stop cock (E) 7. Run the turbocharger dry for 2 minutes at reduced engine capac- iy, 8, Repeat the washing procedure and the running dry (work steps 4-7) 3-5 times. ‘Shut drainage cock (B). 10, Run the turbocharger dry for 8 minutes at reduced engine power, then slowly increase the load, Note! In case vibrations of the turbocharger occur that were previously not existent, repeat the washing procedure. Important! If vibrations due to irregular heavy deposits of debris can not be corrected through the washing, the turbocharger must be dismantled and the respective parts must be cleaned ‘mechanically. StXKtmae—- Gr 6671 02 500.21-01& 02.05 TCAGS 4StXerp0— Gan) 6671 €2 600.21-01 E 02.05 TCASS 12Cleaning the Turbine (Dry Cleaning) 500.22 Short Version Required Personnel and Time Technical Data Introductory Remarks General Cleaning Interval £ StXempace— am 6671 C2 600.22-01 Dry cleaning of the turbocharger (it available) is carried out in HEO op- eration. Carry out the cleaning in time according to the maintenance plan; clean components from debris/residue. ‘Amount| Qualification ‘Required Time [h] ‘Qualified mechanic 03 Designation ‘Specification Granulates: ~ Particle size: ‘Nutshell or activated charcoal 1mm (max. 1.5 mm) (soft - _ Filing volume ~ approx, 151 ‘The exact layout of the components depends on the engine type and ccan vary from the illustration. Note! For turbine cleaning with this setup, do not use water, as in this case the cleaning is carried out at normal operating load of the engine. At normal operating load of the engine, every 24 operating hours. o7.04 ToASS 1131 Compressecair pipe (6-8 bar) 2 Screw plug 3 Tank 4. Pipes (25x 2.0mm) 5 Connection flange 6 Adaptor 7 Gas-admission casing 8 Gas outlet casing 9 Turbine whee! 10. Nozzle ring A. Stop cock (compressed air B Stop cock (exhaust gas) l Fig. 6. Diagram dry cleaning of turbine Work Sequence ~ Dry Cleaning of Turbine (during Operation) Work Steps ‘Stop cocks (A) and (B) must be shut. Unscrew screw plug (2), fill cleaning agent (granulates, active car- boon) into the tank (3) and then shut again. (pen stop cock (A) (compressed air) Slowly open stop cock (B) (exhaust gas) until a whisting sound ind cates thatthe granulates are being blown in. Blowin duration approx. 30 seconds. 5. Shut stop cock (A) and (B). StXeme-G\ 6671 02 500.22-01& 07.04 TCAGS 114SUX emace Gard 6671 Cleaning the Compressor (Pressure Sprayer) 500.23 Short Version Required Personnel andTime Introductory Remarks General Cleaning Agent Cleaning Interval C2 500.23-02 ‘The cleaning of the compressor is carried out during operation. Carry out the work in time according to the maintenance schedule, Clean the components from debrisiresidue. Amount] Qualification ] Required Time [h] 7 | Qualified mechanic 03 The layout of the components depends on the engine type and can vary trom the illustration, See plate with the cleaning specifications (see Fig. @) on pressure sprayer. Use fresh water only for cleaning. Every 150 operating hours. ‘The cleaning intervals depend on the contamination degree of the maximum possible system inclination +5°. (See Section C1 - Chapter 4.2) Work Steps 1. Remove the closutes at the bearing casing (517.000) and connect, the lube oll supply and drain pipes to the turbocharger. Important! Alter fitting the lube oll pipes to size and prior to the final assembly, treat all pipes in acid bath and thoroughly clean them. 2. Mount and connect lube oll pipes, gauges and pressure controllers. Important! Use only seals that are in proper condition. Work Sequence 4 ~ Connecting the Speed Transmitter Work Stops Connect the read-out unit of the speed measuring device to the termi- nal box (compressor casing) according to the electrical wiring diagram. Also see work card [500.41]. Work Sequence 5 ~ External Sealing Air Connection (Option) Work Steps 1. Unscrew pipe bend from non-return valve of compensation line. 2. Adapt compressed-air supply line with ortice and pressure gauge to turbocharger. Important! Debris in the sealing air system can lead to a total loss! Therefore all sealing air pipes are to be thoroughly cleaned after fitting them to size and prior to final assembly. SUXKtrae— ean 6671 C2 500.31-01 E 07.04 CASS 1253. Mount compresse¢-air supply line with orifice and pressure gauge and screw together. Important! Use only new seals that are in proper condition. Work Sequence 6 - Jet Assist Connection (Option) Work Stops 1. Check if the O-ring seals (540.015) are in the insert (540.001). 2. Fit air-supply pipe (delivery scope of engine) with pressure reducer, solenoid valve and non-return valve to the connection at the compressor casing and bolt together. Work Sequence 7 ~ Cleaning System Connection (Option) © Connect the dry cleaning system for the turbine at the intended location on the engine/turbocharger {500.22} ‘© Mount the wet cleaning equipment for the turbine to the connections of the cleaning nozzles (gas-admission casing) and the dit water drain [500.21] © Connect the wet cleaning equipment for the compressor to the Connection ofthe injection pipe in the compressor casing (500.23) Work Sequence 8 ~ Removal of the Turbocharger Fiemoval of the turbocharger is carried out in reverse order of assembly. Due to restricted space conditions, it may be necessary to remove the turbocharger in partially disassembled condition (silencer, compressor and admission casing, and rotating element disassembled) (see Chapter 4.4 and 4.5). Z\ attention Danger of burns from hot components! Many engine and turbocharger components become very hot during operation and require ample time for cooling down afterwards. + Prior to taking any action, allow the engine and turbocharger to @ cool down sufficiently! + Wear protective clothing! SWC Ga 6671 C2 500.31-01 E 07.04 TCAGS 126SEX enpace— (and 6671 @OPe €2500.31-01 E Danger of burning/scalding from running-out lube oil! The lube oil is under pressure and very hot! + Before opening pipes, flanges, screwed connections or gauges, {ree the system of pressure and check that itis pressure-free! + Before opening oil pipes, wait until the lube oil has cooled down sulticiently (1-2 h). + Drain the system and check that it has been drained completely. + Wear protective clothing! 07.04 TCAGS 127StXerp0— Kan 6671 C2 500.31-01 E 07.04 TCAGS 128Silencer Short Version Required Personnel and Time Required Tools/ Appliances Spare Parts Corresponding Work Cards Technical Data StXewewe—Gad 6671 C2500.92-01 E 500.32 Removal and installation of the silencer is carried out in completed con- dition. Disassembly of the silencer is required for all work that must be per formed from the compressor side (see Chapter 4.4) ‘Amount Qualification ~ | Required Time th7 1 | Qualified mechanic 1 7 [Assistant i Amount] Designation [ Number | Status 1] Open-jaw wrench 24 [= [inventory 7 [Torque wrench = [inventory = [lifting tackle with ropes = [inventory = [Eve bolts, shackles =| inventory =| Wood (for placing undemeath) |__| Inventory ‘Amount Designation Number 24) Lock washer pair 544.181 [Work Care Work Card | ‘Work Card | ‘50024 Designation ‘Specification Silencer 00 kg —| 07.04 TASS 129Introductory Remarks General 544.182 Hexagon nut 544.181 Lock washer pair 546.000 __ Compressor casing Fig. 12. Instalationemoval ofthe silencer at the compressor casing For cleaning of air filter, see work card [500.24], Danger to life from crush injuries or blows against rotating (500.24) of the silencer during operation. There is danger of becoming entangled in or coming against rotating components of the silencer or turbocharger and being seriously injured. + Shut down the engine before working on the silencer. + During the work, secure the engine against starting! + Sot up danger signs! components! Never remove the inspection cover (see Fig.© in work card Z\ warnine Danger of injury from suspended loads! A A rocking silencer is difficult to maneuver and can therefore seriously injure people and cause damage to material. + For attachment of the liting equipment, use only the iting hooks (on the silencer which are intended for this purpose. +_Move the silencer slowly away from or towards the silencer. StKtwxo—Gan) 6671 C2 500.32-01 E 07.04 ‘TCA66 130i StXemae—Gr 6671 C2 500.32-01 E 07.04 ‘TCAGB 131 Work Sequence 1 ~ Removing the Complete Silencer Starting Condition Connection of the compressor washing equipment loosened (it available). Work Steps: 1. Fasten silencer to lifting equipment using ropes. Important! The studs on the silencer casing are secured with Loctite 586. Therefore do not heat them upon disassembly. 2. Loosen hexagon nuts (544.182) at intermediate flange of com- pressor casing/silencer from the stud bolts of the silencer casing, preceding in circumferential direction. 3. Move silencer in axial direction away from the compressor casing and place it on wooden support with the flange surface down, Work Sequence 2 — Installation of the Complete Silencer Work Steps. Installation is carried out in reverse order of removal. Important! Lubricate contact surfaces and threads (e. g. Molykote HSC). Important! @ ‘Mount hexagon bolts with lock washer pairs! Important! — Observe tightening torques upon installation! Hexagon nut (544.182): 140/NmStKerpxo—Gan 6671 C2 500.92-01 E 07.04 TCASS 132Air Intake Casing 500.33. Short Version Removal and refiting of the air intake casing is carried out in complete condition. Dismantling of the air intake casing is necessary for all jobs that must be performed from the compressor side (Chapter 4.4). Required Personnel and Time ‘Amount| Qualification Required Time [hy] 1| Qualified mechanic 7 1 [Assistant 7 Required Tools/ Appliances Designation ‘Number | Status [2] Open-jaw wrench 24 = inventory 7 Torque spanner Inventory =| Lifting tackle with ropes = awentory —] Wood (or placing underneathy | | Inventory 7 | Shackles 596.046 | Standard 1| Eye bot 7 596051 | Standard Spare Parts ‘Amount Designation [_Mamber 48 | Lock washer pairs T 545.428 Technical Data Designation ‘Specification | Air intake casing 237 kG SUX tmace Gad 6671 C2 500.83-01 E 07.04 ‘TCA66 133Introductory Remarks General 545.401 Air intake casing 545.425 Hexagon bolt 545.427 Hexagon nut 545.428 Lock washer pair 546.000 Compressor casing 596.046 Shackles 596.051 Eye bolt Fig. 13. Installatior/removal of the air intake casing at the compressor casing Work Sequence 1 ~ Removing Starting Condition Connection of the compressor washing equipment loosened (i available). Work Steps 1. Screw eye bolt (596.051) into air intake casing (546,401). 2. Hang air intake casing via shackle (596.046) to liting device; ten- sion the rope. 3. Loosen hexagon nuts (545.427), hexagon bolts (545.425), lock washer pairs (545.428) in circumferential direction 4. Move air intake casing away from compressor casing in axial di- rection and place down on wooden supports. SUX C2 $00.33-01 07.04 ‘TCASS 134Work Sequence 2 ~ Installation Work Steps: StKemace— Gd 6671 a @ wN 2 500.23-01 E Reflting Is carried out in reverse order of removal. Important! Lubricate contact surfaces and threads (e.g. with Molykote HSC). Important! ‘Mount hexagon bolts and hexagon nuts each with lock washer pairs. Important! Observe tightening torques upon installation! Hexagon nut (648.427): 140.Nm 07.04 TCAGS 135StXcreie—fann 6671 C2 500.33-01 E 07.04 TCAGS 136Emergency and Post-lubrication System Short Version Required Personnel and Time Required Tools/ Appliances ‘Spare Parts Technical Data StXemaa—Gan 6671 C2500.34-01 E 500.34 ‘The emergency and post-lubrication system is removed only when the compressor casing is disassembled. ‘Amount | Qualification | Qualified mechanic Required Time [hy] et Designation [Number | Stanus ‘Open-jaw wrench 13 {| — [| inventory_| Operriaw wrench 24 = [inventory Lifting tackle with ropes = inventory Wood (or pacing undemeaty | =| Inventory [ Amount| Designation | Number — ‘8 | Lock washer pair ~ 554.049 7 [Seating ring S5A061 7 | Sealing ting ~ 854.062 2 | Sealing tng 354.088 “4|Washer 554.088 7] Sealing ting = 554.097 7 | Sealing ring 554.098 [Emergency and post-lubrication system 07.04 TCAGG Specification 740 kg 137Work Sequence 1 ~ Removal of the Emergency and Post-lubrication System Starting Condition 554,001 Olltank 554.031 Bracket 554.047 Plate 554.048 Hexagon bolt 554,001 554.049 Lock washer pair 554.050 Hexagon nut 554.055 Resifont sleeve 554,056 Hexagon bolt 54.060 - Non-return valve 554.083 554061 Sealing ring Ree, 554.062 Sealing ring 6 554.080 554,063 Hexagon bolt i) \P- 554.096 584.056 coats 554055 Hose poo win SB sson Coreen sstoco wee start poset ee 584080 Hose pp win eA ~ conten 354.062 554.083 Sealing ring ssaéeo [SY Setoe0 554,087 — Hexagon bolt J j- 554.096 sows S009 Washo S ss1o0s 554088 Hexagon bot 554.097 Sealing ring 554.098 Sealing ring Fig. 14. Removal of the emergency and past-lubrication system (554.000) Oil hoses (554.066 and 554.080) have been released from bearing casing and oll tank, and oil drained, The openings at the emergency and post-lubrication system (554.000) and the bearing casing have been provisionally shut. Check if the sealing rings (554.061, 554.062, 554.083) need to be re- placed, Work Steps Fasten cil tank (554.001) to rope; use lifting device. Loosen hexagon bolt (554.048) of plate (554.047). Loosen hexagon bolts (554.056) of bracket (554.031). Lift emergency and post-lubrication system (554.000) with liting device and set down on wooden support. StXere— Gan 6671 C2 500.34-01 E 07.04 TCAGS 138Work Sequence 2 ~ Installation of the Emergency and Post-lubrication System Work Steps: Installation is carried out in reverse order of removal. Afterwards con- rect the oil hoses (554.066, 554.080). Use new sealing rings, as re- quired, Important! Lubricate contact surfaces and threads (e. g. Molykote HSC).! BY Important! — Observe tightening torques upon installation! Hexagon bolts flanges/oil hoses: 60Nm Hexagon bolt (554.048) 60Nm Hexagon bolt (554.058): 140. Nm StXtme— Gan 6671 C2 500.94-01 E 07.04 TCAG6 139StXtrmce— GY 6671 C2 500.34-01 E 07.04 TOAGS 140Assembly and Maintenance - Compressor Side SWXtre— Gar 6671 024.4-01E 07.04 TCAGG 44 141Stereofan 6671 02.4.4-01 07.04 TOASs 142Speed Transmitter and Insert 500.41 Short Version Installation and removal of the speed transmitter/insert required for as sembly/disassembly of other assemblies/components and for control purposes or replacement. Required Personnel and Time Amount] Qualification Required Time [h] 1 | Qualified mechanic 1 1 [Assistant ~ Required Tools/ Appliances Amount] Designation ‘Number | Status 7 | Open-jaw wrench 22 - Inventory | | 1 | Torque wrench = Inventory 7 | Screwdriver =—Pinventory =| Lifting tackle with ropes, chains = Inventory =| Eye bolis = : 5 Inventory 7] Wood (for placing undemeathy =—Pinventony | Removing and refiting tool forinsert| 596.518 | Standard 2| Guide bar 596.045 | Standard Spare Parts “Amount] Designation ‘Number 2 [O-ring seal 540.015 ~__1| Seal disk 540.026 | Seal disk 546-050 Corresponding Work Cards £ a Work Card Work Card Work Card 500.32 500.88 500.48 SUX tmae— and 6671 C2 500.41-02 E 07.04 TOAGS 143Technical Data Dasignation Specification insert 198 kg Prerequisites 520.044 Compressor wheel 546.000 Compressor casing 540.001 Insert 596.045 Guide bar 540.030 Balance ring 596.046 Shackle Fig. 15. Removal and instalation of the Insert in the Compressor Casing General Disassembly of the insert (540.001) enables removal of the compres sor wheel (520.044) and a part of the bearings without having to disas- semble the compressor casing (546,000). Important! Prior to removal of the insert, the connection of the speed transmitter must always be released from the terminal box at the compressor casing. Work Sequence 1 ~ Removing the Insert Starting Condition Silencer [500.32Vintake casing [500.33] disassembled. Work Steps. 1. Disconnect the cable ofthe spaed transmitter (562.040) in the ter ‘minal box (562.089), open cable socket (546.049) and pull the ca- ble to the inside (see Fig. ©) 2. Loosen two undercut bolts (546.073) from the compressor casing (646.000) and replace them with guide bars (596.045). 3. Loosen the other undercut bots and remove insert with liting tackle. For ths, fasten insert to shackle (596,046) and attach iting tackle (see Fig. ©). 4. Carefully place insert onto wooden supports and remove balance 3 ring (640.030) 3 StKerpe—Gan 6671 C2 500.41-02 & 07.04 ‘TCA66 144Work Sequence 2 ~ Installation of Insert and Balance Ring Starting Condition i SUX creaco— an 6671 Bi 62 500.41-02 E Compressor whee! [500.43] installed. ‘Spead transmitter (562.040) assombled in insert (540.001) (see Work ‘Sequence 4), Note! ‘Mount O-ring seals (540.015) only for version with JET ASSIST! 1. Apply machine oll to O-ring seals and mount into the ring grooves of the insert (540.001). Important! O-ring seals must be tensed all around the circumference and ‘may not be twisted upon mounting. 2. Screw two assembly rods (596.045) (every second mounting thread, starting from the top center) into the compressor casing (546.000), 8, Place on balance ring (540.030). 4. Fasten insert to lifting tackle at upper mounting hole of lifting tack- le using shackle (596.046) (observe installation position of speed transmitter), 5. Liftinsert, place on compressor casing and carefully slide over the compressor whee! (520.044). 6. Fasten insert with 2 undercut bolts (546.073) and disassemble mounting rods. 7. Mount all undercut bolts and tighten with specified tightening torque. 8. Measure radial gap between compressor wheel/nsert with feeler gauge and record (see Chapter 3.2) Important! {fa new insert and/or compressor wheel is installed [500.43], ‘measure and check the axial gp of the inservcompressor wheel (see Chapter 3.2 - Gaps and Clearance). 9. Guide the cable of the speed transmitter (562.040) through the ca~ ble socket (546.049) and seal disk (546.050) in the compressor casing and tighten the cable socket. 10. Connect the cable of the speed transmitter in the terminal box (662.083). Important! Lubricate contact surfaces and thread (e. g. Molykote HSC)! Important! (Observe tightening torques upon installation! Undercut bolt (646.073) for insert: 100 Nm 07.04 TCAG6 145Work Sequence 3 - Disassembling the Speed Transmitter Starting Condition Insert (540.001) is removed and placed on a firm support 1. Open cable socket (540.025) and pull the cable end of the speed transmitter (582.040) to the inside. 2. Unscrew the speed transmitter from the insert Work Sequence 4 — Installing the Speed Transmitter 562.040, 562.003, 540.001 562.040 0..0,4 mm 540.026 — 546.073 — [cece 546,000 —{Z as 546.049 \ £22001 os oo 546.050 @ 562.100 @ 562.100 562.083 562.210 ( x 540,001 Insert 562.020 Lock washer 540.025 Cable socket 562.040 Speed transmitter 540.026 Seal disk 562.077 Sealing material 546.000 Compressor casing 562.083. Terminal box 546.049 Cable socket 562.086 Cable socket 546.050 Seal disk 562.087 Seal disk 546.073 Undercut bolt 562.100 Speed indicator, analog 562.003 Loctite 222 562.200 Frequency-current converter 562.019 Cylindrical screw 562310 Speed indicator, digital AB Variants for speed indicators (compare Fig. @) Fig. 16. Overview, speed-measuring equipment Starting Condition Insert (540.001) is removed and placed on a firm support. Work Steps 1. Degrease the bot hole and the locating face in the insert (9. with Loctte Cleaner 7061). 2. Apply Loctite 222 (562.003) tothe thread ofthe speed transmitter (62.040) and sorew nto the insert unl Hush Turn the speed transmitter back sofar unti.a gap cimension of 0.1 mm to the surface area of the insert is adjusted (check with siee! or stralght-edge - see Fig. ©), SWepe- Gn 6671 C2 500.41-02 & 07.04 TCAGS 1468. Secure speed transmitter with lock nut. 540.001 _ Insert 562.040 Speed transmitter Fig. 17. Installing speed transmitter 4 a SUXcomco— Gar 6671 62 500.41-02 E ‘Guide cable through cable socket (540.025) and seal disk (640,026) at insert to the outside and tighten cable socket. Assemble insert (see work sequence 2). Guide cable through cable socket (546.049) and seal disk (646.050) in compressor casing (546.000) and tighten cable sock- et. Connect cable of the speed transmitter in the terminal box (662.089) according to the wiring diagram (see work sequence 5). 07.04 TOAGS 147Work Sequence 5 — Connection Assignment of the Speed Measuring Equipment |— 562.040 | — 882.040 2200 laa AST 118) 2.075 mnt pte TD a sors Hoo arm TE Hr gowcsomy | | aise [LESS ae “OC 62.100 | ent 2O4 | 562.040 Speed transmitter 562.200 Frequency-current converter 352089 Tonal box 862.310 Dipl speed inccatr 562.100 _ Analog speed indicator Fig. 18. Cable connection of speed measuring equipment (bl=black, ye=yellow, re Connection] Designation A | Frequency-current converter (562.200) | Option: Additional analog speed indicator (562.100) Option: Additional analog speed indicator (582.100) | -__andior transmission of measured values. StXeamco— Gan 6671 C2 500.41-02 E 07.04 TCAS6 ) and/or transmission of measured values. B | Digital speed indicator (562.310) ») 148Compressor Casing and Diffuser 500.42 Short Version Disassembling the compressor casing in order to check the diffuser. Required Personnel and Time Amount | Qualification Required Time [AT 7 | Qualified mechanic 70 T[ Assistant o5 Required Tools/Appliances ‘Amount| Designation Number_| Status 7 | Open-jaw wrench 30 = Trventory 7 Open-jaw wrench 19 = inventory [Ti Hexkeys = inventory [if Torque wrench = [inventory] 1 | Serewariver = inventory = |Lifting tackle with ropes, chains) —_— Tnventory Wood (for placing undemeathy |= Taventory Wood blocks = inventory Eye bolt Miz 306057_| Standard Eye bok MEOXZ 596.058 | Standard Flexagon bolt M16 x 50 596.280 | Standard Spare Parts ‘Amount| Designation ‘Number | Oring seal 317068 Corresponding Work Cards Work Card "Work Card Work Card | 00.92 500.88 500.54 “300.41 [500.58 Technical Data Designation ‘Specification [Compressor casing 330 kg Diffuser 4 64k 5 SXeico— Goan) 6671 C2 500.42-01 07.04 CASS 149Z\ Warnine As Danger of injury from suspended loads! A rocking compressor casing is difficult to maneuver and can therefore seriously injure people and damage material (Le. the compressor wheel)! + Use tackle line/chains to guide the silencer. + For attachment of the lifting equipment, use only the lifting eye bolts intended for this purpose, as described under Required Tools/Appliances" Work Sequence 1 ~ Compressor Casing Removal Starting Condition Work Steps StXemie—Gad 6671 €2.600.42-01 E Emergency and post-lubrication system (600.34), silencer [600.32] or air intake casing [500.33] as well as insert with speed transmitter [500.41] removed. Important! The insert must be disassembled before removal of the compressor casing! 1. Dependent on the position of the compressor casing (546.000, fasten 1 oF 2 iting eye bolts (596.058) to the compressor casing, 2. Insert the wire rope of the lifting tackle. Make sure that the rope is. tensioned. 3. Loosen the hexagon nuts (546.104) alongside the circumference. 4, Screw in three forcing-off bolts (596.280) and evenly loosen the ‘compressor casing. 5. Move the compressor casing away in axial direction, and place it, con a wooden support. Important! ‘Secure the compressor casing against rolling off. 546,000 | if 546.000 Compressor casing 546.104 Hexagon nut 508.099 _Undercut bolt 596.058 __ Eye bolt Fig. 18. Assembly of a single-stage compressor casing to the turbo- charger 07.04 TCASS 150SEX ema — Gan 6671 Work Sequence 2 Diffuser Removal Starting Condition Work Steps C2 500.42-01 E Compressor casing (546.000) disassembled and positioned on a wooden. support (2. g. two wood blocks) while property secured against rolling off. 1. Fasten iting eye bolt (596.051) to diffuser and attach lifting tackle. 546.000 — 546.045, 546.047 546.000 Compressor casing 546.045 Countersunk bolt 546.047 Lock nut Fig. 20. Ditluser fastening 2. Loosen lock nut (546.047) of countersunk bolt (646.045) in com- pressor casing. 3. Loosen countersunk bolt Remove diffuser (542.001) in axial direction. 596.051 596.045 546.000 542.001 542.001 Dittuser 546.045 Countersunk bolt 546.000 Compressor casing 596.051 Eye bolt Fig. 21. Removing the diffuser trom the compressor casing 07.04 TCAG6 151Work Sequence 3 ~ Compressor Casing Installation Starting Condition Work Steps StXeme—- Gn 6671 _ a —< 62 800.42-01 E Compressor wheel [500.43] mounted on turbine rotor [500.53]. Important! The insert [500.41] must not be mounted for assembly of the compressor casing, otherwise the compressor wheel may become damaged upon assembly of the compressor casing. 1. With the lifting eye bolt (596.051), hang the diffuser (542.001) to the iting tackle. 2. Mount the diffuser (542,001) to the compressor casing (546.000) with the countersunk bolt (546.045). Save countersunk bolt with lock nut (546.047), 546,000 542.001 546.045 542.001 Diffuser 546.045 Countersunk bolt 546.000 Compressor casing Fig, 22. Installation oiftuser 8. Dependent on the position of the compressor casing, fasten 1 or 2 lifting eye bolts (596,058) to the compressor casing, 4, Insert the rope of the lifting tackle, Ensure that the rope is ten- sioned, Important! Oil O-ring seal lightly! 5. Control and insert O-ring seal (517.063) between compressor casing and bearing casing, 6. Guide the compressor casing axially to the turbocharger, slide onto the undercut bolts (506.099) and tighten hexagon nuts (646.104) with the specified tightening torque. Important! Do not damage the compressor wheel with the compressor casing. Important! Lubricate contact surfaces and thread (e. g. Molykote HSC)! Important! Observe tightening torques upon installation! Countersunk bolt diffuser (546.045): 60.Nm Hexagon nut compressor casing (508.104): 250 Nm 07.04 TCAG6 182Compressor Wheel 500.43 Short Version Removal of the compressor wheel for checking of the bearings and the bearing bushes. Required Personnel and Time ‘Amount| Qualification Required Time 1 | Qualified mechanic 06 Required Tools/Appliances ‘Amount| Designation ‘Number | Status 7 |Open-jaw wrench 36 fem Trventory T]Torque wrench T=170Nm | 896.170 | Standarc 1 | Sacket wrench insert x10 | 696.107_| Standard =| Wood (for placing undemeathy | inventory 1 | Dismantiing/assembly | 896510” Standard compressor wheel | [ap Paiierring [596.007 | Standard [ T[_ Assembly ring [596.002 | “Standard [ T[_ Forcing-off bolt 596.003} Standard I a} threadedrod 596.004 | Standard | a] Hexagon nut 96.005 | Standard T]_ Tum pin AZ 596071 | Standard T[ Sleeve — 396.167 [Standard 1| Suspension device for 596.522 | Standard pressor wheel T[_Tumpin ATz 396.071 | Standard ee 596.160 | Standard tT] Sleeve [596.167 | Standard T|_ Hexagon bot 596.168 | Standard T | Support 596.170 | Standard T]_ Hexagon bot [596.187 | Standard T|_ Hexagon nut 96.198 | Standard ay ShacWle 596.208 | Standard Tf Lever cairier 596267 | Standarc T| Pipe - 596.270 | Standard Tf Side 396.271 | Standard T] Cylindrical screw MIO 35 | 596.272 [Standard T_Bolt ~~} "896.273" | Standard 3|_Cylinaiicalsorew MT0x50_| 596.274 | Standard SUX ewico— an) 6671 C2.500.43-01 E o7.04 TCAGS 153Spare Parts ‘Amount] Designation ‘Number =| Superbot lubricant = = [Moiykote P40 = Corresponding Work Cards Work Card Work Card 500.33 [50044 300.58 Technical Data Designation Specification Compressor wheel — 66 kg ‘Suspension device compressor wheal 24 kg, 520.035 520.001 Turbine rotor 520.066 —_Undercut bolt 520.028 Thrust ring 520.067 Spinner 520.035 Labyrinth ring 520.068 Tension nut 520.044 Compressor wheel Fig. 23. Assembly and disassembly of the compressor wheel StXemo—G 6671 62500.43-01 E 07.04 TCAGS 154Work Sequence 1 - Removing the Compressor Wheel General For disassembly of the compressor wheel, use the pullerring (596.001) and the suspension device (596.522). Starting Condition Silencer (500.32)/air intake casing [500.93] as well as insert with ‘speed transmitter [500.41] removed. ek 520.044 Compressor wheel 520.067 _ Spinner Fig. 24. Compressor wheel and compressor casing Note! The compressor whee! can also be removed without disassembly of the compressor casing (see Fig. @). Work Steps: 1. Unscrew (520.067) spinner. Important! The thrust screws of the tension nut must be loosened step by step! Do not fully loosen single screws under any circumstances. 2. Release all thrust screws, one after the other, approx. 1/4 turn (one time through) in circular order beginning with the top thrust screw (see Fig. @). 8. Repeat the procedure (1/4 turn per screw, one time through) until the pressure on the thrust screws is completely released, 4. The tension nut (520,068) can now be loosened by hand, 5. Completely unscrew the tension nut and pressure disk (Fig. @/1) from the turbine rotor. StXKemace—Gd 6671 C2 500.43-01 E 07.04 ‘TCAG6 155Pal ‘520.044 Compressor whee! 596.004 Threaded rod 596.001 Puller ring 596.005 Hexagon nut 596,003 Forcing-off bolt 596.167 Sleeve W. Balancing mark Fig. 26. Pulling off the compressor wheel with disassembling device (596.510) 6. Mount the sleeve (596.167) and assembiing/disassembling de- vice (596.510) to the turbine rotor (520.001), and mount the com pressor wheel (520.044). 7. Release the compressor wheel with the puller (see Fig. ©). 8. Dismountihe assemblingllsassembing device (see Fig. the Sleeve remains assembled to the turbine foto. 596,001 | 596,003, 596. fa wend 596.005 (4x) 520.001 Turbine rotor 596.004 Threaded rod 520.044 Compressor wheel 596.005 Hexagon nut 596.001 Puller ring 596.167 Sleeve off bolt __ 596.003 Fort Fig. 26. Pulling off the compressor wheel with disassembling device (596.510) SUespco— Gan) 6671 C2 500.43-01 E 07.04 TCAG6 19. Fix the slide (596.271) of the suspension device (596.522) (see Fig. ©) with cylindrical screw (596.272) to the compressor whee! 10. Fasten the lever carrier (596.267) with 3 additional cylindrical screws (596,274) tothe slide and compressor wheel and insert the pipe (596.270). 11. Atlach suspension device to crane. 12, Fasten suspension device to sleeve (596.167) using bolt (696.273) and lightly tension the rope of the lifting tackle, 13, Pull off compressor wheel. 14, Fully slide the compressor wheel onto the pipe (596.160) of the suspension device and secure with the turn pin (596.071), 15. Remove bolt (586.273) from the sleeve (596.167). 16. Carefully place down compressor-whee lifting tackle onto wooden support; remove suspension device. Work Sequence 2 ~ Installing the Compressor Wheel General For assembly of the compressor wheel, use the assembly ring (696.002) and the suspension device (596.522). Starting Condition Silencer [500.32V/intake casing [500.33] as well as insert with speed transmitter [500.41] removed. Turbine rotor [500.53] and labyrinth disk [500.44] mounted. 517.089 Labyrinth disk 596.167 Sleeve 520.001 Turbine rotor Fig. 27. Starting condition before assembly of the compressor wheel Work Steps. 1. Fix the slide (596.271) of the suspension device (596.522) with cylindrical screw (596.272) to the compressor wheel (520.044) (see Fig. ©), 2. Fasten the lever carrier (596.267) with 3 additional cylindrical ‘screws (596.274) to the slide and compressor wheel and insert the pipe (596.270). StXtre— Gan 6671 C2 500.43-01 E 07.04 TCASB 187596.271 520.001 Turbine rotor 520.044 Compressor wheel 596.071 Turn pin 596.160 Pipe 596.167 Sleeve 596.168 Hexagon bolt 596.170 Support 596.197 _ Hexagon bolt | 520.044 596.272 | 596.197 Important! Mark the balancing mark “O” of the compressor wheel on the ‘slide of the suspension device, as the slide would cover the mark ‘on the compressor wheel after assembling (see Fig. @). 3 Screw sleeve (596.167) onto undercut bolt (520.066) of the tur- bine rotor (520.001) (see Fig. ©). After cleaning, apply a thin coat of special lubricant (0. g. Molykote P40) to the compressor wheelturbine shaft seats in order to pro- tect against fretting (see Fig. @). 596.198 596.208 596.267 596.270 596.271 596.272 596.273 596.274 Fig. 28. Suspension device (596.522) for compressor wheel 5. Slide the pipe (596.160) of the suspension device through the slide (596.271) at the compressor wheel and secure the compres- SWXeamce— Gar) 6671 62 800.43-01 E sor wheel with the turn pin (596.071) (see Fig. Important! Lubricate the suspension tube with machinery oil so that the compressor wheel can glide. Hexagon nut Shackle Lover carrier Pipe Slide Cylindrical screw Bort Cylindrical screw ©) 520.044 596.071 596.167 <— 520.004 6. Fasten iting tackle to suspension device with the shackle (696.208) and lift the compressor wheel. Important! The compressor wheel on the suspension tube can now be brought into a level, (596.168) (see Fig. ©). 7. josition by adjusting the hexagon bolt Fasten suspension dovice to the sleeve (596.167) on the turbine rotor, and fasten the pipe of the suspension device to the sleeve using a bolt (596.273). Pull out the turn pin (596.071), 07.04 TCASS 158SUX eamce—G) 6671 Important! Rotate the compressor wheel on the suspension tube in such a ‘manner that the balancing marks of the slide (596.271) and the turbine rotor match. 9. Slide the compressor wheel onto the rotor shaft. 10. Remove the suspension device from the sleeve, 11, Remove the pressure disk (1) from the tension nut (520.068) and attach onto assembly ring (596.002). | 1 Pressure disk 520.068 Tension nut 2 Thrust screw 596.002 Assembly ring Fig. 29. Pressure disk on tension nut and assembly ring 12. Screw assembly ring (696.002) onto the undercut bolt (520.066) Of the turbine rotor and tighten with tommy bar (596.071) until ‘compressor wheel is flush, Important! In the area of the compressor outlet, the hub collar of the compressor wheel must be flush with the bearing casing. 13. Dismount assembly ring and pressure disk (1), Work Sequence 3 ~ Fastening the Compressor Wheel General Starting Condition Work Stops ‘The thrust screws of the clamping nut are delivered readily lubricated; otherwise, lubricate with Superbott lubricant. Compressor wheel slid onto the rotor shaft (compare with work se- quence 2), 41. Clean and lubricate the main thread and the contact surfaces of the clamping nut (520.068) and thrust screws (2). Important! The thrust screws (2) are fully screwed back. 2. Attach pressure disk (1) to tension nut (520.068) (see Fig. @). 2 500.43-01 E o7.04 TOAGS 159SUG 6671 62 500.43-01 E 1 Pressure disk 520.068 Tension nut 2 Thrust screw Fig. 30. Attach pressure disk to tension nut Note! \Markings on pressure disks that have already been in operation are ‘normal and do not inevitably require the pressure disk to be replaced. The pressure disk can be used for up to 10 tensioning procedures. Fig. 31. Pressure disk (1) 3. Screw thé clamping nut and pressure disk onto the undercut bolt (620.066) ofthe turbine rotor by hand and then screw it back 1/2 turn (see Fig. @). 4, Sorew in 4 thrust screws all the way and then tighten over cross with half ofthe tightening torque (approx.17 Nm). Then tighten with the full tightening torque (34 Nm). 5. Tighten all 8 thrust screws in circular direction with the full tighten- ing torque. 6. Repeat the tightening in circular direction until the thrust screws are tightened (approx. 2-3 times over). 07.04 TCAGS 160Compressor wheel 1 Pressure disk 520.066 Undercut bolt 2 Thrust scrow 520.068 Tension nut Fig. 32. Compressor wheel with mounted tension nut 7. Fasten spinner (520.067) (see Fig. @). Important! SA ote atoning trast ‘Thrust screw (tension nul} 34.Nm SWXermcs— GO 6671 C2 500.43-01 E 07.04 ToAGS 161StXepe— Gan) 6671 €2.600.43-01 E 07.04 TCASS 162Labyrinth Disk Short Version Removing and installing the labyrinth disk in order to semble additional assemblies. Required Personnel andTime 500.44 assemble/disas- Amount] Qualification Required Time [a] 7 [Quad mechanio - z Required Tools/Appliances Amount| Designation ~ ‘Number ‘Status 7 | Spanner 18 =| Tnventory 7 | Torque wrench =| inventory T|/Liting tackle, ropes =| Tnventory ~3| Forcing-off bolt M12. 596.041 ‘Standard | 1] Suspension deve forlabyrinth | 696507 | Standard sk 2) Guide bar 596.044 ‘Standard 2{ Eye bait [306.057 [Standard Spare Parts [Designation — Mumber ‘O-ring seal ‘517.085. [ 8 | Lock washer pair [817.095 Corresponding Work Cards Wark Card Work Card | Work Care 30048 300.45 30058 i StKemae—Gan 6671 C2500.44-01 E 07.04 ‘TCA66 163Technical Data Designation ‘Specification Labyrinth disk ‘50K Work Sequence 1 ~ Removal of the Labyrinth Disk 517.001 596.051 596.044 517.089 517.001 Bearing casing 596.044 Guide bar 517.089 _Labyrinth disk 596.051 Eye bolt Fig. 33, Removing and refitting the labyrinth disk with disassembled compressor casing Note! The labyrinth disk can also be removed and refitted without disassembly of the compressor casing. Starting Condition Compressor whee! [500.43] removed. Work Steps 4. Remove two hexagon bolts fastening the labyrinth disk (517.089) and substitute them with two guide bars (56.044). Note! Unscrew the second hexagon bolt each from the center/top. 2. Release the hexagon bolts around the circumference of the labyrinth isk, 3. Loosen the labyrinth disk from the bearing casing using the fore- ing-off bolts (596.041), 4, Screw the eye bolt (596.051) to the labyrinth disk. 5. Screw shackle/hook to the suspension device (596.521) of the labyrinth disk and tension the rope/chain of the lifting tackle. 6. Move the labyrinth disk away from the turbocharger using theliting tackle, StKtso— fan) 6671 C2 500.44-01 E 07.04 TCAG6 1647. Dismantle the guide bars, 8 Check for marks of wear on the labyrinth disk and on the sealing ‘cover (517.197) assembled to the labyrinth disk. Check the O-ring seal (517.085). Note! Slight grooves in the bore of the sealing cover, which have developed through the tips of the labyrinth ring, increase the sealing effect and are 1no reason for replacing the part. Work Sequence 2 - Installation of the Labyrinth Disk Starting Condition Labyrinth ring mounted on turbine rotor {500.45}. Work Steps. 1. Insert two guide bars (598.044) (second mounting thread each {rom center/top) in the bearing casing (517.001). 2. Screw eye bolt (596.180) into labyrinth disk (517.089). 3, Fasten ling tackle to suspension device (696.521) with shackle (696.208) or hook. 4. Insert new O-ring seal (517.085) into labyrinth disk if required. Important! Apply machinery oil for assembly of the O-ring seal. 5. Slide labyrinth disk in front of bearing body and fasten with 8 hexagon bolts (517.093) and lock washer pairs (517.095). Important! Ensure correct installation position of the labyrinth disk: Sealing air grooves located sidewards! 6. Unscrew eye bolt from labyrinth disk Disassemble guide bars. 8, Screw in the rest of the hexagon bolts (517.093) and lock washer pairs (517.095), and tighten all § hexagon bolts with the specified tightening torque. Important! Lubricate/oil contact surfaces, threads and sealing rings (e. g- with Molykote HSC)! Important! NN Observe tightening torques upon installation! Hexagon bolt (517.093): 60.Nm SUXKemace Gd 6671 C2 500.44-01 E 07.04 TCAG6 165StXepice— Gd 6671 ©2.500.44-01 E 07.04 TCAGS 168Ring Nut and Labyrinth Ring Short Version 500.45 Installing and removing the labyrinth ring from the rotor in order to as semble/disassemble further parts. Required Personnel and Time “Amount| Qualification Required Time [h] Qualified mechanic 2 Required Tools/Appliances ‘Amount| Designation ‘Number | _ Status 1 | Fitting/unfitting tool 596.513 ‘Standard T]_ Spanner for ring nut 596.065 2] Threaded rod 596.070 | Standard 2[ Hexagon nut 506.072 | Standard 7] Pale ting 596.073 | Standard 5 | Plastic pamamer =| Inventory | Moiykote P40 =| aventony Corresponding Work Cards Work Care Work Card 30044 30046 SUXere— an 6671 C2 500.45-01 E 07.04 CASS 167596.072 ay 596, 517.075, ae 520.028 $20,001 SS (OME \ a 517.075 520.028 517.075 Bearing disk 520.088 Ring nut 517.153 Thrust bearing 520.066 Undercut bolt 520.001 Turbine rotor 596.070 Threaded rod 520.028 Thrust ring 596.072 — Hexagon nut 520.035 Labyrinth ring 596.073 Pullerring Fig. 94. Assembly/disassembly of the labyrinth ring StKtrex0— Gad 6671 C2500.45-01 E 07.04 TCAGE 168Work Sequence 1 - Removal of the Labyrinth Ring — 596,065 596.065 Spannor‘orring rut | Fig. 85. Starting Cone Compressor whee! [500.43] and labyrinth disk [500.44] removed. Work Steps. 1. Loosen ring nut (520.038) with mounting wrench (596.065). 2. Fully screw puller ring (596.073) onto undercut bolt (520.066) of the turbine rotor (520.001). 3, Insert two threaded rods (596.070) through the holes inthe puller fing and screw them into the labyrinth ring (520.035). Mount nuts (696.072) tothe threaded rods. 4, Pull the labyrinth ring from the turbine rotor by alternately tighten- ing the nuts of the puller ring, Replace the labyrinth ring when the labyrinth tips are damaged or wor: D=131.6mm Work Sequence 2 ~ Assembly of the Labyrinth Ring Starting Condition “Thrust ring (520.028), bearing disk (517.075) and thrust bearing (517.153) are mounted on the turbine rotor (520.001) [600.46]. Work Steps: 1. Lubricate the seat of the labyrinth ring (520.035) on the turbine ro- tor with Molykote P40. 2. Slide labyrinth ring in front of thrust bearing onto the turbine rotor. 8. Secure labyrinth ring with ring nut (520.088). Tighten ring nut with, ‘mounting wrench (596.066) (slight hammer blow). SEX ema —G 6671 C2 500.45-01 E 07.04 TCAGG 169See Ga 6671 C2 500.45-01 07.04 TCAGS 170Thrust Bearing, Counter-Thrust Bearing 500.46 and Bearing Disk Short Version Carry out tasks regularly according to the maintenance plan and check ccondition/degree of wear of the parts. Removal of the bearings for inspection purposes or replacement. Required Personnel andTime ‘Amount Qualifieation Required Time 1h | 7 [Qualified mechanie 2 Required Tools/Appliances ‘Amount Designation ‘Number | — Status T/Spanner 19 ~ = Taventory [a Rubber hammer inventory 7 Punch wood (=a inventory [Removing tool thrust bearing | 506.524 | Standard T Extension shaft 596.040 ‘Standard 3|_ Forcing-off bots 306.041 | Standard T Protecting sleeve 596.075, ‘Standard | ___1|Removing tool thrust ring 396.514 | Standard T[_ Assembly ring 396,086 | Slandard 3| Hexagon bot | 596.087 | “Standard Spare Parts ‘Amount| Designation ‘Number 7 [Bearing disk 517.075 | Lock washer pal for rust bearing 317.095 7 | Counterthrust bearing | si7184__| 6|Lock washer pair for counterchrust | S17.186 bearing Corresponding Work Cards [Work card | Work Card | Work Card [50043 S00 500.8 500.53 500.55, I 500.56 SUXcrome— Gad 6671 C2500.46-01 E 07.04 TCAGS wmsr7s7 ote 517.156 st707s ee. | 520.0. LE 7 | a 7 fo | sr : a 1702 17.162 596.040 | see.07s 517075 Bearing disk 517.187 Hexagon bot 517008 Look washer pir 51762 Beanng body §17100 Stud 820001 Tubie rotor S17102 Lock nut 20.028 Tht ring 517169 Thust bearing $20.06 Underet bot 517184 Countertmst bearing 826010 Exonson shat 517.186 Look masher par £96075 _ Protecting sleeve : Fig. 36. Assembly/disassembly of counter-thrust bearing, thrust ring, bearing disk and thrust bearing Work Sequence 1 — Removal of Thrust Bearing, Bearing Disk and Counter-thrust Bearing ‘Starting Condition Compressor whee! [500.43], labyrinth disk [500.44] and labyrinth ring [500.45] removed. Work Steps 1. Mount protecting sleeve (596.075) with extension shaft (596.040) ‘onto undercut bolt (520,066) of the turbine rotor (520.001). 2. Loosen six lock nuts (517.102) of the thrust bearing (517.158). 3. Press off thrust bearing from the bearing body (517.162) with the three forcing-off bolts (596.041) and remove. Unscrew protecting sleeve. 5, Remove bearing disk (517.075) from the thrust ring (520.028) and, check it (see work sequence 2). 6. Screw the assembly ring (596.086) of the removing tool (596.514) nto the external thread of the thrust ring (520.028) and loosen the thrust ring with three forcing-off bolts (598.087). 7. Remove thrust ring. StXerpxo—Gan) 6671 C2 500.46-01 E 07.04 TCAGS 1728. Unscrew hexagon bolts (517.187) and remove counter-thrust bearing (517.184) from the bearing body (517.162). 9. Check counter-thrust bearing (see Work Sequence 3). Note! Removal and inspection of the bearing bushes, see [500.56]. Work Sequence 2 - Inspection of the Bearing Disk 517.075 517.075 i a_Tapertace b Wing v Edge 517.075 Bearing disk Fig. 97. Bearing disk in new condition (left) and with clear traces of wear (right) Starting Condition Bearing disk (517.075) removed (see work sequence 1). Work Steps ‘The length (1) of the taper faces (a) is measured for evaluation of the degree of wear. The length ()) begins at the edge of the oil groove and tends at the edge (v) of the wearing surfaces (b). Important! Depending on the incidence of light, a dark band can be seen in tront of the edge (v) on the taper face (a). This is also to be included in the length measurement (). “The bering disk can be reused again when one of the lengths (I) is not below the following value: 1mm. f 5 Senne — GO 6671 C2 500.46-01 E 07.04 TCAG6 173,Work Sequence 3 ~ Checking the Counter-thrust Bearing 517.154 a Tapertace b Wing v Edge __517.154 Counter-thrust bearing Fig. 38. Counter-thrust bearing in new condition (lef), and with clear traces of wear (right) Starting Condition ‘Counter-thrust bearing (517.14) removed (see work sequence 1). Work Steps. ‘The length (I) of the taper faces (a) is measured for evaluation of the degree of wear. The length (I) ends at the edge (v) of the wearing sur- faces (b). Important! Depending on the incidence of light, a dark band can be seen in front of the edge (v) on the taper face (a). This is also to be Included in the length measurement (). Replace counter-thrust bearing in case one of the lengths () is below the following value: 125mm. StXemxo— Gan 6671 C2.500.46-01 E 07.04 TCASS 174StKemace— Gd 6671 Work Sequence 4 — Installation of Thrust Bearing, Bearing disk and Counter-thrust Bearing Starting Condition Work Steps: BV C2 500.46-01 E Bearing bushes [500.56] and turbine rotor [500.53] mounted. ‘The protecting sleeve (596.075) is not mounted. 4, Mount the counter-thrust bearing (517.154). 2. Slide the thrust ring (520.028) onto the shaft, ccounter-thrust bearing, front of the Important! Apply Molykote P40 to the bearing location for the thrust ring on the turbine rotor (protection against fretting). 3. Apply machinery oil to both sides of the bearing disk (517.075) and place bearing disk on thrust ring. 4, Screw protecting sleeve with extension shatt (596.040) onto un- dercut bolt, Important! Check if the studs (517.068) are completely screwed into the end cover (517.064) (see work card [500.55}) and do not project out of the bearing body (517.162)! 5. Slide thrust bearing (617.153) onto stud screws of the end cover (see [500.55)) until these can be fully seen, and the thrust bearing completely faces against the bearing body (517.162) Important! Do not misalign the thrust bearing upon assembly. 6. Secure the thrust bearing with lock nuts (517.102) and lock wash- or pairs (517.095). Important! Lubricate thread (e. g. with Molykote HSC)! Important! (Observe tightening torques upon installation! Lock nut thrust bearing (517.102) 60Nm Hexagon bolt counter-thrust bearing (517.157) 17Nm 07.04 TAGE 175StXerpe0— Gand 6671 €2.500.46-01 07.04 TCAss 176Assembly and Maintenance - Turbine Side StXtme- Ga 6671 C24.5-01E 07.04 CASS 45 1707.04 TCAGS 178 StXeme—Gar 6671 C24.5-01EGas-admission Casi Short Version Required Personnel andTime Required Tools/Appliances Spare Parts Technical Data StXtmace—-G 6671 C2 500.51-01 E ng 500.51 Removal of the casing for inspection of replacement of the turbine noz~ 2le ring or for disassembly of parts inside. [Amount] Qualification Required Time Th | {Qualified mechanic 40 7 [Assistant 70 Amount] Designation [Number | Status 7 |Open-jaw wrench 24 =| Taventory 7 [ Torque wrench = inventory = [Lifting taco, ropes, winches | =| Inventory jd (for placing underneath | inventory 7 | Suspension device 596.520 Standard 1) Shackle At a 596,046. ‘Standard 7) Suspension plate "B96 065 | Standard 1] Eye bolt 596.058 ‘Standard ‘Amount Number 20] Lock washer pair 306.107 Designation Specification Gas-admission casing (axa) 270Kg Gas-adimission casing (80°) 380 kg | 07.04 ToAS 179Z\ warning Danger of injury from suspended loads! A ‘The gas-admission casing must not rock, or else it could fall | down and seriously injure people and cause damage to material, + Use tackle line/chains to guide the gas-admission casing, + For attachment of the liting equipment, use only the suspension device intended for this purpose as described under “Required Tools/Appliances’. + Move the crane slowly. g 596.046 a 596.055 if 501.001 Gas-admission casing 596.055 Suspension plate 506.106 Hexagon bolt 596.058 Eye bolt 596.046 Shackle Fig. 39. Mounting of the gas-admission casing Work Sequence 1 ~ Removal of the Gas-admission Casing Starting Condition Connection and exhaust gas lines are disconnected, Note! ‘Main dimensions/disassembly measures, see Fig. QAQ in Section C1, Chapter 3.1, Work Steps 1. Remove coverings (if available). 2, Unscrew two hexagan bots (506.105) rom gas-admission casing (601.001) (see Fig ®), ‘3. Fasten suspension plate (596.055) with a hexagon bolt to the gas- admission casing. StXtrre— Gan) 6671 C2 500.51-01 E 07.04 TCAGS 180 §Work Sequence 2~ Installation of the Gas-admis Work Steps: StXemne— Gan 6671 BY €2.500.51-01 E Important! Both bolts of the suspension plate must be inserted into the fastening holes of the gas-admission casing. 4, Hang the gas-admission casing tothe liting device, and tension rope. 5. Remove all hexagon bolts (508.106) along the outer circumter- ence. Note! ‘Mark bolt holes on the casing that are not occupied - these must be kept free when assembling the gas-admission casing. 6. Move the casing away from the gas outlet casing (506.001) in ax- ial direction. 7. Carelully place the gas-admission casing onto a wooden support ion Casing Installation is carried out in reverse order of removal. Important! Fasten gas-admission casing with twenty hexagon bolts (606.106) and lock washer pairs (506.107). Important! Lubricate contact surfaces and threads (e. g. with Molykote HSC)! Important! Observe tightening torques upon assembly! Hexagon bolt (506.106): 165 Nm 07.04 TCASS 181SUteo- GA 6671 62 500.51-01E 07.04 TCAGG 182Turbine Nozzle Ring 500.52 Short Version Removal of the turbine nozzle ring is carried out for inspection purpos- sin accordance with the maintenance plan. Required Personnel and Time Amount| Qualification | Required Time Th] 7 |Qvalied mechan Lot Required Tools/Appliances “Amount Designation Mumber | Status 7 [Open jaw wrench 79 = [vent 1 Torque wrench = [ventory [— —| Lifting tackle, ropes: = Inventory 7 | Fitinganiting oot 396505 | Standard_| 2| Guide bar 596.050 | Standard t 2] Eye bolt 596.051 | Standard Spare Parts “Arno Designation Number 2i |exagon bots 518013 Bi | Tock washer pair 513.014 Corresponding Work Cards Work Card Work Card Work Card 500.51 ~~ Technical Data Designation Speciication Turbine nozzie in akg 1 ‘SUX ewico— fan) 6671 C2.500.52-01 E 07.04 TCAGG 183Work Sequence 1 ~ Nozzle Ring Removal cores 501.001 Gas-admission casing 513.013 Hexagon bolt 513.001 Nozzle ring 513.014 Lock washer pair 518.010 Clamping ring 596.050 Guide bar Fig. 40. Installatior/removal of the turbine nozzle ring (90° gas-admission casing) 513.013, 513.014 513.013—g 513.0144, 513.013 Hexagon bolt 513.014 Lock washer pair 596.050 Guide bar 501.001 Gas-admission casing 513.001 Nozzle ring 513.010 Clamping ring Fig. 41. Installation/removal of the turbine nozzle ring (axial gas-admission casing) StXemce—Gan 6671 C2 500.62-01 E o7.04 TCAGG 184 3 2 &Starting Condition, Gas-admission casing [500.51] removed and placed on firm support. Work Steps: 1. Loosen outer hexagon bolts (513.013) from gas-admission casing (601.001), Remove clamping ring (518.010) by hand, 90° Gas-admission Casing 2. Unscrew two hexagon bolts (513.013) on the inside and replace them with guide bars (596.050). Loosen the other hexagon bolts. 3 Slightly pull off the nozzle ring (513.001). Position rope around nozzle ring and remove from the gas-admi sion casing in axial direction. Axial Gas-admission Casing 2. Unlock all inner hexagon bolts (513.013) and screw 2 eye bolts (596.051) in the nozzle ring (513.001), Position rope in the eye bolts and lft nozzle ring out of the gas admission casing. a Work Sequence 2 ~ Nozzle Ring Installation Work Steps. Installation is carvied out in reverse order of removal Important! Lubricate contact surfaces and threads (e. 9. Molykote HSC)! Important! (Observe tightening torques upon assembly! Hexagon bolt (513.013): 70Nm TCASS 185 StKewae—Gad 6671 C2500.52-01 E 07.04SUXte- GQ 6671 C2 600.52-01 E 07.04 ToASS 186Turbine Rotor 500.53 Short Version Removal of the turbine rotor for inspection of the bearing bushes and the bearing points. Required Personnel andTime Amount] Qualification I Required Time [h] 7 | Qualfied mechanic i os 1 [Assistant | 06 Required Tools/ Appliances: ‘Amount Designation ‘umber | Status 2] Oper-jaw wrench 19 =| Trventory 1 | Fting/uniting fot 596.515 | Standard i] Protecting sleave 506.075 | Standard 7] Clamping sleeve Standard 1] Pipe (= 36mm, langihapprox |] Tnventory 1000 mm) 7 [Ling tacks, ropes = [inventory =| Wood (fr placing underneath) | =| Inventory Corresponding Work Cards Work Card | Work Card Work Card 300.43 «800800 500.46, ~~ 500.51 ~ Technical Data Designation - Specification Turbine rotor Ta0Kg StXKemae—Gan 6671 C2 500.53-01 E 07.04 TCAG6 1871 Turbine blade Fig. 42. Turbine side: View of gas outlet casing ‘Fig. 43. Compressor side: View of bearing casing Work Sequence 1 ~ Removal/inspection of Turbine Rotor and Labyrinth Ring Starting Condition Compressor Side Starting Condition Turbine Side Work Steps: Stee Ga 6671 62 800.53-01 E Compressor whee! [500.43], labyrinth disk [500.44], labyrinth ring [500.45], thrust bearing and bearing disk [500.46] removed Protecting sleeve (596.075) screwed onto turbine rotor (520.001)(see Fig. @). Gas-admission casing [500.51] removed. Note! Disassembly measure for rotor, see Fig. QQ Section C1 - Chapter 3.1 1. Position clamping sleeve (596.504) onto shaft ond of turbine disc and secure with hexagon bolt and nut (see Fig. @). 2. Pull turbine rotor (520.001) as straight as possible out of the bear- ing casing. 3. Hang turbine rotor with the rope to the iting tackle as close as possible to the turbine. Lightly tension rope. 4. Insert a suitable pipe (0 < 35 mm, length approx. 1000 mm) into the clamping sleeve (596.504) to guide the rotor upon removal. 5. Carefully pullout the turbine rotor all the way, guiding the crane along Important! Do not misalign the rotor upon pulling out, otherwise the bearing of the rotor could be damaged. Important! The inserted pipe can be used to keep the free-hanging rotor in balance. 07.04 ToAss 1886. Place down the turbine rotor on wood blocks (in horizontal posi- tion) or on wooden support (in vertical position). Important! Do not set down the rotor on the turbine blades. Do not damage the bearing locations. 7. Check the turbine rotor (520.001) (visual check): © Do the blades show traces of thrust? © Do the bearing locations show traces of scoring? Z\ Warning There Is a substantial accident risk when operating a A turbocharger with improperly mounted turbine blades! Incorrect fastening and securing of replaced turbine blades can ead from loosening of the blades to the total loss of the turbocharger. + Have all maintenance work on the turbine blades performed through MAN B&W service personnel! + Incases of doubt, definitely ensure to contact MAN B&W. + When maintaining turbine rotor and turbine blades, these are to bbe handled with utmost care. INN 520.001 Turbine rotor 596.075 Protecting sleeve §96.504 Clamping sleeve Fig. 44. Check points, rotor shaft Note! In order to check the diameters (D;), the turbine rotor must not be pulled completely out of the bearing body. ‘8. Measure and record the bearing points. Replace rotor when falling short of the diameter measure (D}): Dy = 80.96 mm, SUX ema — Gan) 6671 C2 500.53-01 E 07.04 ‘TCAG6 189Note! For checking of the bearing clearance between bearing bush and turbine shaff, see [500.56] work sequence 3. 596.508 (20.001). 520.001 Turbine rotor 596.504 Clamping sleeve Fig. 45. Clamping sleeve mounted on shaft end 9, Measure labyrinth ring. Replace labyrinth ring when falling short of the diameter measure (D2) Dy 114.5 mm, 520.001 Turbine rotor 520.021 Ring nut 520.018 Labyrinth ring, turbine side 596.075 Protecting sleeve Fig. 46. Check points, labyrinth ring Work Sequence 2—Turbine Rotor Installation Starting Condition Work Steps: StKerpc0— fan) 6671 C2 500.53-01 E Condition and accuracy to measure of the bearings [500.56] and the turbine rotor checked (see work sequence 1 - "Removallinspection of Turbine Rotor and Labyrinth Ring") Installation is carried out in reverse order of removal. 07.04 TCAGS 190Shroud Ring 500.54 Short Version Check shroud ring for wear; adjust gap to the turbine. Required Personnel and Time ‘Amount Qualification [ Required Time Thy 1 | Gualied mechanio 3 Required Tools/ Appliances ignation Number | — Status itting/unfitting tool 506.525 | Standard 2] _Guide bar 596.050 | Standard [2] Bye bot 506.051 | Standard 1 |Opersaw wrench 13 = [inventory 7} Torque wrench = [nventory 1|Fester gauge = [ventory | =| Moiykote HSC = Spare Parts | Amount] Designation umber 72 Fexagon bot “300.072 [72 |Look washer pair 509.014 Corresponding Work Cards Work Card Work Card Work Card a 300.55 Technical Data Designation ‘Specification ‘Shroud ring 19 kg StXemc—Gan\ 6671 02 .600.54-01 E 07.04 TCAs 191Work Sequence 1 ~ Shroud Ring Removal Starting Condition Gas-admission casing [500.51] removed, 509.001 Diffuser outside wall 509.012 Hexagon bolt 509.008 Shroud ring 509.014 Lock washer pair Fig. 47. Shroud ring and turbine rotor mounted Work Stops 41. Unscrew two hexagon bolts (509.012) and replace them with two guide bars (596.280). 2. Unscrew all hexagon bolts around the circumference. Note! A screwdriver can be applied to the top and bottom recess (see Figure @)) in order to loosen the shroud ring. 8. Remove shroud ring (509.008). 4, Remove guide bars (596.050). Work Sequence 2~ Shroud Ring Installation Starting Condition Turbine rotor 500.53] installed, gas-admission casing [500.51] re- moved. Work Steps 1. Screw two guide bars (596.050) into diffuser (509.001) of the gas- ‘outlet casing (506.001). 2. Place on the shroud ring (509,008) and secure with three hexa~ ‘gon bolts and lock washer pairs. Unscrew the guide bars. 3. Screw in all hexagon bolts (509.012) with lock washer pairs’ (609.014) around the circumference, and lightly tighten. SUXéroue—faan) 6671 C2 500.54-01 E 07.04 TCAGS 192SUXtnosee— Ga) 6671 2 800.54-01 E Important! Always use new lock washer pairs when mounting! 4. Measure gap dimension $ between turbine blade/shroud ring at both locations A with feeler gauge. Lightly loosen hexagon bolts (608.012) and align shroud ring (509.008) horizontally tothe center (gap dimensions left and right must be equal). 5. Lightly tighten the hexagon bots. 6. Measure gap dimension S atthe vertical measuring points B and C and align shroud ring (509.008). Important! Due to the floating bearing of the turbine, the turbine rotor Is lightly elevated during operation by the oil. Therefore, the shroud tring rhust be fastened 0.2 mm higher than the turbine rotor upon mounting (in the neutral position). 809.008 Shroud ring s Gap dimension 509.012 Hexagon bolt ABC Measuring points | 520.001 Turbine rotor 1 Top recess Il 2 Turbine blade Fig. 48. Measuring points for gap dimension of turbine blade/shroud ring A B=A-02mm C=A+0.2mm O7 a HOS 08 12 4 09 138 Table 4. Gap dimensions at measuring points B and C are dependent of Ain ‘new condition 07.04 TCASS 193SUX empaco GQ 6671 7 a 2 500.5 Important! For maximum permitted gap dimensions of components that have been in operation, see Chapter 3.2 ~ Gaps and Clearances. 7. Compare all 4 measured values again with the permitted gap di- mensions (see Chapter 3.2) and record in the inspection report (Section Ct in Chapter 6.6). 8. Tighten all hexagon bolts (509.012) with the specified torque. Important! Lubricate contact surfaces and threads (e. g. with Molykote HSC)! Important! Observe torque settings upon installation! Hexagon bolt (509.012): 70Nm o7.04 TCASS 194End Cover Short Version 500.55 Removal of the end cover is required for inspection of the bearing bush (urbine side), Required Personnel and Time “Amouni| Qualification 1 [Qualified mechanic Required Tools/Appliances ‘Amount| Designation ‘Number | Status T]Open-jaw wrench 18 inventory Spare Parts Amount] Designation 1 Number "(| Seal, turbine side 517.070 Corresponding Work Cards Work Card Work Card Work Card 500.44 500.45 500.46 500.58 500.56 Technical Data Designation ind cover with sealing cover and stud sorews 26kg SUX tna —Gad 6671 C2 500.55-01 E 07.04 TAGS 195517.068) Bearing casing 517.072 Sealing cover, turbine side End cover 517.094 Lock nut Stud screws 517.159 Cover Seal, turbine side 517.161 _ Bearing bush Fig. 49. Installation of end cover in the bearing casing Work Sequence 1 ~ Removal of the End Cover Starting Condition Turbine rotor [500.53] and thrust bearing [500.46] removed. Work Steps 1. Unscrew the eight lock nuts (517.094) for attachment of the studs (617.068), 2. Pull off the end cover (517.064) from the bearing casing, Work Sequence 2 ~ Installation of the End Cover Starting Condition Bearing bushes [500.56] mounted. Turbine rotor [500.53] not mounted. Work Steps 1, Slide sealing cover (517.072) and seal (517.070) on stud screws (617.068) of the end cover (517.064). Important! Check if the studs (517.068) are completely screwed into the end cover (517.064)! 2. Slide end cover with stud screws into bearing casing (517.001) - turbine side. 3. Fasten the end cover with the lock nuts (517.094) Important! Lubricate contact surfaces and threads (e. g. with Molykote HSC)! BV Important! — Observe torque settings upon installation! Lock nut (517.094): 60 Nm StXtrpx0—Gan\ 6671 C2 500.55-01 07.04 TCAGS 196Bearing Bushes 500.56 Short Version Removal of the bearings for inspection purposes or replacement, Required Personnel and Time Amount] Qualification [ Required Time [a] 7 [Quaid mechanic 7 Required Tools/Appliances, Designation Number | Status Open-jaw wrench 13 inventory P 1 | Micrometer (outside and inside) 7 Inventory [1] Depth gauge = [inventory Spare Parts Amount] Designation ‘Number T2|Lockwasherpar 317.156 2| Bearing bush S764 Corresponding Work Cards Work Card Work Card Work Card 300.46 500.53 500.54 500.55 StXemnc—Ga 6671 02500.56 02 E 05.05 TCA66 19717187 [sive 517.075 517.154 817.161 | 517.161| 517.159 ) | | | 517.001 Bearing casing 817.163 Thrust bearing 517.064 End cover 517.154 Counter-thrust bearing 517.066 Locating disc 517.156 Lock washer pair 517.067 Countersunk screw 517.157 Hexagon bolt 517.068 Stud 517.159 Cover 517.075 Bearing disk 517.161 Bearing bush 517.089 Labyrinth disk 517.162 Bearing body Fig. 60. Bearing casing Note! Before disassembly: Mark the installation position of the bearing bushes on the bushes in the bearing body with a felt pen (compressor side/turbine side), so that these can not be mixed up. Work Sequence 1 ~ Bearing Bush, Compressor Side: Checking the Axial Gap and Removing Starting Condition Turbine rotor [500.53] as well as thrust and counter-thrust bearing 1500.46] are removed. Important! When removing the bushes (517.161) the bearing body (517.162) and the locating disc (517.066) remains firmly installed in the bearing casing (517.001). Work Steps 41. Slide the bush by hand completely into the bearing body and take measure A with the depth gauge (compare Fig. @). 2. Replace the bearing bush when Az05mm, ‘StXenpe— (Gan) 6671 2500.56 02E 05.05, CASS 198517.162 517.161 Bearing bush 517.162 Bearing body Fig, 51. Measuring the axial clearance ofthe bearing bushes -compressor side 3. Mark the bush with a felt pen (compressor side). 4, Remove the bush from the bearing body and check for wear (see Work Sequence 4). Work Sequence 2 ~ Bearing Bush, Turbine Side: Checking the Axial Gap and Removing Starting Condition ‘Turbine rotor [600.53] and end cover [500.65] removed from the bearing casing, Important! When removing the bushes (617.161) the bearing body (517.162) and the locating disc (517.066) remains firmly installed in the bearing casing (517.001). Work Steps Loosen hexagon bolt (517.187) and remove cover (517.158), Side the bush by handinto the bearing body and take measure A with depth gauge (compare Fig. ©) 3. Replace the bearing bush when A205 mm, 517.161 517.161 Bearing bush _517.162_ Bearing body Fig, 52. Measuring the axial clearance of the bearing bushes - turbine side 4. Mark the bush (turbine side). 5, Remove bush from bearing body and inspect for wear (see Work Sequence 4). SWtwme— Ga 6671 C2 500.56 02E 05.05 ‘TCAGS 199Work Sequence 3 ~ Checking the Bearing Body Starting Condition Bearing bushes (517.161) are removed out of bearing body (517.162) (see Work Sequence 1 and 2). Bearing body remains installed in the bearing casing (517.001)! Work Steps 1. Clean the bearing locations in the bearing body. 2, Measure both location bores (inside-diameter Ds- compare Fig. @) in the bearing body for the bearing bushes (turbine and compressor side) and record the measured values. Replace the bearing when D5 > 117.03 mm. 517.161 517.161 Bearing bush 517.162 Bearing body Fig. 53. Checking the bearing body and bearing bushes Work Sequence 4 — Checking the Bearing Bushos/Radial Clearances of Bearing Bush Starting Condition ‘The diameter measures (D3) of the bearing locations on the turbine shaft for both bearing bushes (517.161) have been determined (com- pare [500.53] Work Sequencept). Measures for both location bores (inside diameter D,) of bearing bush- {8s taken (compare Work Sequenceb3). Marked bearing bushes (turbine side/compressor side) removed from bearing body. ZX warning Defective bearing bushes can cause major turbocharger /\ damage. During operation, worn or defective bearing bushes can lead to breakdown of components in the turbocharger. This can lead to the injury of persons and cause damage in the engine room. + Carry out checks and maintenance work regularly! + Pay attention that the bearing bushes do not have deep grooves ‘or scoring on the running surfaces. + Check the accuracy to measure ofthe bearing bushes! + _In.cases of doubt, replace the bearing bushes! Work Steps 4. Thoroughly clean the bearing bushes. SU erpx0—Gad 6671 C2 00.56 02E 05.05 TCAGS 2002. Measure the inside diameter (Ds) and the outside diameter (D,) of the bearing bushes and record (see Fig. @). 3, Replace the bearing bush when Dy 2 81.09 mm, D4 $116.70 mm. 4. Calculating the radial clearances (see Chapter 3.2. - Gaps and Clearances). Important! The radial clearance between bearing bush/turbine shaft is calculated out of the difference between the interior diameter of the bearing bush (D,) and the respective diameter dimension (D;) of the turbine rotor as follows: Raa) = Ds~ Dy (compare [500.53]. Important! The radial clearance between bearing body/bearing bush is calculated out of the difference between the exterior diameter of the bearing bush (D,) and the respective location bore (inside diameterpDs) in the bearing body as follows: Rap) = Ds~ Dg 8. Replace the bearing bush when Rega) 20.12 mm, Reon) 2 0.33 mm. ‘Work Sequence 5 ~ Installation of the Bearing Bush Starting Condition ‘Work Steps. SUKemace— Gan) 8671 BY 2 500.56 02 Condition and accuracy to measure of the bearing bushes (517.161) ‘and the bearing body (517.162) checked. Important! Before inserting the bearing bushes, lubricate them with machin- ery oll. Installation of the bearing bushes in the bearing casing is carried outin reverse order of removal, Important! Lubricate contact surfaces and threads (e. g. with Molykote HSC)! Important! Contro! tightening torques of countersunk screw (517.067) of locating disc! Observe tightening torques upon assembly! Hexagon bolt (517.157) 47 Nm ‘Countersunk screw (517.067): 34.Nm 05.05, ToAGS 201StXeae—-G 6671 C2 500.56 02E 05.05 TCAGS 202Gas Outlet Diffuser Short Version Required Personnel and Time Required Tools/ Appliances Spare Parts Corresponding Work Cards Technical Data SEX eapow Gan) 6671 2 500.57-01 E 500.57 Removing and reiting he gas outlet cifuser. ‘Amour fon [Required Time Th] | 7 1| Qualified mechanic 1.0 ‘Amount Designation umber | ~ Status 7 iting tack, ropes =| Tnwentory 2| Guide bar 396.045 | Standard | 4| Eye bolts M20 x 2 ‘596.052 ‘Standard [Ta] Shackte AOS 396.208 | Standard 1] Torque wrench = | Inventory 1 Open jaw wrench 2 =P wentary 4] Foraing-off bots M6 = ventory | =/Molykote HSC = inventory [Amount] Designation ‘Number 7] Lock washer pair : 306.107 Work Card Work Card Work Card 300.51 B0055 300.54 [Designation ‘Specification Gas outlet diffuser L 232 kg 07.04 TcAG6 203Work Sequence 1 — Removal of the Gas Outlet Diffuser Starting Condition Gas-admission casing [500.51], shroud ting [500.54], turbine rotor 1500.53] removed. Work Steps 1. Screw three guide bars (596.045) into the bolt hole circle (1), each divided by 120°. 2. Loosen all four hexagon bolts (506.108). 3. Press off gas outlet diffuser (509.001) with the hexagon bolts (606.108) from the gas outlet casing (506.001) and fasten to liting tackle with eye bolts (596.052). 4, Move gas outlet diffuser away from the gas outlet casing using the lifting tackle, and place down carefully. 508.107 506.108 506.001 506.001 Gas outlet casing 506.107 Lock washer pair 506.108 Hexagon bolt 509.001 Gas outlet diffuser 1 Bolt hole circle Fig. 54. Gas outlet diffuser, installed SUXtepco— Gan) 6671 C2 500.57-01 E 07.04 TCABE 204‘Work Sequence 2 ~ Installation of the Gas Outlet Diffuser Work Steps 1. Screw three guide bars (596.045) into the gas outlet casing (606.001), 2. Liftgas outlet diffuser (509.001) with ling tackle and position into the gas outlet casing, 3. Fasten gas outlet diffuser with four hexagon bolts (506.108) and lock washer pairs (506.107). Note! Mount the shroud ring [500.54] after mounting the turbine rotor 1500.53]. Important! a lubricate contact surfaces and threads (e. g. with Molykote HSC)! Important! oN Observe tightening torques upon assembly! Hexagon bolt (506.108): 165m SUXemae— Gand 6671 C2 500.57-01 07.04 TCAG6 205StXeme—-Gad 6671 2 500.57-01 E 07.04 TCAGG 206Technical Documentation Exhaust Gas Turbocharger Spare Parts Catalogue C3 Exhaust Gas Turbocharger. TCAGG D36 6671-1 E SEK Enpaco Co,Ltd. 452-7, Nae-dong, Changwon, Gyunsangnam-do, 641-050 Korea « Phone ++82 55 280 0770 = Fax ++82 55 282 1938 E-mail: sdlee285@stxenpaco.cokr http://www stwenpacocokt StXtnmo— Gand 6671 C3-01E 07.04 TCAGS 207Table of contents c3 1 Introduction 209 1.1 Preface 1.2 Layout and Usage ofthe Spare Pants Catalogue 1.3 Ordering Spare Parts . 2 List of Assemblies 500 List of Assemblies : oe 216) 3 Spare Parts .. 501.01 Gas-admission casing axial 220 501.02 Gas-admission casing 90". 506.01 Gas outlet casing 509.01 Gas outlet difuser .... 513.01 Turbine nozzle ring = eeanooa, 517.01 Bearing casing 230 518.01 Casing feet... re errr 520.01 Rotor, complete 236 540.01 Insert, complete... 238 542.01 Diffuser . nnn nnn 240 544,01 Silencer, complete .... . 242 545.01 Air intake casing, complete .. omnnninnsinnnnnnnnnnnnnnninennnnnnnsss BOM 546.01 Compressor casing (single outlet) 246 549.01 Cooling System Turbine Disc 248 554,01 Emergency and Postlubrication System : : 578.01 Wet Cleaning of the Turbine (Gas-admission casing 90") 578.02 Wet Cleaning of the Turbine (Gas-admission casing axial)... sense B56 578.03 Dry Cleaning of the Turbine . vn 258 579.02 Wet Cleaning of the Compressor (for pressure connection) 260 579.03 Wet Cleaning of the Compressor (pressure sprayer) sn . sonnei 262 591.01 Annular lagging Gas-admission casing 264 591.02 Sound insulation compressor casing (single outlet)... 268 4 Reserve Parts 269 595,01 List of Reserve Parts ... 271 5 Tools 275 596.01 List of Tools ... 277 Index I Sep - Ga 6671 C3-01E 07.04 TCAGG 208Introduction Preface 11 Spare Parts / Spare Parts Catalogue SUX ema — (and 6671 C31.1-01E Maintenance and repair work can be carried out properly only when the required spare parts are available. ‘They are to bo kept in stock or to be ordered in good time. The stock ‘numbers required for ordering can be found in spare parts catalogues. The spare parts catalogue for the exhaust gas turbocharger is available, ‘The structural principle of this spare parts catalogue is explained in Chapter 1.2. Stock numbers for engine components, measurement and control equipment as well as for system accessories of the engine can be found in other modules of the technical documentation, See the enclosed Notes in Chapter 1.3. Sincerely yours STX Enpaco Co,, Ltd. 07.04 TCAGS 209Layout and Usage of the Spare Parts Catalogue 1.2 Layout Contents ‘Structural Principle Assemblies Ordinal number ‘Sheet Number ‘Stock Number & Steno — Gand 6671 C31.201€ ‘The spare parts catalogue includes ‘all essential components of the turbocharger. The spare parts catalogue does not include ‘* secondary or systom-specitic insulations/coverings and ‘* subordinate cablings and pipes that lead away from the ‘turbocharger or are carried out by other manufacturers The pages of the spare parts catalogue are structured according to the assemblies system of the turbocharger. ‘The assemblies of the STX Enpaco - MAN turbocharger can easily be determined with the List of Assemblies (see Chapter 2). ‘Subassembly group numbers given in brackets do not exist forall tur- bochargers. Subassembly group numbers marked with * can not be viowed in the List of Assemblies. ‘The ordinal number located at the top right of the spare parts sheets consists of the 3-digit subassembly group number and a 2-tigit version number, which complies with the design, ‘The sheet number consists of the 4-digit printing number (6671) on the bottom left and of the ordinal number (e. g. C3 620.01 E) next to it on the right. ‘Stock numbers consist of a S-digit subassembly group number and a 3-digit position number. Subassembly group number and position num- ber are thereby separated with a dot. 520.001 Stock Number (e.g. turbine rotor) Position Number ‘Subassombly group number 07.04 ToASs 210Validity Valiity Replacement Sheets Changes/Alterations on the ‘Turbocharger Delivery of Changed Parts StKtnoe— fan 6671 C31.2-018 Spare parts catalogues are specially adapted to the respective turbo- charger version. Therefore, the respective spare parts catalogue Is val- id only for the turbocharger or the turbocharger series with the works No. oF factory-number group on the cover sheet. Important! ‘Spare parts catalogues may not be transferred from one turbocharger to another. ‘Spare parts catalogues which are handed out in advance for informa- tion purposes are marked with a red note sheet as “Informational Is sue” Important! Informational issues are not suitable for ordering spare parts, not suitable for the planning of inventory, rot suitable to be taken over into electronic data processing systems! In case of changes at a later point of time, the respective auxiliary or replacement sheets will be sent to you. Important! Please ensure that such auxiliary or replacement sheets, as have been assigned to you, are properly filed into all corresponding spare parts catalogues. If changes/alterations are carried out to the turbocharger over the coarse of the operating period for which no new drawings are drawn up and subsequently no new spare parts sheet is made out by the STX Enpaco, the operators of the engine themselves must enter a respective remark into the spare parts catalogue. This will help to avoid false orders. Due to continuous development on the turbochargers, future spare parts for orders might be delivered that are changed in comparison to the original components, which nonetheless fulfill the same function. In ‘such cases, the identifying card of the delivered part wil contain an ap- propriate note. 07.04 TCAG6 aitOrdering Spare Parts 1.3 Overview The turbocharger is part ofa system from which he assemblies can be from various manufacturers, The folowing table gives an overview of the various spare parts cataloguestiniormation aides from which the necessary data for spare parts orders can be taken. [Component/Assembiies Tatormation Aid ‘Section of the Techni | ca! Documentation | Turbocharger Spare paris catalogue, turbocharger C3 | = [Datainworkcards —SSS*dSSCSCi ‘id Tools (urbocharger) List inthe turbocharger fool box cs [Detainworkeards C2 Engine Engine and system accessories Measurement and control equipment ‘Spare paris catalogue, engine [See technical documen- List of measurement and control equipment | tation of engine and ‘Spare parts catalogue /Spare parts sheet |¥St@™ depending on manufacturer and product | Table 1. Spare parts catalogues and comparable information aides Ordering of Spare Parts StKtypo— fad 6671 C31.3-01E To avoid questions when ordering spare parts, the following informa tion is required: ‘Type of turbocharger. 2000 Factory number of the turbocharger. 2000 (Type of engine) seeessee 200000 (Factory number of the engine). .. 20K Designation of the part........ 101K Ordinal number 200.200 Quantity... Xx Shipping address. XH ‘Shipping method 2010000 Important! Ifparts must be ordered that are not contained or can not be found in the spare parts catalogue, describe the part and the build-in location as precisely as possible (send photo along). For parts of ‘subsuppliers which can not be found in their records, the information on the type plate must be quoted. 07.04 TCAES 212Address § StXemae— Gar 6671 Ca1.sO1£ Please direct your order to: STX Enpaco Co., Ltd 452-7, Nae-dong, Changwon, ‘Gyunsangnam-do, 641-050 Korea Telephone: ++82 55 2800770 Telefax: +482 55 282 1938 7.04 TCAGS 213SWXereace— Kan 6671 C31.3-01E 07.04 TCAG6 214List of Assemblies StXtmao—-G 6671 C32-01E 07.04 TCAGSseereorevas s9voL roo A0-008€9 1299 Wy ortaNgS satiquiessy Jo 1817uz. e9vOL 020 10-0529 1199 Ky —orags 217 xgenene u (~) sain6y uu umoys you serquiessy Luopeinsuy pue Buyenog ses Josseid.oo 30} soinep Bue ‘es. ‘auIQIMA JO} aotap BuIweEaiQ tus eowep Busnseew peeds ‘zs uwoishs uopeougn sod pue foueBiowa ss ‘281p auiqum wershs BUyooD 6S (venne aiqnop “jepno ei6uss) Busseo Josseidwog, ore Buyseo eyeul ay (gps) so0u0Hs (os) sesnuia zs vasu} ons etdwoe 1104 ozs 9) Buse, es Buse Buve9g ais fy apz0u ougung eis 22eniyp ene se) 60s use jaino se5 205 (.06 00) seo uossupe-sep 10s 06184009 $00 enews oo uoyeuBiseq Aiquessy SarqUIassy J0 1817Spare Parts § SUK — Gand 6671 C33-01£ 07.04 TOAGSoz reer useen s9vOL 020 BLOLOSEO 1199 Kry—ereNQS 000"L0g yr0'108 Lo"Los lepxe Bujseo uojssjwpe-sep §ize 99¥0L v0'L0 Biotoseo 189 Ky-oags, spdsoysenyooy 9 syotos yoquoesH ¢ —Hro'L0S obuey pug y= z0L0s Sw Guess 2 saat0s Gnd meng = 2 S20"10S Guu Buyees ‘¥20"LOS frdmans 2 © aos _Queysyse.-yeey) juewso Buyreag: 1‘ GLO LOS, uoqerneu yk Gusea uossiupe se) }+00'L08 }dwoo ‘Buiseo Uorssmupe-seD ' 000"F0S wojeubjseq sequmy “0M 20p10 vopeubieeq sequny “oN s2p0 Lo'Los Teixe Buyseo uoyssjwpe-seg eatwe reo" 99¥O1, 00 AZOLOSCO 1199 yeas £20'108-@, 820108 —O._ 00'10s 000°0s 20°L0S .06 Gurseo uolssiwpe-se5eee s9voL 020 AZLSE 1199 KYy-egs Bndmens 4 Bz0'L08 bots b gzotoe b seotos uu Suess tS pe0't0S Srid moog 620408 Loneinsul wm BuseD UOISSMIpESeD | ———.00'L0S ‘ydwoo ‘Buses uolssupese) 1 ——900'108 UwoneuBjs2q soquiNN “oN JopI0 voneuBjseq sequinN “oN JepI0 20°L0S: .06 Gulseo uolssiwipe-sey 223B10908€0 use C-eags o t00'908 ce 8 cor 208 000'905 4o'90S Burseo yeyno sep awe 99¥OL 020 Blorg0sed 1199 Er eagS yoquosexey = apt'908 aedaoysemyoor 22 ——404'908 yoquosexcH 92 901908 nu voBexeH 92 ——_—sot'90s wuuodersH ez 901908, Woquesexe 92 © -z01'908 yoamaopun 2 660'908 ebuey 800905 Woawsexc gz ea 908 Yoquotero 9 9008, aedcusen oor 9 950908 ed sousem 007 ez «90°90 cusuess 2 —ov0'008 Snidmons 2 © ——6e0'908 res 220905 Uonemsu ua BuseDiemne sep} «100908 “yoo ‘Guseoiamnoseg + ~=—=—g00908 opusysoq soquiny “ON Jep10 oneuBiseq sequin “oN JoRIO 10'905 Bulszo yayino sepreer 98¥OL, 00 BLO6OSEO 1299 H—otaNQS 000°609 +0°60S Jesnyip yepyno seg §ie sav. 020 ALeOSED 1299 KY —eHgS sedsousemyor1 21 p0'608 WoquebexeH zi —_zi060e Sw proms 4 ————g0g;08 wemepssinoesnyia | ———L00'608 eidwoo esa — 000608 uoneuBjseg sequiny “on s0p19 uopeuB}seq sequiNN “ON s0pIO. 10'60s Jesnylp yelino sep 27eee sever 99voL 020 BIEISEO 199 EY omgS 8 oumeis o00"e Ls LO’eLS Buy ejzzou eurqunyww sovon 020 ALOEISEO 1299 Crys aed soysem yoo) sz pLOeNS woquofexe 6 LOTS Buy Guide ouwers Buy eizon borers jdwoa ‘Guu epzzou aun, ooo'ers uoneuBiseq sequin “oN J0pi9, voneuBiseq seqUNN “ON 29p19 LoveLs. 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&, 80'0_|_meros peoupuiiko, £ vLe96S gh 4ouseo sene7 | L £97'96S. os BY ~ be 100 wal | exes zo_| epoeus| 1 | soze6s sexouw ow Q, £0'0_|_maxos yeoupUIiKD L 22z'96S £00 nu uobexoH t 864°96S, oexoun set Opis | L jzz'96s zo yoq uoBexeH 4 261965 006 XE X OE L eh dl 4 022°96S ge uoddns | L OLL'96S vesea | 88, | —wnmatrog| cunn | ono10) ——tieng | 91] wogeatieg| cum | on B10 Lo'96s 81001 J 3819 senna, 281ze, Serena gevon 020 FILO-LO6SEO 1499 KrY—ewagE £0. yoq uoBexaH | £ 09z96S, veo | f,| wonmtise| soaunn | ow neo || —utesa | 8881 | vopetiag| agus | on s9s0 1o'965 si0o1 Jo 3817 282Index A accessories 7 accleration system ‘Jet Assist” 45-46 address STX Enpaco 213 addresses service 9-11 addresses and contact persons MAN B&W Diesel AG, STX Enpaco 8 air intake casing 134 spare parts 244-245 alarm system 18 appliances (emergency operation) 58 arresting wrench 100 ‘auxiliary equipment 6 availbilty-codes 83 balancing mark marking 158 bearing bearing bush 199, bearing disk 172 counter-thrust bearing 172 thrust bearing 172 bearing body 199-200 bearing casing spare parts 280-283 builtin equipment 6 c casing design 6 casing feet spare parts 234-235 characteristics (fuels) 29 checks during operation 56 cleaning agent, turbine 31 cleaning system dry cleaning 47-48 wet cleaning of the turbine 4-50 wet cleaning, compressor 51 coefficient p 20 ‘compressed air connection $1 compressor cleaning 115 ‘compressor casing single outlet 246-247 spare parts sound insulation 266-267 ‘compressor wheel 157 connection charge air and exhaust pipes 123 several turbocharger 41 the lube oil system 125 SUXKemae—-Gar 6671 I-01 containment safety 15 cooling system turbine disc spare parts 248-249 counter-thrust bearing 172 cutaway view, TCAG6 34 D danger of fire/ firefighting equipment 17, deconserving of turbocharger 122 diffuser 151 spare parts 240-241 dimensions and connections 26 documentation 7 dry cleaning turbine 113-114 spare parts 258-259 E ‘emergency and post-lubrication system 38, 138 spare parts 250-253 ‘emergency operation 58 ‘operation without rotating element 103 with holding device 99-100 ‘emergency operation of the engine failure of turbocharger 59 ‘end cover 196 ‘oxhaust gases 17 ‘external sealing air 43 F fuel specification 29 fuels 27 functional description (exhaust gas turbocharger) 35 G gaps and clearances 93-95 gas outlet casing 188 spare parts 224-225 1928 outlet diffuser 204 spare parts 226-227 ,gas-admission casing 180 spare parts 90 degree 222-223 axial 220-221 ‘spare parts annular lagging 264-265 H hearing protection 17 holding device 99, insert 144 spare parts 238-239 inspection 07.04 TCASS 283,bearing bush 199 P bearing disk 173 f counter-thrust bearing 174 Pre york cards 81 turbine rotor 189 product liability 5 inspection cover of silencer 118 protective covers 18 inspection of individual components(goneral) 75 Pinsent Inspection report 77 inspection turbocharger a four-stroke engine qualification of personne! during operation 69 mainenancelrepairs 20 two-stroke engine ship systems 19 «during operation 71 stationary systems 19 J R jet assist 45 replacement shoots 211 L required personnel and time eral labyrinth disk 164 ting ut ted labyrinth ring 168 rotor labyrinth ring, measurement points 190 eee ce aa, tayout rotor shaft 189 spare parts catalogue 210 list s reserve parts 271-273, safety tools 277-282 during maintenancelrepairs 20, during operation 15 safety instruction list of assemblies 216-217 locations and addresses MAN B&W Diesel AG, STX Enpaco 8 attention 13 lube oil diagram 37 danger 13, lubricating oil 30 warning 13, uw safety instruction sign 86 safety instructions 13 safety instructions (symbols) 85 ‘scope of supply 6 ‘screw connections 73 sealing air system 42-44 service bearing disk 173 counter-thrust bearing 174 turbine rotor 188, 189 service addresses 9 shaft sealing 39 sheet number 210 shipment mode 7 shroud ring 192 maintenance remarks 73 maintenance schedule 65, 68 maintenance turbocharger four-stroke engine during operation 69 in common with an engine maintenance 70 two-stroke engine during operation 71 in common with an engine maintenance 72 maintenance work general hints 65 measuring points ‘gaps and clearances 87 silencer 129 A ‘spare parts 242-243, spanner rumbering for ring nut 169 work cards 82 spare parts a general 22 order numbers 66 spare parts catalogue assemblies 210 informational issues 211 structural principle 210, validity 211 special services / repair work 68 special tools 67 speed measuring equipment with speed indicator \JAQUET” 148, operating characteristics 25, operating conditions (lube oil) 39 operating faults (what to do) 57 operating life 25 operating media 27-31 ordering spare parts 212 ordinal number 210 outputs/speed (failure of a turbocharger) 58 StXeme—fad 6671 Ole 07.04 CAG 284speed transmitter cable connection 148 installing 146 speed-measuring equipment 146 starting of operation (intial) 55 starting operation 55 status inventory 83 option 83 special tools 83 standard 88 stock number 82, 210 T thrust bearing 172 thrust ring 172 tightening torques bolted connections 89 turbocharger TCAG6 91 tools 67 toolsfixtures general 83 ‘rouble shooting 60 turbine cleaning dry cleaning 113, wet cleaning 109 turbine nozzle ring 184 spare parts 228-229 turbine-dise cooling 53 turbocharger classification/engine 23 connecting several to engine 41 general 33 ‘ype 6 type plate 23 v venting 28 w weights of assemblies 24 wet cleaning compressor (pressure connection) 260-261 compressor (pressure sprayer) 262-263 turbine 109-110 spare parts 254-255 turbine (gas-admission casing axial) spate parts 256-257 wet cleaning system compressor 116 work cards 65 work prior to starting the engine 55 works number 6 SUX eco — oan 6671 LOL E 07.04 TCAGG 285StXtre-Ga 6671 HO1E 07.04 ‘TCASS 286Man Alpha Lubricator System 707X-40C Alpha Lubricator System Operation Manual MC Engines MAN B&W Diesel A/S Teglholmsgade 41 K-2450 Copenhagen SV, Denmark Phone +45 33.85 11 00 Fax +45.33.85 1020 Exmail_manbw@manbw.dk When referring to this page, please quote Alpha Lubricator 707X-40C TOG 1 MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28Le : Alpha Lubricator System san Table of Contents Page List of Abbreviations: 5 1. General Information 1.1 Main components 6 1.2 Working principle 9 1.3 Guidance values automation 10 2. Operation of the System 10 2.1 HML-Panel / Operating Pane! 10 2.2 Control butions and indicator lamps on pump station starter panels 1" 23 Start-up of Alpha Lubricator System (Engine not running) n 2.4 Checks during start-up of the engine 12 25 Periodic checks during normal operation of the engine 13 3. HMI-Panel and Configuration of MCU 13 3.1 Description of HMI Panel 13 3.2 HMI-Panel operation and configuration of MCU 4 3.2.1. Navigation principle 14 3.2.2 — Reading of total stroke/min [XXX] 14 3.2.3. Reading of total strokes [Str.hi] and [Str.1o] 14 3.2.4 Reading of active alarms [ALAXX] 18 3.2.5 Reading of logged alarms [LALXX] 15 3.2.6 Adjustment of cylinder oil feed rate [F.rAtE] 15 3.2.7 Monthly change of operating pumps (master pump) 16 3.2.8 Test sequence for inspection during standstill 7 3.2.9 Menu structure 7 3.2.10 HMI panel parameter reference list 21 33 MCU setup 32 3.3.1 Dip switches for MCU 32 3.3.2 Upload of MCU basic program 33 3.3.3 Upload MCU set-up file a 3.3.4 MCU LED information 35 3.3.5 Read-out of raw parameters in HM Panel 36 Page 2 (75) "When referring to this page, please quote Alpha Lubricator 707% 40C TOC 2 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmark‘Man Alpha Lubricator System - FESS Table of Contents Page 4. Configuration of BCU 36 4.1. Injection rate with BCU in control 36 4.2 Detection rate (BCU take over from MCU) 36 4.3 Number of cylinders for the engine 36 4.4 BCU board revision 37 4.5 Slow down output 37 4.6 Number of lubricators 37 4.7 Upload of BCU basic program 37 Alpha Lubricator — Alarm Handling and Trouble Shooting Guide 38 Fuses 38 MCU-Unit 38 BCU-Unit 42 External alarm signals 44 Common alarm 44 MCU power failure 44 BCU power failure 45 MCU failure 45 BCU failure 45 Slow-down 45 BCU in control 45 MCU — alarm handling and trouble shooting 46 Alarms 1-24 ~ Feedback failure 46 Alarm 29 ~ Marker signal failure trom encoder a7 Alarm 30 ~ BCU pickup 1 failure 48 ‘Alarm 31 ~ Trigger signal failure from encoder 49 Alarm 33 - Engine stop signal failure 49 ‘Alarm 34 ~ LCD signal abnormal 50 Alarm 35 ~ BCU active signal missing 50 Alarm 36 ~ Aster signal abnormal 50 Alarm 37 ~ Prelubrication signal abnormal 50 Alarm 38 ~ Oil temperature high 50 Alarm 39 ~ Oil pressure low 51 Alarm 40 ~ Speed deviation alarm 51 ‘Alarm 41 ~ Index transmitter abnormal 51 When referring to this page, please quote Alpha Lubricator 707X-40C TOC 3 Page 3 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-04-28707X-40C Alpha Lubricator System TOC 4 (4) ph ator Sy: Ban Table of Contents Page 5.3.14 Alarm 42 — Cable failure index transmitter St 5.3.15 Alarm 43 — BCU pickup 2 failure 52 5.3.16 Alarm 44 — BCU in control 52 5.3.17 Alarm 45 and 46 — Thermal overload electric motor 52 5.3.18 Alarm 47 — MCU parameter list not loaded 52 5.3.19 Alarm 48 — Angle deviation fail 53 5.3.20 Alarm 49 ~ Stand-by pump is running 53 5.4 BCU alarms 53, 5.4.1 Led #1 BCU internal failure 54 5.4.2 Led # 2 Engine stop signal failure 54 5.4.3 Led #3 MCU alive signal missing 84 5.4.4 Led # 4 Feedback signal missing on two lubricators 54 5.4.5 Led # 5 Feedback signal missing one lubricator 55, §.4.6 Led #6 BCU marker signal 1 and 2 missing 55 5.4.7 Led #7 and 8 BCU marker signal 1 or 2 missing 56 5.5 Emergency running without extemal trigger signals 56 5.6 Sequence diagram for alarm handling 58 Appendix 1 Function of the LEDs in the Intermediate Box 59 Appendix 2 Control Unit Cylinder Lubrication — Logic Diagram 60 Appendix 3 Replacement of MCU, BCU, SBU Boards 68 Appendix 4 Cylinder oil feed rate during running-in 70 Appendix 5 ALCU signal description 72 Page 4 (75) When referring o this page, please quote Alpha Lubricator 707X-40C TOG 4 2003-01-28 MAN B&W Diesel A/S, Copentiagen, Denmarksan Alpha Lubricator System 707X05-40C List of Abbreviations: This is a list of abbreviations used in this manual. AC Alternating Current ACC Adaptive Cylinder oil Control ALCU Alpha Lubricator Control Unit AMS: Engine alarm System BCU Backup Control Unit pc Direct Current ECR Engine Control Room FBU Fuse Board Unit FPGA Fast Programmable Graphic Array HMI Human Machine Interface Ic Integrated Circuit Led Load change dependent LED Light Emitting Diode mcu Master Control Unit MEP Mean Effective Pressure PCB Printed Circuit Board RPM Revolutions Per Minute ‘SBU Switch Board Unit ToC Top Dead Centre ups Uninterruptable Power Supply When referring to this page, please quote Alpha Lubricator 707X05 Edition 40C Page 5 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28Index Operation Commissioning Maintenance Components Electrical Wiring707X06-40C_ Alpha Lubricator System Man 1. General Information 1.1 Main components The Alpha Lubricator System Layout is shown in the diagram below: Alpha Lubricator System Layout TANK LUBRICATOR, PUMP ALCU STATION = 9 -—-——=- Pipe System Electical Connection Page 6 (75) When referring to this page, please quote Alpha Lubricator 707X06 Edition 40C 2003-01-28 ‘MAN B&W Diesel A/S, Copenhagen, Denmark(e238) Alpha Lubricator System 707x07-406 oS Pump station and starter panels ‘The pump station consists of two individually op- | 8488() |} 8d8e(] erating pumps, heating coil, filters and a suction tank. The power supply to the pump station start- er panels is taken from two separate circuit breakers, one supplying each pump. For further information, see Maker's pump sta- tion manual. Lubricator units The lubricator units, one for each cylinder, each comprise two lubricators for 98-70 bore engines and one lubricator for medium and small bore engines. Each lubricator unit is equipped with ‘one accumulator with nitrogen pre-pressure of 25-30 bar on the inlet side, and one accumulator on the outlet side of each lubricator, with nitrogen pre-pressure of 1.5 bar. Each lubricator features 3, 4, 5 of 6 lubricating pistons, depending on engine type, a feedback pickup and a solenoid valve. One-lubricator unit Two-lubricator unit FL a — = =“ Teyh | a Alpha lubricator control The three main electronic components for controlling the lubricating oil are com- prised in one steel cabinet — the so-called ALCU unit. ou The three units are:MCU(Master Control Unit) BCU (Backup Control Unit) SBU (Switch Board Unit) When referring to this page, please quote Alpha Lubricator 707X07 Edition 406 Page 7 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X08-40C Alpha Lubricator System (ge8) A terminal block interfaces all electrical connections to the engine. MCU SBU BCU ‘The 24 V DC power is supplied from two individual power sources, from different breakers in the UPS unit. Please note that some installations might be connected differently by the shipyard. Load transmitter The load transmitter is connected to the fuel rack, thereby continuously transmitting the fuel index % to the MCU, which calculates the engine load from this information and the detected engine rpm. Page 8 (75) When referring to this page, please quote Alpha Lubricator 707X08 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmark(a3) Alpha Lubricator System 707X09-400 man ‘Trigger system (Shaft encoder, The shaft encoder is connected to the fore end of the crankshaft, and the signals are transmitted to the computer panels via a terminal box. For en- gines on which the crankshaft fore end is not avail- able for angle encoder installation, a trigger ring and tacho pickups are installed at the turning wheel. Backup trigger.system ‘The backup trigger system comprises two tacho pickups in a box at the turning wheel, thereby transmitting the engine rpm to the BCU. The backup pickups are also connected to the MCU for surveillance purposes. Human Machine Interface (HMI) panel On the HMI panel, individual cylinder lubrication adjustment is possible, various values and alarms are displayed, control buttons for the pump station are available, and manual execution of prelubrication is possible. As standard the HMi-panel is mounted in the engine control room. 1.2 Working principle * The pump station supplies the Alpha Lubricators with 40-50 bar oil pressure. * The MCU controls the oil injection by activating a solenoid valve situated on the relevant lubricator. When referring to this page, please quote Alpha Lubricator 707X09 Eaition 406 Page 9 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X10-406 Alpha Lubricator System eran) * A feedback signal from each lubricator indicates that oil injection has taken Place. This is shown by Light Emitting Diodes (LEDs) on intermediate boxes for each cylinder. * Timing is based on two signals from the angle encoder, a TDC cyl. 1 marker and a crankshaft position trigger. The Alpha Lubricator system is normally timed to inject cyl. oil into the piston ring pack during the compression stroke. * The cylinder lubrication is based on a constant amount of oil being supplied per injection. The specific feed rate is controlled by variation of the injection fre- quency, * The injection frequency is calculated from index and speed, and is normally pro- Portional to the engine MEP. However, a power Mode or RPM Mode is possible. * The basic cylinder oil feed rate at MCR (100%) is calculated as a correlation be- ‘tween a number of injections / rpm and the stroke of the lubricators. * On the HMI panel, adjustment of lubrication feed rate for individual cylinders is possible between 60% and 200%. Default value is 100%. * During normal operation the system is controlled by the MCU. If any failures are detected in the system, a common alarm is activated in the control room. The detailed alarm reference is displayed on the HMI panel. * I acritical failure in the MCU is detected, the BCU automatically takes over (Note — control switch must be in “auto” position). An indication lamp “BCU in contro!” is lit on the panel that contains the HMI panel. Note that on older installations, the indication lamps can be situated elsewhere. * The BCU is based on random timing and RPM Mode. The injection frequency is adjustable on the BCU and is normally, as minimum, set to the basic cylinder oil feed rate for the engine, plus 50%. 1.3. Guidance values automation Cylinder Lub. Oil Pressure [ Gylinder Lub. Oil Temperature Normal Service Value | 40~50 bar | Normal Service Value | 30- 60° C Alarm min, 35 bar Alarm max. 70°C Alarm max. 60 bar 2. Operation of the System 2.1 HML-Panel / Operating Panel 1. As standard, the HMI panel (for description, see Section 3), a three-position ‘mode switch, and an indicator lamp are mounted in the engine control room. Page 10(75) When referring to this page, please quote Alpha Lubricator 707X10 Edition 406 2003-01-28 MAN B&W Diesel A/S, Copenhagen, DenmarkAlpha Lubricator System 707X11-406 However, an additional HMI panel, etc. can, as an option, be installed in one of the pump station starter panels. In this case a local/remote switch has to be installed. The three-position mode switch enables selection between * Auto-mode ~ BCU takes over automatically, if lubrication cannot be main- tained by the MCU. If the BCU has taken over the control, this mode can only be cleared by manually switching to MCU-mode, and back to Auto- position. * MCU-mode ~ Forced MCU control * BCU-mode ~ Forced BCU is in control. An orange Indicator lamp - Indicates that BCU is in control 2.2. Control buttons and indicator lamps on pump station starter panels Each starter panel contains the following switches, buttons and lamps: 2, ae A three-position switch controls the pump activity as follows: ‘*_ REM.(Remote) ~ Automatic control of pumps (normal working position) + LOC.(Local) ~ Manual start of the pump * OFF —Manual stop of pump. ‘A two-position main switch — Switches off 3 x 440 V AC power supply. ‘A green indicator lamp — lights if pump is running. ‘A white indicator lamp — lights if 3 x 440 V AC from fuse panels is switched ON 2.3. Start-up of Alpha Lubricator System (Engine not running) 1 To fill the pump station with cylinder oil, open the valves for the cylinder oil supply line and the venting cock (if installed). Close the venting cock wherrcyl- inder oil flows out into the venting line. 2. Switch on the main switches on the pump station starter panels. 3. Switch to “Local” and manually start pump 1 and subsequently pump 2. Check that both pumps can run simultaneously. 4. Check that the pressure differential indicator on the pump station filter is green, when one pump is operating When referring to this page, please quote Alpha Lubricator 707X11 Edition 40C Page 11 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X12-40C Alpha Lubricator System mat Check that the oil pressure builds up to. 40-50 bar, or carry out adjustment on the pressure control valve on top of the . pump station. FA Check that the pressure remains at an acceptable level, also with two pumps running. ey Press [Esc] and [PRELUB] at the same time on the HMI panel to activate the test sequence, and check that all lubri- cators are operating correctly by watch- ing the LEDs (feedback signals) on the intermediate boxes for each lubricator. Stop the test sequence by pressing [PRELUB] again. At commissioning or after overhaul of the system, check visually from the ‘scavenge air receiver that all non-return. valves inject cylinder oil into the cylinder liners. Stop the pumps manually, and switch to “Remote” on the starter panels. ‘The Alpha Lubricator System is now ready for normal operation. For engineers commissioning the Alpha Lubrication System, procedures are made for Testbed Commissioning and Dock Trial Commissioning. The proce- dures are shown in the Commissioning chapter. For flushing the system, please read special instruction. 2.4 Checks during start-up of the engine 1. Upon start of the engine's auxiliary blowers, the Alpha Lubricator System is programmed to carry out automatic prelubrication. The pump station will au- tomatically stop if the engine is not started shortly after. Check that a pump on the pump station automatically starts up when the en- gine is started, and that the cyl. oil pressure builds up to 40-50 bar. Check that all the green LEDs flash on the intermediate boxes for each lubri- cator. Check that no alarm is detected in the control room and on the HMI panel. Page 12 (75) 2003-01-28 ‘When referring to this page, please quote Alpha Lubricator 707X12 Edition 40C MAN B8W Diesel A/S, Copenhagen, DenmarkGAS Alpha Lubricator System 707x13-406 2.5 Periodic checks during normal operation of the engine 1. Check that all lubricating points supply oil by: a) inspecting that all LEDs for feedback indication on the intermediate boxes are flashing ») feeling the pressure shocks from injection of the lubricators on each lubricator pipe. If in doubt, dismantle the pipe at the cylinder liner to observe the oil flow. 2. Inspect the local oil pressure gauge on the pump station. Normal service value = 40 — 50 bar. 3. Check for oil leakages in the system, HMI-Panel and Configuration of MCU 3.1 Description of HMI Panel Bar graphs The two upper bar graphs display relative values in percent of engine speed and fuel index (= mep%),, respectively. The range is from 0 to 120 percent, where 100 percent corresponds to the physical val- ues at MCR. The third upper bar graph displays oil pressure in the range of 0 to 100 bar. Fault category indicators Five LEDs for indication of fault category are placed below the numerical display, as follows: * Oil pressure low * Fuel index failure © Marker/Trigger failure * Feedback failure * Common alarm — For explanation of the alarm code, see the alarm list in Section 5. Buttons (4) Move up in the HMI panel menu structure. See item 3.2.9. (v] Move down in the HM panel menu structure. See item 3.2.9 esc} Move to the left in the HMI panel menu structure. See item 3.2.9. When referring to this page, please quote Alpha Lubricator 707X13 Edition 40C Page 13 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X14-40C Alpha Lubricator System Man fenrer} Move to the right in the HMI pane! menu structure. See item 3.2.9, (Lawerest] All lamps are lit in the HMI panel. [pumet) Slarts or stops booster pump 1 [pump2] Starts or stops booster pump 2 [pRELUB] Can only be activated when engine is stopped. Activates prelu- brication sequence. The lubricators will be activated continuously from Lubricator 1A, 18, 2A... 14B. The cycles will be repeated a pre-pro- ‘grammed number of times (normally 12). [esc] +[PReLuB] Starts test sequence of 1000 pre lubrications. The test se- quence is stopped by pressing [PRELUB] again. [esc] + [Pump] Selects default booster pump to be pump 1. [esc] +[PumP2] Selects default booster pump to be pump 2. 3.2 HMI-Panel operation and configuration of MCU This section describes the menu system in the HMI-panel numerical display. Six ‘of the most common manoeuvres are described below and the complete structure and parameters are shown in items 3.2.9 and 3.2.10. 3.2.1 Navigation principle HMI panel menu system is a hierarchic menu system. The following four buttons are used to navigate through the menu system. a) Move up in the HMI panel menu structure. See item 3.2.9. (v] ‘Move down in the HMI panel menu structure. See item 3.2.9. [esc] Move to the left in the HMI panel menu structure. See item 3. [enter] Move to the right in the HMI panel menu structure. See item 3.2.9. 3.2.2 Reading of total stroke/min [FXXX] Press [4] or [¥] until rXXX is shown in the display (Note that this value is an average value over 1 min.) 3.2.3 Reading of total strokes (Str.hi] and [Strlo] 1, Press [4] or[ ¥) until diSP is shown in the display. Str_hi} 5 Sto] Lemme] 2. Press {enter and [4] or [¥] until Str-hi or Str.lo is shown in the dis- LdiSP play. 3. Press [ENTER] to read the stroke counter. Page 14 (75) ‘When relerring to this page, please quote Alpha Lubricator 707X14 Edition 40C 2003-01-28 MAN B&W Diesel NS, Copenhagen, Denmarkman Alpha Lubricator System 707X15-406 4. Press [ES] to return to main menu (one press [esc] = one step backwards). 5. The total number of strokesis a ten digit number and is obtained by combining the values of Str-hi and Strlo as follows: The value of Str.lo represents the five rightmost figures and the value of Str.hi the five leftmost figures. Example: str.hi | Sto i ' t 8 Total number 2 ofstrokes= [12345 67890] =1234567890 The total stroke amount is used to calculate the amount of cylinder lube oil used within a specified amount of time. The following formula can be used: ‘See example on page 31 (str.hi). 3.2.4 Reading of active alarms [ALRXX] Press [4] or [¥] until ALAXX is shown in the display. For explanation of the alarm code see the alarm list in Section 5. 3.2.5 Reading of logged alarms [LALXX] 1. Press [A] or [¥ J until LALxx is shown in the display. For explanation of the alarm code see the alarm list in Section 5. 2. Toclearalogged alarm, press [ENTER] when the alarm is shown in the display. To clear all logged alarms, press [ENTER] for 5 seconds while an LALxx is, shown in the display. 3.2.6 Adjustment of cylinder oil feed rate [FrAtE] ‘The feed rate is entered in the HMI panel as a percent value. = ~ For systems with MEP regulation, 100% feed rate setting normally corresponds to the basic setting with reference to service letters and general guidelines for cylinder lubri- cation. [Cysac } > ooone ] When referring o this page, please quote Alpha Lubricalor 707X15 Edition 406 Page 15 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X16-40C Alpha Lubricator System Man) ~ For systems with Alpha ACC (Adaptive Cylinder oil Control) the feed rate is set proportionally to the sulphur content in the fuel oil. The feed rate setting per- centage can be obtained from the regulation plate. Alpha Lubricator System Adaptive Cylinder oil Control Suiphur | Specie Titi ting Ph 1. Press [4] or [ ¥] until F.rAtE is shown on the display. 2. Press [ENTER] and [cYL1] is shown on the display. 3. Press[4]or{¥] until the cylinder to be adjusted is shown or select SEt.Al to set all the cylinders to the same value. 4. Press [ENTER] and the current feed rate is shown. Please note that if SEt.Al was selected the value shown is the last value saved in SEL.Al, and this value is not true if any cylinder has been individually adjusted since. 5. Press[4]or[¥] ~The oil feed rate can be changed to the desired value be- tween 60 and 200%. 6. Press [ENTER] - The value is stored in the computer memory, and the main display will prompt with “Save”. 7. Press [ESC] three times to return to main menu. 3.2.7 Monthly change of operating pumps (master pump) 1. Check which pump is running (1 or 2) 2. Press [Esc] + [Pump 1] or [Pum 2] (pump not running). 3. New master pump is now chosen and running, Page 16 (75) When reterring to this page, please quote Alpha Lubricator 707X16 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, DenmarkMan Alpha Lubricator System 707X17-40C. 3.2.8 Test sequence for inspection during standstill 1. Press [esc] .+ {[PRELUB] simultaneously (the lubricators will lubricate 1000 times). 2. Press [PRELUB] the test sequence will stop. 3.2.9 Menu structure The following pages show how to navigate in the HMI-panel menu structure. When referring to this page, please quote Alpha Lubricator 707X17 Edition 400 Page 17 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X18-40C Alpha Lubricator System MAN Ban Alpha Lubricator HMI Panel menu structure — part 1 A) down = [¥) sight = [ENTER] let = fESC} Bar Sek} ae from ome i t a ! ! por et ake eer —— fers aa = Een &— t= Prion, [ermssis fener bara an Looe rman 8 [eae Seis |__ oe far eter cay ee ema oa ee. 7 —> fens] cd ; i . : feeb sous ara i i [ose ee enatneas fe eee fe ca i i esos ! : x} [LAL xx: 1 1 esa ae leet fem wren a aaa ss i : hea ar i a ; = i : t Fak i Fomor manny — a Is [SEtuP [Par eee PB aransarnences a vito [GoALr rub. + ~ mona acraton of CU enon Js aut WCU 32 tml 82) FFTon lerAnat) (AIL¥1 togates (cack age ony ata stertaneg f—7 value ore rio ead) PET Page 18 (75) When referring to this page, please quote Alpha Lubricator 707X18 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmark(een) Alpha Lubricator System 707X19-406 wan Alpha Lubricator HMI Panel - menu structure ~ part 2, setup menu ferenr FRE ir Fear navigation ere seg password = [ney seine “ayes frvit at fesctenert isms) aero Imeem lace par irs et [orem nustnrncarle | _e eced 0 e Ieee faa Sent | [pata frcereamne ater fe alse aor [ror sau [rm rant crecin ote fete erste ng [ss saer t 4 ere t ! fram oso i i ie) : F famine i i | |iteak tense nex fet ccc i [eerie feaar fatana Irene an a Hex fees [oe ehat ey Pen oe, r neat ray ace : va bay, omen [ectve sa i ate) [osu : Lg hess hoy tanse Ger i i parce [rosetta i a [oscor= tener : gap sna scale) fp —) ae i i joes Fo feces) : : AY eye i i econ |" seater sae fase : : roa [smn i i lex i ; reese kK] tenvaaviaton [Sonne : ! trem 30 in farssay-veseee fer i= ES fcr ators _| fron fmetcurae cents 4 [tnt K—| fees [seu —} erste com como} (ongap sion sag fees ro : 1 ES ego [co Seney i i od ke fae i i oa fonectes every, fra Lt rosy fe = [een oraasmann Ly rom er) [rican tc (FED ; ee fenu navigation peo sere ree ayesnee rn a feson Ea | fore on aon fir an [npamtnsteswe : Jarl devaton inet = i jedan ofa ect ps bes fr tourna) os ume lene [sacs fsx fase cme {eae om amen tot, eso yocmetey When reterring to this page, please quote Alpha Lubricator 707X19 Edition 400 Page 19 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X20-40C Alpha Lubricator System Mam Alpha Lubricator HMI Panel ~ menu structure — part 3, setup menu [atent PASE [Ein Feviecion) par ane eee [passions reine eject Ly pes AY “tocrnce [tvitAt fee) frien icone 39) pens ewer won InEE Par och Pa res tent [econ r.co em res) faaar [tc nom 1 beater [setae aime frase [rom sososn rot np ee) lm aston al from 5 fesrer [tte rng aire ata [rom-040°0) fren [rower fe —f [cs oe) Fe |r [nao [fetctaroe epee [aESie foo) Kesar nou fromm fe F rome lceax rec aman azeatn EScuE Ra [ico stawsy rent easter tse) [x —| oo. con FED ES [ALR [eetiewounion fe —! ERT) active stems poser asusenn cera sea riniowy fe —| [ice srmian t rom 250) rerwrg ; ; fexeTe Jtcoved stars) q q ies te stig ow ies fe —J [saree 3 ; [meme era [secniray cece ay i tier mont Je} [ase fame a a Irom [Sonar ferun Fmd [meen omen asusinenn [ren rom sete [anaaer) fea 7 Jecusmeny fe} rae ernton terse, gL pss AY cae ees seven) fic chen 3 bic Sarcwwenve Pena navigation [pon J ower tosaea Fl i i ffir mites i i i [scuo ! 4 i Feces, eo mane i [pase ene 3 Hy [att pao seein, onc roar ernie net shee cunt Pat pou oar ine) Jowresmenseney fy —L press AY cae sa [rem SS eNen eS eset) ow aware ot sp PASS patsword = [leseHlaltyLtenteor Pres euremen save fea xitian sf manary cae dnage tine | Page 20 (75) When referring to this page, please quote Alpha Lubricator 707X20 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmarkears Alpha Lubricator System 707x21-400 3.2.10 HMI panel parameter reference list A.inJ [°] (abbr. of angle injection) The specific crank angles for oil injection for each lubricator. Normally itis the crank angle at the point where No. 1 piston ring passes the oil quills on the upward stroke of the piston. The number consists of an online measurement of the angle for the first flank of the feedback signal plus the angle corresponding to the hydraulic delay time. ‘Only active when engine is running ahead. Normal value for cylinder one is around 270 to 310°. AbS.Lo [%] (abbr. of absolute ou) Absolute minimum reduction percentage. The injection frequency can be reduced to the value of AS.Lo in % of the basic frequency. The basic frequency is the frequency at 100 % load, 100 % rpm, 100 % feed rate setting and is defined as rE.inj Example: ‘Maximum number of revolutions between injections = 10 revolutions => 1 max.nos. of rev between injections 10 minimum infection roquency =0.ifj/rev] {E.inj = 4 revolutions => basic frequency = - + =0.25finj/rev] rE.ind tninimam injection frequency 0:1 _ 9 49 gong basic frequency 025 AbS.Lo = The normal maximum number of revolutions between injections is 15. ALR XX (abbr. of alarm XX) Code number for active alarms, where the number ‘XX’ represents the alarm code. For explanation of the alarm code see the alarm list in Section 5 Ang.dE (abbr. of angle deviation) ‘The Maximum allowable angle difference between the marker signal (TDC signal) from the encoder (or trigger ring) and the marker signal from the BCU pickups. Only valid when engine is running ahead. Normal value is 2 degrees. Co.ALr (abbr. of common alarm) Manual activation of the MCU common alarm output ALCUIx1:1, ALCU x1:2 (MCU/J32:1, MCJ/J32:2), dry contact, normally closed. When referring to this page, please quote Alpha Lubricator 707X21 Edition 40C Page 21 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X22-40C Alpha Lubricator System ( Conn (abbr. of connection test) Connection test menu. Blocked when the engine is running, Cr.Ang [°] (abbr. of crank angle) Indication of actual crank angle from the shaft encoder. Blocked when the engine is running. Only valid when continuously turned in same direction by turning gear and after having passed TDC cyl. 1. The indication is sensitive to rocking motion and should therefore only be used as an indication. ISP (abbr. of display) Display menu. Values and parameters are displayed, but cannot be changed from diSP menu, F-hi [%] (abbr. of feed rate high) Feed rate setting high limit. The maximum possible feed rate setting on the HMI Panel. The value is a percentage of the basic recommended feed rate setting. Normal value is 200 %. F.Lo [%] (abbr. of feed rate low) Feed rate setting low limit. The minimum possible feed rate setting on the HMI panel. The value is a percentage of the basic recommended feed rate setting. Normal value is 60.%. F.rAtE (abbr. of feed rate) Feed rate setting adjustment, The feed rate can be adjusted individually for each cylinder or for all cylinders at one time with the SEt.Al function. Please note that the value shown when entering the SEt.Al menu is the last value saved in the SEt.Al menu. Thus if the cylinders have been adjusted individually since, the value shown when entering the SELAI function is no longer true for all cylinders. 100 % feed rate setting normally corresponds to basic setting. (Reference is made {o the guidelines for cylinder lubrication) F.SCUF [%] (option) (abbr. of feed rate scuffing) Feed rate increase in case of scuffing, Input for each cylinder on the MCU board can receive signal from a cylinder liner temperature monitoring system. If begin- ning scuffing is detected, a signal can be given and extra lubrication activated. Please contact MAN B&W if this function is needed. Normal value is 200 % FE.AD (abbr. of feed rate adjustment) Feed rate regulation parameter adjustment menu Page 22 (75) 2003-01-28 When referring to this page, please quote Alpha Lubricator 707X22 Edition 40C MAN B&W Diesel A/S, Copenhagen, DenmarkMam Alpha Lubricator System 707X23-40C FPA (abbr. of fast programmable graphic array) FPGA software revision number. The IC (Integrated Circuit) (u33) contains the program for the FPGA. If the FPGA code is updated, a new IC will have to be in- stalled. The current FPGA software revision is 6. gEn (abbr. of generator) Load transmitter calibration menu for generator curve running. When the engine is running 50 % load and 100 % load (with reference to testbed results), enter the menu by pressing [ENTER] and choose the correct engine load (50 % or 100 %) followed by pressing [ENTER]. The program will respond with donE. hY.dEL [ms] (abbr. of hydraulic delay) Hydraulic delay (time offset value). The value is inserted to compensate for the time-delay from the first flank of the feedback signal, until the oil enters the cylinder through the cylinder liner non-return valves. The longer the hydraulic delay - the earlier the solenoid valve is activated. The Hydraulic delay is calculated in the de- ‘sign process and is confirmed by measurements on prototype engines. A good es- timate of the value is 1 ms for each meter pipe length from the lubricator to the cylinder liner. The value cannot be adjusted individually for each cylinder, but is common for all cylinders. Normally values are from 1 to 6 ms in.A [mA] (abbr. of indox ampere) Read out of the index transmitter current. The mA signal from the index transmitter without scaling. Used for mechanical adjustment of the index transmitter during commissioning. The index transmitter is adjusted to 4.5 mA at mechanical mini- mum index and to 19.5 mA at mechanical maximum index. The adjustment is made on testbed before initial start up. in.AdJ (abbr. of index adjustment) Index transmitter adjustment/calibration menu. The adjustment is done during run- ning at testbed, at 50 % load and at 100 % load. Choose between propeller curve (ProP) or generator curve (gEn). Select the load percentage (50 % or 100 %) cor- fesponding to the actual load. Press [ENTER] and the system replies donE. After- wards press [ESC] 4 times until you are back in the main menu showing RPM. The system has now been calibrated. Use the vALue menu if manual correction of the parameters is necessary. in.hi [%] (abbr. of index high) Index transmitter raw calibration value. The index transmitter calibration values are given as an index low (in.Lo) value and an index high (in.hi) value. These val- ues are the theoretical index percentages when the pickup gives respectively 4 and 20mA. Estimated values are pre-programmed from MAN B&W, and the sys- tem is calibrated by means of the (ProP) or (gEn) menus on testbed. The raw val- ues should only be changed if the automatic calibration in the ProP and gEn menus, proves insut Wien referring to this page, please quote Alpha Lubricator 707X23 Edition 40C Page 23 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28‘707X24-40C Alpha Lubricator System Man The values are normally around ~30 to ~10 for [in.Lo] and around 125 to 140 for [inhi in.Lo [%] (abbr. of index low) See in.hi. InJ.AL (abbr. of injection algorithm) Injection amount algorithm menu. Injection rate calculation can be chosen in pro- Portion to mean efficient pressure (nneP), rpm (rPnn) or power (Po.). Normal mode is nnep proportional. 1J.0F [°] (abbr. of injection offset) Injection offset. Angle offset inserted to compensate for small deviations between the injection angle determined in the design process and the actual crank angle for injection. The actual crank angle for injection is normally when the first piston ring passes the oil quill during the upward stroke of the piston. inJ.oF can be ad- justed within +/- 5°. The value cannot be adjusted individually for each cylinder, but is common for all cylinders. Normat value is 0. LALXX (abbr. of logged alarm XX) Logged alarms where the number ‘XX’ represents the alarm code. When an alarm is activated, it will appear as both ALRXX and LALXX. The LALXX will remain after the alarm is gone. For explanation of the alarm code see the alarm list in Sec- tion 5. To clear a logged alarm press [ENTER] while the alarm code is displayed. To clear all logged alarms press [enTER] for 5 seconds while one of the alarm codes is dis- played. Led X (abbr. of load change dependent X) Load change dependent extra lubrication status. X indicates the status. When LCD is active, i.e. when a load change situation occurs, the status changes from 0 ( 38400 Baud Swit OFF,SW1.2: ON-> 19200 Baud SW11: ON, SW1.2: OFF—>9600 Baud SW11-2: ON, > 4800 Baud ‘SW1.3-8, SW2.1-8 and SW3.1-6 are presently not used, and the positions are not relevant. SW3.7 is to be set tOFF(Multiple trigger systems) ‘SW3.8 is to be set tOON(MCU revision C and later) OFF (MCU Null-series) 3.3.2 Upload of MCU basic program ‘A.VT100 terminal is part of the standard Windows software on a PC, and the ‘Hy- per Terminal’ can be found in the Programs directory ‘Accessories’ and ‘Commu- nications’ Connect the PC to the MCU by means of the serial cable, and start the VT100 ter- minal. The settings for the serial port in the PC are: — Bits per second: 19,200 (must correspond to setting of Dip Switch SW1, pos. 1 and 2, see item 3.3.1.) If the MCU main led (positioned in the upper left corner) is flashing red/green, the MCU only contains production test software. In this case the baud rate must be set to 38,400. When the main program ‘has been uploaded to the MCU, set the baud rate to 19,200 before uploading the set-up file. ~ Data bits: 8 ~ Patity: None — Stop bits: 1 Flow control: None Transter menu: Transmit / Receive Protocol: Xmodem. When referring to this page, please quote Alpha Lubricator 707X33 Edion 40C Page 33 (75) MAN BAW Diesel AVS, Copenhagen, Denmark 2003-01-28707X34-40C Alpha Lubricator System Man Press [Space] on the PC keyboard and the screen will display a menu as follows: (/) Alpha Lubricator [1] Transfer of set-up data [2] Connection test [3] System and alarm status [4] Feedback failure status [5] Mechanical delay [6] Logged atarms 17] Logged feedback alarms [8] Revision menu [9] MBD development menu IR] Reset The PC is connected to the MCU by means of the RS 232 serial cable, and the VT100 terminal is started. From the Alpha Lubricator menu, press (RI followed by [Y], [ASD and [Ctel-U}. Send / transfer the latest version from ASD of the E-prompt file called *.epr from the PC to the MCU by means of menus in the VT100 terminal program. Make sure to use Xmodem protocol. When the file is transmitted to the MCU, press [Ctrl-P] after confirming that calculated and read check sums are equal. Now the basic program is uploaded to the MCU board. If a new basic program is uploaded to a MCU in service, the original set-up file is deleted and a default set-up file is loaded in the MCU. Consequently, a new set- up file must be uploaded to the MCU in this case. 3.3.3 - Upload MCU set-up file The PC is connected to the MCU by means of the RS 232 serial cable, and the Vt100 terminal is started, From the Alpha Lubricator menu, press [1] (Transfer of setup data), followed by [1] (Upload setup file). A capital C will start moving from left to right, indicating the time remaining for uploading of set-up file. If the file is not uploaded successtully the first time, just try again. This is not critical. In the VT100 terminal, select menu item {Transfer} followed by [Send File], then browse until you have found the correct setup file on your PC. Select the file and press (Send}. When the file is transferred, ignore the command “Type password”, which is dis- played for a few seconds. Press [Y]. Now the new configuration parameters are uploaded. Interrupt the 24DC volt power supply. The green light will turn on and the MCU is ready for operation. Page 34 (75) When referring to this page, please quote Alpha Lubricator 707X34 Edition 40C 2003-01-28 MAN B&W Diese! A/S, Copenhagen, Denmark(aa) Alpha Lubricator System 707X38-40C man Ifthe MCU set-up file generated by the set-up program does not match the basic MCU program, the VT100 terminal will display an error message and the MCU will load the default set-up file. The remedy for this is to download the default set-up file from the MCU to your PC and manually change the displayed parameters for this specific file to match the originally generated parameters. Save the new set-up file on your PC and upload it to the MCU. If the MCU is not able to receive the set-up file, turn to the VT100 menu 9 (MBD. Development menu) in order to reset RAM. 3.3.4 MCU LED information On the MCU a main LED is positioned in the upper left comer. The status of the unit is given as follows: Red/green flashing: The MCU basic program Green flashing: MCU set-up file is not loaded. Green light: Normal condition. Red light: Alarm condition is not loaded. 3.3.5 Read-out of raw parameters in HMI Panel The HMI pane! facilitates a menu that enables the use of read-out of all set-up pa- rameters. This feature might be helpful when troubleshooting the system. To read-out the raw parameter, follow the instruction below: Navigate through the menu as follows: tEcH [|-—>| “Par Press [4] or[ ¥ to display the parameter number. When the requested parameter ‘number is displayed, press [ENTER]. The parameter value is displayed. When referring to this page, please quote Alpha Lubricator 707X35 Edition 40G Page 35 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X36-40C Alpha Lubricator System (ee3\ To view a new parameter number, press [ESC] until the parameter number is dis- played again. Press [4] or [¥] to select a different parameter. To return to the RPM read-out, press [esc] four times. 4. Configuration of BCU ‘Two dip switches, SW1 and SWa2, are placed in the upper left corer of the BCU board. These dip switches are used to configure the BCU, see below in Items 4.1 10.4.6, 4.1 Injection rate with BCU in control Injection rate for the BCU is set on the dip switches SW1 positions 1 ~ 4, as a bi- nary value. Examples: If SW1.1-2 is ON and SW1.3-4 is OFF, the injection rate will be 3 reviinjection. 8 rev /inj 4.2 Detection rate (BCU take over from MCU) The lowest injection rate the MCU can perform before the BCU takes ove on the dip switches SW1 positions 5-8, as a binary value. is set Examples: If SW1.6 and SW1.8 are ON and SW1.5 and SW1.7 are OFF, the lowest injection rate is 20 rev/injection for the MCU before BCU will take over control. 20 rev / inj 7248/2 4 816 4.3 Number of cylinders for the engine The number of cylinders for the specific engine is set on SW2 positions 1-4, as a binary value. €.9.7 oy FREE \sw2 ' Page 96 (75) When referring fo this page, please quote Alpha Lubricator 7O7X36 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, DenmarkMan Alpha Lubricator System 707X37-40C 4.4 BCU board revision The revision number of the printed circuit board is set on SW2.6. For installations with revision 8, SW2.6 must be OFF. For other installations SW2.6 must be ON, ‘The revision is printed on top of the board below the MAN B&W logo, as “BCU-250-X" where X is the revision. 4.5 Slow down output The slow down output switch (BCU terminal J8.3, 4) is NC (normally closed) if ‘SW2.7 is ON and NO (normally open) it SW2.7 is OFF. 4.6 Number of lubricators The number of lubricators for each cylinder is set on SW2.8. For installations with one lubricator on each cylinder SW2.8 must be ON. For installations with two lubricators on each cylinder SW2.8 must be OFF. 4.7 Upload of BCU basic program Connect the PC to the BCU by means of the serial cable and start the Philips WINISP program, 1. Set switch SWS on the BCU in position: [Program] 2. Press reset button (SW4) on the BCU (the lamp will turn off). 3. In the Philips WINISP program key in the following data: a. Chip: 89C51RD+ b. Port — : Choose COMI or the relevant port setting c. OSC :22Mz d. Vector : FC e. Status :0 4. Warning! It parameters 3d and 3e are not set to FC and 0 respectively, the 89C51RD+ will be permanently damaged. 5. Erase blocks by opening the [Erase Blocks] menu, Erase the first three blocks (32 k), by marking the three blocks and press the [ERASE] button. 6. Load the BCU basic program file designated BCU"-".hex. 7. After loading, the status display should read: “File loaded ok’ 8. Press [Program Parl], and the new program will be uploaded to the BCU. When referring to this page, please quote Alpha Lubricator 707X37 Edition 40C. Page 37 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X38-40C Alpha Lubricator System an 9. When the uploading is completed (see Status Display), set switch SW3 on the BCU in position: [Normal] and interrupt the power supply. The green light will tun on, and the BCU is ready for operation. The Reset button (SW 4) must not be pressed during normal operation. This will cause “Internal Failure” (Alarm LED #8). Ut, by mistake, the Reset bution has been activated and the LED #8s lt, the error message can be removed by interrupting the 24V power as follows: ~ Remove plug FJ1 on the filter board of the BCU. 5. Alpha Lubricator — Alarm Handling and Trouble Shooting Guide Hf you encounter difficulties while operating the engine with the Alpha Lubricator system, this guide will help find and solve some of the problems. The information in this section will help you with: 5.1. Fuses §.2. External alarm signals 8.3. MCU ~ alarm handling and trouble shooting 5.4 BCU alarms 5.5 Emergency running without extemal trigger signals 5.6 Sequence diagram for alarm handling 5.1 Fuses Schematic drawing of the ALCU power connections are shown in Appendix 2, page 3 5.1.1 MCU-Unit Normally, a fuse does not blow without reason. It is therefore important to locate and correct the problem before normal operation can be restored. There are two different fuse ratings: 12 Amp and 3 Amp. Itis very important to re- place a fuse with one of the correct rating and type. Page 38 (75) When referring to this page, please quote Alpha Lubricator 707X38 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmarkss Alpha Lubricator System 707x39-40C MCU fuses The MCU unit has three fuses located on the filter board, as indicated in the draw- ing below. 7 MCU board ij t IN Jrae a Sae= sae to SS The designations are F1, F2. and F3. E1 Main fuse Fuse F1 is rated 12 Amp and is the main fuse for the MCU unit. If this fuse is blown, a consumer connected to plugs FJ8, FJ9, FU11, Fu12, Fut3, FJ14 may be suspected of overloading the fuse. Check for shorts by removing the fuse. Connect a multimeter to the right fuse hold- er and measure the resistance to the negative terminal of FJ1 When referring to this page, please quote Alpha Lubricator 707X39 Edition 40C Page 39 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X40-40C Alpha Lubricator System Man ] MCU board aiid Ameasurement below 10 ohmis defined as a short. If the measurement indicates a short, disconnect plugs FJ8 to FJ14 one by one and observe the reading on the meter. If the short can be located by this method, continue investigating the problem in the circuit connected to the suspected plug. I the reason for the short cannot be found by the procedure described above, an internal MCU failure may be suspected. F2and 3 Fuse F2is rated at 3 Amp andis the main fuse for the SBU unit when running MCU mode. This fuse supplies control power (pump running signal) to the pump station via the SBU unit when running in MCU mode as well as power to the feedback sensors. 11 this fuse is blown, a fault in the pump station wiring or in the connections to the cylinder intermediate boxes may be suspected. Page 40 (75) 2003-01-28 When relerring to this page, please quote Alpha Lubricator 707X40 Edition 40C MAN B&W Diesel A/S, Copenhagen, Denmarkees Alpha Lubricator System 707x41-40C 'n order to check whether the problem is in the pump station or the intermediate boxes, follow the check procedure below: Remove fuse F2. Connect a multimeter to the right fuse holder clip, and measure the resistance to the negative terminal of F.J1 (right terminal). A measurement be- low 10 ohm is defined as a short lt the measurement indicates a short, disconnect plug FJS on the MCU iter board (disconnecting the supply to the pump station) and observe the meter reading. If the shortis stil present, disconnect the plugs L1 to L14 in the SBU one by one until the short is located. Investigate the problem further by disconnecting the plug J1 in the intermediate box and reconnect the suspected plug in the SBU. If the prob- lem disappears, the short is located in the intermediate box or the lubricator units. Fuse F3 is rated at 3 Amp, and is the main fuse for the shaft encoder. ! this fuse is blown, a fault in the encoder connections may be suspected. When referring to this page, please quote Alpha Lubricator 707X41 Edition 40C Page 41 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X42-40C 5.1.2 avorancaa Alpha Lubricator System BCU-Unit There are two different fuse ratings 12 Amp and 3 Amp. It is very important to re- place a fuse with one of the correct rating and type. BCU fuses ‘The BCU unit has three fuses located on the filter board as indicated in the drawing below. BCU board 4 . tou "cs _ iz don Se IK Eon ir tor Ta te The designations are F1, F2 and F3. £1. Main fuse Fuse F1 is rated at 12 Amp and is the main fuse for the BCU unit. If this fuse is blown, a consumer connected to the plugs FU8, FJ9, Fu11, FU12, FJ13, FJ14 may be suspected of overloading the fuse. Check for shorts by removing the fuse. Connect a multimeter to the right fuse hold- er, and measure the resistance to the negative terminal of FJ1 Page 42 (75) 2003-01-28 When referring to this page, please quote Alpha Lubricator 707X42 Edition 40C MAN B&W Diesel A/S, Copenhagen, Denmark(e835) Alpha Lubricator System 707X43-400 BCU board oe ee Her = ty a A measurement below 10 ohm is defined as a short. If the measurement indicates short, disconnect plugs FJ8 to FJ14 one by one and observe the reading on the meter. It the short can be located by this method, continue investigating the problem in the circuit connected to the suspected plug. F2and £3 The fuse F2is rated at 3 Amp andis the main fuse for the SBU unit when running BCU mode. This fuse supplies power to the feedback sensors in BCU mode as well as power to the pump station. If this fuse is blown, a fault in the pump station wiring or in the connections to the cylinder intermediate boxes might be suspected Remove fuse F2. Connect a multimeter to the right fuse holder clip, and measure the resistance to the negative terminal of FJ1 (right terminal). A measurement be- fow 10 ohm is defined as a short li the measurement indicates a short, disconnect plug FJ5 on the BCU filter board (disconnecting the supply to the pump station) and observe the meter reading. If When referring to this page, please quote Alpha Lubricator 707X43 Edition 40C Page 43 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X44-40C Alpha Lubricator System (S23 the shortis still present, disconnect the plugs L1 toL14 in the SBU one by one until the short is located. Investigate the problem further by disconnecting the plug J1 in the intermediate box and reconnect the suspected plug in the SBU. If the prob- lem disappears, the short is located in the intermediate box or the lubricator units. Fuse Fis rated at 3 Amp, and is the main fuse for the BCU pickups. If this fuse is blown, a fault in the wiring to the BCU pickups or a fault in the BCU box connec- tions might be suspected. 5.2 External alarm signals Alarm system signals: — Common alarm — MCU power failure — BCU power failure = MCU failure = BCU failure Safety system signals: = Slow-down State indicator: = BCU in control Please note that some installations might have some alarm signals connected in serial to save alarm channels in the alarm system. §.2.1 Common alarm ‘The common alarm is a normally closed contact. In case the MCU system detects a fault, the alarm will be released. Information about the cause of the alarm can be read of the number in the HMI panel. To solve the problem, read the information related to the alarm number found in the HMI panel. 5.2.2 MCU power failure The MCU power failure alarm is a normally closed contact. In case the power to the MCU system is interrupted the alarm will be released. Start by checking the breaker and fuse in the UPS cabinet. It no problem can be found in the UPS, check that 24 V is present at terminal X1 PWR Ain the ALCU box. Continue by checking the fuse F2 on the MCU filter board {see page 40). Page TH 2009-01-28 ‘When referring to this page, please quote Alpha Lubricator 707X44 Edition 40C MAN B&W Diesel A/S, Copenhagen, DenmarkAlpha Lubricator System 707X45-40C han Baw §.2.3 BCU power failure The BCU power failure alarm is a normally closed contact. In case the power to the BCU system is interrupted, the alarm will be released Start by checking the breaker and fuse in the UPS cabinet. If no problem can be found in the UPS, check that 24 V is present at terminal X1 PWR Bin the ALCU box. Continue by checking the fuse F2 on the BCU filter board (see page 43). 5.2.4 MCU failure The MCU failure alarm is a normally closed contact. The BCU system has detected that the MCU system program execution has halt- ed. ‘Start by checking if the power to the MCU system is OK. See Item 5.2.2 MCU power failure. if the Power supply is OK interrupt the power to the MCU for 5 secs. in order to reset the MCU. If the MCU failure alarm is still active, the MCU itself might be dam- aged and has to be replaced. Note that if the power to the BCU is interrupted, the MCU failure will be activated eventhough the MCU system is working well, 5.2.5 BCU failure The BCU failure alarm is a normally closed contact. The BCU system has detected a fault in the BCU system. Check the LED on the BCU board and read the instruction in item 5.4. The BCUis not connected to the HMI panel and, consequently, no alarms from the BCU willbe displayed. 5.2.6 — Slow-down The slow-down output is a normally open contact, The slow-down commands released if the MCU and BCU systems fail to lubricate one or more cylinders. Check for other alarms in the HMI panel and follow the recommendations stated. 6.2.7 BCU in control The BCU in control is a normally closed contact. This output indicates that the backup control unit is controlling the lubrication. I the BCU system is able to re-establish the lubrication, the lubricators are working properly. The problem is to be found in the MCU system. Check for other alarms When referring to this page, please quote Alpha Lubricator 707X45 Edition 40C Page 45 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X46-40C Alpha Lubricator System Man and read the alarm codes on the HMI panel and follow the recommendations stat- ed, 5.3 MCU -alarm handling and trouble shooting 6.3.1 Alarms 1-24 — Feedback failure Iffor any reason a feedback signal from a lubricator is measured as abnormal by the MCU a feedback alarm will be given. A common alarm will rig the AMS system {engine alarm and monitoring system) and an alarm code will be stored in the HMI panel. If the alarm stated in the HMI panel is a logged alarm (the alarm has disappeared again) the alarm will be displayed as LAL XX ‘The alarm code in the HMI panel provides information about which lubricator is ‘suspected to fail. (Alr 2 in the HMI panel indicates that lubricator 2 on cylinder 1 is failing.) Note that in case of one lubricator per cylinder (engines with a bore below 0,60 m), the alarm will only read uneven numbers e.g: 1, 3, 5, 7 for cylinder 1, 2, 3, 4. Generally it is recommended that a defect lubricator is replaced completely with a spare when convenient (in case of one lubricator per cylinder, the defect unit must be replaced immediately) In the event of feedback failure, check as follows: First check the feedback indicator light n the intermediate box If the feedback indicator light is: * Continually on the lubricator might 8| 6) be sticking in a position where the feedback sensor gives signal all the time. To verify that the problem is in the lubricator, disconnect the plug for the lubri- cator and observe the indicator light on the intermediate box. If the light turns off after the plug is removed, the problem is located in the lubricator. The lubri- cator must be replaced and overhauled (instruction 903-2). Alternatively, if the light in the intermediate box remains lit after the plug to the lubricator has been removed, the fault is not in the lubricator. Check the cable and plugs from the intermediate box to the lubricator for shorts. The intermediate PCB might also be suspected, Page 46 (75) When referring to this page, please quote Alpha Lubricator 707X46 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmarkee Alpha Lubricator System 707x47-406 * Continually off start by checking if the fed light in the lubricator solenoid plug flashes. Note that in the event of a feedback failure, the remaining working lubricator is running double feed rate, and the defective lubrica- tor.is only activated once every ten lubrica- tor strokes by the MCU to check if the lubricator is still failing, {no light flashes in the solenoid plug, re- ‘move the plug from the solenoid and check again if the light starts flashing. If yes, the solenoids coil may have an internal short, which can be confirmed by measuring the coil resistance. The normal resistance is 15 to 22 ohm for a new solenoid. eronances If the red light flashes in the solenoid plug, but no feedback is observed, check the connections in the lubricator plugs, mounted on the cable from the intermediate box, for loose connections or shorts. Hf connections in the plug are OK, the lubrica- tor must be replaced and overhauled (In- struction 903-2 (change of sensor). Flashes according to the light in the lubri- cator plug (once every ten lubricator strokes) the lubricator is working well but the feedback signals are not detected by the MCU. Replace the intermediate box PCB (Printed Circuit Board). Mf the fault is still present, check the cable to the ALCU box. 5.3.2 Alarm 29 ~ Marker signal failure from encoder The Marker signal (one pulse per revolution) is abnormal. The system will change to random lubrication based on the remaining Qood signals. First check the electrical connections in the encoder terminal box as well as the connections to the ALCU control box. no problems are found in the wiring or fuse, replace the encoder. Adjustment procedure can be found in Procedure 905-8. In the event of failure of all Tacho signals, see item 5.5. When referring to this page, please quote Alpha Lubricator 707X47 Edition 40C Page 47 (75) MAN B&W Diesel AVS, Copenhagen, Denmark 2003-01-28707X48-40C Alpha Lubricator System man 5.33 Alarm 30-BCU pickup 1 failure ‘The two marker pickups mounted on the flywheel side of the engine gives one pulse every one engine revolution. These signals are used by the BCU system to determine the engine speed. The signals are also used by the MCU system to monitor the signals and release an alarm in case of signal failure. Alarm number 30 indicates that BCU pickup # 1 is abnormal and alarm number 43, indicates that BCU pickup # 2 is abnormal. If the Alpha lubricator system is running in BCU mode due to a MCU unit failure the alarms for pickup failure can be found by observing the LED on the BCU pcb (see picture below). ‘Alarm Led © aoe 2 ‘ A 4 =e i It lo Sou 4 oy “ dq i y i "og 7 be 777 Gin 3&5 The BCU system can be operated with only one pickup signal present. Failure of one sensor is not critical and can be replaced when convenient. Page 48 (75) When relerring to this page, please quote Alpha Lubricator 707X48 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmarkan Alpha Lubricator System 707X49-406 The BCU pickups have a built-in indi- cator lamp which will flash once every ‘one engine revolution. In case one of the pickup alarms is ob- served first check that the light flashes \\ in the pickup. If not, check that there is 24 volt at terminals 1, 2 and 4-5 in the xX BCU terminal box. if power is present at terminal 1 and 2 disconnect the sen- sor wire connected to terminal # 3 (sensor # 1) or terminal # 6 (sensor # 2) and observe ifthe light starts flash- ing. yes the wiring from the sensor to the ALCU box is shorted. Ifthe indicator light stil does not flash, replace the pickup. es 20808 Sensor gap is to be adjusted to 340/-1 mm. Regarding distance: Always refer to manufacturer's recommendation. In the event of failure of all Tacho signals, see item 5.5. 5.3.4 Alarm 31 ~ Trigger signal failure from encoder ‘The trigger signals (1024 pulses per revolution) are abnormal. The system will change to random lubrication based on the remaining good signals. First check for loose connection and shorts in the encoder terminal box, as well as the wiring to the ALCU control box. 1 no problems are found in the wiring or fuse, replace the encoder. Adjustment procedure can be found in Procedure 905-8. In the event of failure of all Tacho signals, see item 5.5. 5.3.5 Alarm 33 - Engine stop signal failure Engine stop signal failure will be released if the engine stop signal is detected as abnormal by the MCU There are two cases that will rigger the stop signal alarm. 1. The engine is running above 8 r/min and engine stop signal is present at the MCU input for more than 20 minutes. Check the engine stop signal circuit in the bridge control system 2. The engine is stopped (detection is only active for 30 seconds after stop) but there is no engine stop signal present at the MCU input. Check the engine stop signal circuit in the bridge control system. When referring to this page, please quote Alpha Lubricator 707X49 Edition 40C Page 49 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X50-40C Alpha Lubricator System Man 5.3.6 Alarm 34~LCD signal abnormal ‘The MCU has detected that the external LCD signal has been continuously ON for more than 48 hours. Check the LCD signal and parameters in the governor system, 5.3.7 Alarm 35 — BCU active signal missing The MCU has detected that the BCU is abnormal. Start checking if there are other alarms from the system. Power fail from the BCU will give this alarm. Check the wiring in MCU plug J52 terminal 4 and 5 as well as BCU plug J7 terminal 3 and 4. (BCU alive signal connections) Iinone of the above problems are found, try to interrupt the power to the BCU unit for 5 sec. If the problem is stil present, the BCU is probably damaged and must be replaced. However, the engine can be operated in MCU mode until anew BCU unit can be obtained. 5.3.8 Alarm 36 ~ Astem signal abnormal The MCU unit has detected that the astern signal has been ON for more than 24 hours. The engine can be operated with this alarm present, however the lubrication amount is increased. Check the astern signal circuit in the bridge contro} system. 5.39 Alarm 37 — Prelubrication signal abnormal The MCU has detected that the prelubrication signal is ON and the indexis higher than 80%. This fault is not critical. Check the pretubrication signal circuit 5.3.10 Alarm 38 — Oil temperature high The oil temperature has exceeded the alarm level normally adjusted to 70°C. Check the oil temperature sensor (Pt-100 type) by disconnecting the plug from the sensor and measure the sensor resistance. ‘At: 20°C, the reading must be 100.0 ohm 50°C, the reading must be 119.4 ohm Page 50 (75) When relerring to this page, please quote Alpha Lubricator 707X50 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, DenmarkAlpha Lubricator System 707X51-40C 60°C, the reading must be 123.2 ohm 70°C, the reading must be 127.1 ohm. It the readings do not correspond the values stated above, the sensor is damaged and must be replaced. This fault is not critical and the sensor can be replaced when convenient. Alarm 39 — Oil pressure low ‘The oil pressure is below the normal alarm level of 35 bar. ‘Automatic start of stand-by pump and common alarm is activated plus alarm 49 in the HMI panel Ifoil pressure is re established after start of stand-by pump, common alarm is not de-activated until the stand-by pump is manually stopped. Both pumps will run continuously due to the detected fault. This fault is cleared by manually pressing one of the PuMP-buttons on the HMI panel. Check if the pumps are running. Check for leaks in the high-pressure supply lines. Check the oil pressure sensor (4-20 mA type) by measuring the sensor current and comparing it with the pressure. It the current and pressure differ, the sensor must be replaced/calibrated. 5.3.12 Alarm 40 — Speed deviation alarm ‘The MCU has detected that one or more of the four speed measurements are ab- normal. ‘Check the alarm list in the HMI panel to see which sensor is abnormal (BCU pick- ups or the angle encoder) alarm 29, 30, 31 and 43 and read the chapter concern- ing the alarm. 5.3.13 Alarm 41 — index transmitter abnormal The index level does not correspond to the engine rpm. Fuel index is internally set to a fixed value of 100 percent due to the detected fault. The fault is cleared by activation of engine stop signal. Check the adjustment of the index transmitter, according to instruction $903-21 The index transmitter itself might be damaged. 5.3.14 Alarm 42 — Cable failure index transmitter ‘The index transmitter cable is interrupted or the index transmitter is damaged, When reterting to this page, please quote Alpha Lubricator 707X51 Edition 400 Page 51 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707XS2-40C Alpha Lubricator System Man Correct the cable failure or replace the index transmitter. If the index transmitter is replaced, readjustment is needed. Follow the index ad- justment instruction $903-25. 5.3.15 Alarm 43 ~ BCU pickup 2 failure Please see item 5.3.3. 5.3.16 Alarm 44~ BCU in control The lubricators are running BCU es 7 mode Check that the mode switch is in auto position. Find the cause for the BCU take- over. If the BCU mode has been —_ | (a _u oj started automatically andis running A without slow down command, the (Fi MCU system may be abnormal. 5.3.17 Alarm 45 and 46 — ‘Thermal overload electric motor Electric motor # 1 or 2 is tripped by thermal overload. Check the thermal trip breaker in the pump station contro! box. Press the reset button on the thermal overload breaker to reactivate the pump mo- tor and check the current at the ammeter local side. Check that the voltage on all three phases is OK. If not, check the fuses in the feeder panel. Also verity that the motor windings are OK by measuring the resist- ance of the individual windings. Ino electrical fault can be found check the oil pump for mechanical damage. 5.3.18 Alarm 47 - MCU parameter list not loaded This alarm indicates that the MCU computer has lost its configuration file or that it is missing. Change to forced BCU operation by using the mode switch and replace the MCU with a spare when possible. Page 52 (76) When refering fo this page, please quote Alpha Lubricator 707X52 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmark‘mans Alpha Lubricator System 707X53-40C 5.3.19 Alarm 48 — Angle deviation fail ‘The angle difference between the TDC marker from the angle encoder and the TOC markers from the BCU pickups exceeds the alarm level. Check the Initial adjustment of the angle encoder and adjust as necessary. The adjustment procedure can be found in Procedure 905-8. Also check the flexible coupling between the engine and angle encoder for good condition. 5.3.20 Alarm 49 = Stand-by pump is running The stand-by pump has been activated either by the user or automatically due to a low-pressure alarm. See alarm 39, 5.4 BCU alarms [acarw Leo 6 When reterring to this page, please quote Alpha Lubricator 707X539 Ealtion 40C Page 53 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X54-40C Alpha Lubricator System Man Below is a list of BCU alarms and their description: 5.4.1 Led #1 BCU internal failure An internal failure in the BCU is detected. Check that the small switch SW3 on the BCU board is in the normal position. Reboot the BCU computer by interrupting the power supply for 5 sec. (Plug FJ1). fp | warnina!. | DO NOT PRESS THE RESET BUTTON on the BCU unit, If the alarm comes on again, the BCU board might be damaged and must be replaced. 5.4.2 Led #2. Engine stop signal failure The engine stop signal has been on for more than 20 minutes with the engine running. The engine stop signal is off and the engine is not running (only for 30 seconds). Check the stop signal wiring and the engine control system for correct operation. 5.4.3 Led#3 MCUalive signal missing ‘The BCU unit has detected that the MCU unit is abnormal. The BCUis stil full ‘operational in this condition. Start checking if there are other alarms from the system. Power failure from the MCU will give this alarm as well as a common alarm. Normally this situation will give a BCU take over. Check the wiring in MCU plug J52 terminal 2 and 3 as well as BCU plug J7 terminal 1 and 2. (MCU alive signal connections). The alive signal is a pulse signal with a frequency of approx. 0,5 Hz. An oscilloscope must be used to measure this signal. Ifo problems, as described above, are found try to interrupt the power to the MCU unit for 5 sec. If the problem is still present the MCU unit is probably damaged and must be replaced. However, the engine can be operated in BCU mode until a new MCU unit can be obtained 5.4.4 Led #4 Feedback signal missing on two lubricators If, for any reason, a feedback signal from a lubricator is measured as abnor- mal by the BCU, an alarm will be given (BCU fail alarm). Note that if the systems running in BCU mode due to a MCU failure, the MCU might not be able to show any alarm codes in the HMI panel. The defect lubri- cators are to be found by observing the feedback signal indicator lights at the intermediate boxes at the engine. This alarm indicates that the lubrication is stopped on a cylinder. A slow-down command will be released. Page 54 (75) When referring to this page, please quote Alpha Lubricator 707X54 Edition 40C 2003-01-28 ‘MAN B&W Diesel A/S, Copenhagen, Denmark5.4.5 5.4.6 As Led #5 Led #6 Alpha Lubricator System 707%55-40C First check if the fault is concerning more than one cylinder. If more than one cylinder is affected, check the oil supply system. The oil pressure might be low or the oil supply from the gravity tank has stopped. Check for leaks on the oil supply lines. If the problem can be isolated to only one cylinder, check the feedback wiring from the defect cylinders intermediate box to the control box (ALCU). The in- termediate PCB (Printed Circuit Board) itself might be damaged. To check if the BCU board is damaged, the plug for the defect cylinder can be Femoved from the BCU and a plug from a working cylinder can temporally be ‘mounted instead. If this cylinder that previously worked well is now faulty, the BCU board is probably damaged. Remember to remount the plugs in the correct sockets. The BCU computer can be rebooted by interrupting the main power supply for 5 sec. (Remove plug FJ1 on the BCU fitter board).) EEE DO NOT PRESS THE RESET BUTTON! “eedback signal missing one lubricator If, for any reason, a feedback signal from a lubricator is measured as abnor- mal by the BCU, an alarm will be given (BCU fail alarm). Note that if he system is running in BCU mode due to a MCU failure, the MCU. might not be able to show any alarm codes on the HMI panel. The defective lubricators are to be found by observing the feedback signal indicator lights at the intermediate boxes on the engine. Generally itis recommended that a defect lubricator is replaced completely with a spare when convenient (in the case of one lubricator per cylinder, the detective unit must be replaced immediately) For further information, see chapter covering MCU feedback fail alarms. BCU marker signal 1 and 2 missing The two marker pickups mounted on the turning wheel end of the engine give one pulse every engine revolution. These signals are used by the BCU sys- tem to determine the engine speed. The signals are also used by the MCU system to monitor the signals and release an alarm in case of signal failure. Note that if he system is running in BCU mode due toa MCU failure, the MCU may not be able to show any alarm codes on the HMI panel. This case needs prompt attention. The lubrication will stop, and a slowdown command will be activated, This type of fault is normally caused by mechanical damage to the pickups or interruption of the power supply to the BCU pickups. When referring to this page, please quote Alpha Lubricator 707X55 Edition 40C Page 55 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X56-40C Alpha Lubricator System ‘n Check the sensors and the trigger-bracket on the flywheel for mechanical damage. Sensor gap is 3.0 mm. (Regarding distance: always refer to manu- facturer’s recommendation). Check that there is 24 volt on terminals 1 and 2 in the BCU terminal box. If there is no power present on terminals 1 and 2, investigate further for short- circuited wiring to the BCU pickup system. 5.4.7 Led #7 and 8 BCU marker signal 1 or 2 missing The BCU system can be operated with only one pickup signal present, Failure of one pickup is not critical and it can be replaced when convenient. ‘The BCU pickups have a built-in indicator which flashes once for each engine revolution. If one of the pickup alarms are ob- served, first check that the lamp in the pickup is flashing. If not, check that there is 24 volt on terminals 1 and 2 in the BCU terminal box. If power is presentat terminals 1 and 2, disconnect the pickup wire connected to terminal # 3 (pickup # 1) or terminal # 6 (pickup # 2) and observe if the light starts flash- ing. If yes, the wiring from the pickup to the ALCU boxis shorted. If the indicator light still does not flash, replace the pickup. Pickup gap is to be adjusted to 3+0/-1 mm. (Regarding distance: Always refer to manufacturer's recommendation). 5.5 Emergency running without external trigger signals We strongly recommend that all efforts are made to repair the trigger system be- fore switching to the emergency mode. In the event that all trigger signals to the lubricator system fails (angle encoder and pickups for the BCU system), itis possible to maintain a certain level of lubrication by means of an internal stroke generator on the MCU or BCU card. This stroke generator emits one pulse per second, i.e. approx. 60 rpm. To be able to run in this “emergency mode”, the following electrical connections must be changed: Remove the wire from MCU-J22 terminal 1 Connect an extra wire from MCU-J52 terminal 4 to MCU-J22 terminal 1 Page 56 (75) 2003-01-28 When relerring to this page, please quote Alpha Lubricator 707X356 Edition 406 MAN B&W Diesel A/S, Copenhagen, DenmarkAlpha Lubricator System 707X57-40C MCU board g 5 The system now starts lubricating regardless of whether the engine is running or stopped, The system will also give various alarms. However, feedback alarms will stil function and indicate whether all cylinders are being lubricated. When running in this mode, the BCU system is not active. The MCU siow-down function remains active. Lubrication is effected as “random” and “tpm-dependent’, however with a supple- ‘ment of 25% of the amount set for the individual cylinders, but with a fixed number of revolutions of 60. When referring to this page, please quote Alpha Lubricator 707X57 Edition 40C Page 57 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28707X58-40C Alpha Lubricator System Man 5.6 Sequence diagram for alarm handling fe fe ae HM Pond Aart (Alc 1-24: Foodhack sonata ‘Air 23: Mater fare = encod uggs ing ‘ir 20: Meter fare ECU pica oa 4 Ne Thogpe ebro eer ge ‘Ae 33: Enna sop sere fale ‘it 94; UCD signa abroad ‘Ae 35: BOU Ave soya missing Air 26: Adem sir atrarrad Ae 37: Presaxicaion Sopa abvertrd a ‘Air 38: Ol erperaure Oh eS = ‘Ae 39: Ol presare low oe ee) om ‘Ai 40: Speed cexiaion mak igs ser be ee PL cee (i 44 lcextrareriter ‘abroad tee i ‘ie 42: Cate falure indextrarerrir _ ‘A a3: Neer faze BOU so. 2 FB Ree], [a ‘ie a4: BOUin corte = een ‘ie a5 Themed oicad Meso 1 = a - ‘ir a6: There oveload ek Metor 2 [Ale AT NU pee st eX 10063 Air 48: Peefo dodaton mater sores ‘Ar 49: Sendtby purpnurning Page 58 (75) "When relerting to this page, please quote Alpha Lubricator 707X58 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmark(a8) Alpha Lubricator System 707X59-40C Hae Appendix 1 Function of the LEDs in the Intermediate Box The two green LEDs Ds and Ds (FB-signal input A and FB-signal input B) light when there is an input from one of the feedback sensors. FB-signal output is also a green LED Diz, which flashes every time a feedback sig- nal is sent to the Switch Board Unit. There has to be a flash at FB-signal output every time, shortly after there is an input on one of the two FB-signal input. The Error LED Dr indicates with a red light, if there is an error on the cable from the FB-signal output, or if the input at the Switch Board Unit has an error. I there is an error, remove the plug from Ji and see if the LED stil indicates error. ttitdoes then change the circuit board, if this does not remove the indicated error, then look for any damage on the cable. If the cable is damaged, then change it or, if possible, repair the damage. If there is not any damage on the cable, then the Source of the error could be the input channel at the Switch Board Unit When referring to this page, please quote Alpha Lubricator 707X59 Edition 40C Page 59 (75) MAN B&W Diese! A/S, Copenhagen, Denmark 2003-01-28707X60-40C Alpha Lubricator System an a Appendix 2 Control Unit Cylinder Lubrication — Logic Diagram ol [it iceman Tei sol Page 60 (75) When referring fo this page, please quote Alpha Lubricator 707X60 Edition 40C 2003-01-28 MAN B&W Diesel A/S, Copenhagen, Denmark707X61-40C Alpha Lubricator System [ester] ar ‘mann TET] Set ost ro Page 61 (75) 2003-01-28 When referring to this page, please quote Alpha Lubricator 707X61 Edition 40C MAN B&W Diesel A/S, Copenhagen, DenmarkAlpha Lubricator System 707X62-40C [o-eesrer9] BS Tins ein [armmeare onl COLE o{ iad = i i I x i = bo 7 [_ z Ee al - eee ee : When referring to this page, please quote Alpha Lubricator 707X62 Edition 40C MAN B&W Diesel A/S, Copenhagen, Denmark Page 62 (75) 2003-01-28707X63-40C Alpha Lubricator System 4 =a sieam—tod i egg} rn seal Page 63 (75) 2003-01-28 When referring to this page, please quote Alpha Lubricator 707X63 Edition 40C MAN B&W Diesel A/S, Copenhagen, DenmarkAlpha Lubricator System 707X64-40C O=ee5vEL0) ea | ay nore tAadens 9 move hows MAN B&W Diesel A/S, Copenhagen, Denmark When selerring to this page, please quote Alpha Lubricator 707X64 Edition 40C 3-01-28 Page 64 (75)707X65-40C Alpha Lubricator System 2 aaa oA ST oan rma navn SOLE] 0 fea Las Page 65 (75) When referring to this page, please quote Alpha Lubricator 707X65 Edition 400 MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-28Alpha Lubricator System 707X66-40C [o-sesvero| artes levee arate OT LET St ‘MAN B&W Diesel A'S, Copenhagen, Denmark When referring to this page, please quote Alpha Lubricator 707X66 Edition 40C Page 66 (75) 09-28 2707X67-40C Alpha Lubricator System g 20 ieee When referring to this page, please quote Alpha Lubricator 707X67 Edition 40C MAN B&W Diesel A/S, Copenhagen, Denmark Page 67 (75) 2003-01-28707X68-40C Alpha Lubricator System cane Appendix 3 Replacement of MCU, BCU, SBU Boards If one of the PCB's in the ALCU box is to be replaced, note as follows: Before removing any plugs from the PCB ensure that the plugs are numbered in order to remount them in the correct place. The SBU unit does not need any programming or setup. This board can be re- placed directly with a spare. MCU and BCU units: Normally the spare units are delivered programmed and ready to use. Remove all plugs from the PCB. Remove the eight screws that fasten the unit to the ALCU. Mount the new unit and remount the plugs in the correct position. MCU replacement Page 68 (75) 2003-01-28 If the MCU unit has been replaced, check the following: Note that.a new MCU unit is adjusted to a feed rate of 200% (factory setting). 1. Read out the feed rate setting for the individual cylinders on the old MCU in order to adjust the new MCU to the same setting 2. Start the PRELUBRICATION Sequence and check that all cylinders are lubricated by observing that all LEDs on the intermediate boxes flash. Also check that no feedback alarms are present in the HMI panel, 3. With the engine running, check the injection angles inthe HMl panel and com- pare these with the angles stated in the test sheet supplied with the ALCU box. Pa Adjust the lubrication feed rate according to the settings the engine had before this replacement. Lubricator 707X68 Edition 406 When referring to this page, please quote Al .e1 AIS, Copenhagen, Denmark. ‘MAN B&WAlpha Lubricator System 707X70-40C Appendix 4 Cylinder oil feed rate during running-in sano Bujauny oor oa cote cose 008 ore 00s ooze 08 a X ce +06 on sve proj unui | a ave peo oowis gepusuttooe en os ov: pos ujuns jo osu. | te ‘ayes poo} 21seg res pee) Uy juyuuny= u-ujuur Buuinp eyed peas jlo sapuyjho Sumas 2189 Jo qu92!24 w eBecop Ho 19pLHkS) MAN B&W Diesel VS, Copenhagen, Denmark When referring to this page, please quote Alpha Lubricator 707X70 Edition 40C Page 70 (75) 2003-01-28707X72-40C Alpha Lubricator System MAN Appendix 5 ALCU signal description Page 72 (75) 2003-01-28 When relerring to this page, please quote Alpha Lubricator 707X72 Edition 400 MAN B&W Diesel A/S, Copenhagen, Denmark(S28) Alpha Lubricator System 707X73-400 '0789300.3, MAN B&W Diesel iS oto, Lub co! Uni When referring to this page, please quote Alpha Lubricator 707X73 Edition 400 Page 73 (75) MAN B&W Diesel A/S, Copenhagen, Denmark 2003-01-283 20 Alpha Lubricator System 707X74-40C S750 a VL THT i i i x 5 MAN B&W Diesel A/S, Copenhagen, Denmark When referring to this page, please quote Alpha Lubricator 707X74 Edilion 40C Page 74 (75) 2003-01-28707X75-40C Alpha Lubricator System TORCEEIS ATO TI ev eevo nwa wen | ED SPRUSTTOW ST I reo eons) come esre i a Era wm : Steg nein ISOS veers | sinas ve noe ensins nore g use hg owen ses stn noe Page 75 (75) 2003-01-28 When referring to this page, please quote Alpha Lubricator 707X75 Edition 40C MAN B&W Diesel A/S, Copenhagen, DenmarkIndex Operation Commissioning Maintenance Components Baw Electrical Wiringcan Commissioning Table of Contents See 1 Nz Charging Maintenance 903-2.1, page 2-3 and 103-2 2. Flushing $903-24 5) Testbed Commissioning Procedure $903-21 4. Angle Encoder Maintenance 905-8.1 and 105-8 - Tacho Pickups Maintenance 905-7.1 and 105-7 6. Timing Check Procedure 8903-20 Testbed Trial Test Scheme 8. Dock Trial Commissioning Procedure $903-22 9, Dock Trial Test Scheme When refering to this page. please quote Commissioning TOG MAN B&W Diesel A/S, Copenhagen, DenmarkFlushing of Pipe System on Ban Alpha Lubricators Soos-24 Preparation 1.1 Connect a 440 V power supply to the two pump starter cabinets, and start the two pumps locally for a brief period to check that they run in the correct direction of. rotation. 1.2 Check, and if necessary adjust, the current limits on the two motor-start relays so that they comply with the rating plate on the motor. 1.3 Connect and activate the heating element in the suction tank, 1.4 Dismount the inlet and outlet pipes to the lubricator blocks and mount U-pipes with shut-off cocks instead (bypass the blocks). Remember to seal off the free pipe connections on the lubricator block to prevent the in- gress of ditt Mount an extra full-flow filter (15 to 35 j.) in the return pipe from the engine to the pump station. Disconnect the service tank as hydraulic oil is to be used for flushing 1.5 Mount a U-pipe with shut-off cock on the end of the oll supply main pipe 1.6 Close all shut-off cocks on the U-pipes at the lubricator blocks and open the cock at the end of the main pipe. 1.7 Fill the suction tank on the pump station with hydraulic oil 1.8 Openall relevant cocks on the pumps. 1.9 Stait pump No. 1 locally via the starter cabinet 1.10. Adjust the pressure regulator on the pump station to maximum pressure. 1.11 Check that there are no leaks in the pipe system. 1.12 Check the oil level in the suction tank and, if necessary, top up until the level is stable, 1.13 Shut-down pump No. 1 1.14 Start pump No. 2 and check that it can maintain a pressure level similar to pump No. 1 1.15 Start both pumps. 1.16 Regularly check the oil level in the suction tank and top up as necessary. 1.17 Regularly check that the pressure drop across the suction filters and in the full- flow fiter in the pressure outlet do not exceed the maximum level. Replace the fil- ters if clogged. When referring to this page, please quote Procedure S903-24 Page 1 (3) MAN B&W Diesel A/S, Copenhagen, Denmark3903-24 Flushing of Pipe System on Alpha Lubricators san 2. Flushing The following flushing procedure is to be carried out before starting up on the testbed: 24 22 23 24 25 26 27 28 29 2.10 242 After five hours’ flushing, open one half of the shut-off cocks on the U:pipes on the lubricator blocks, and close the cock at the end of the main pipe. Continue flushing for at least five hours. After five hours’ flushing, open the other half of the shutoff cocks on the U-pipes and close the half that were open, Continue flushing for at least five hours. Close the inlet and outlet cocks on the pump station, and drain the oil from the suction tank. ‘Switch-off the 440 V power supply to the pumps and tank heater via the main switch on the starter cabinets. Remove the inspection cover on the suction tank and clean the inside of the tank so that it is completely free of any oil or dirt Dismount all U-pipes and re-install all the original pipe connections. Open all relevant cocks on the pumps and open for the supply of cylinder oil from the service tank (gravity tank). Start a pump from the pertaining start button on the starter cabinet and adjust the pressure regulator to 45 bar. Check that there are no leaks in the pipe system or lubricators. Check and, it necessary, adjust the thermostat to 45°C, after dis mounting the cover on the heater. The oil system is now ready for service. Page 2 (3) When relerring to this page, please quote Procedurer 5803-24 MAN 88W Diesel A/S, Copenhagen, DenmarkFlushing of Pipe System on ° 3 eas Alpha Lubricators eee The filter must be a "bag-type" filter U-pipe with valve cy at Cyl #2 7 ye roan cmp Btn , a fulfloat gy 15-306 ow When referring to this page, please quote Procedure S903.24 ~ Page 3(3) MAN B&W Diesel A/S, Copenhagen, DenmarkCylinder Lubrication $903-21 aan Testbed Commissioning Procedure PR eee ne RSREREESEEL EE! ALCU - Testbed Procedure ‘ 1. Disconnect the connections to the HMI pan- el. (HMI panel side) 2. Check the power supply for correct polarity before connecting the power to the ALCU control box terminals. Check both Main A and Main B. 3. Check the HMI panel power connection for correct polarity, and connect the HMI panel. np + TBx1 ‘Alcu Box 24Vv DC s ie << puss é a ae 8 9998 i When referring to this page, please quote Procedure $903-21 Page 1 (8) MAN B&W Diesel A'S 2003-01-288903-21 Cylinder Lubrication Testbed Commissioning Procedure han 4. Set the Index transmitter to approx. 4.5 mA at 0 mm index and approx. 19.5 mA at max- imum possible index on the Local Operating Panel. The mA level can be read on the HMI panel. Navigating in the HMI panel menu is done as follows: + [ENTER] goes forward (right) in the menu or changes a set point + [ESC] goes backwards (left) in the menu. * [4] goes up in the menu. + [¥] goes down in the menu. jase ja iY] 5. Adjust the angle encoder to give TOC sig- nal at TOC cylinder No. 1 (tuin the engine to bring the piston of cylinder 1 to TOC po- sition, and turn the encoder until the LED on the encoder junction box lights up) See Procedure 905-8 for angle encoder ad- justment. Adjust the BCU pick-ups, as described in Procedure 905-7. Start one pump. Check that the cil pressure builds up to 40- 80 bar, or carry out adjustment on the pres- ‘sure control valve on top of the pump sta- tion. The pressure can also be read on the HMI panel display. Check that the pressure remains at an ac- ceptable level, also with two pumps run- ning 3 fs Page 2 (8) : When referring to this page, please quote Procedure $903.21 2003-01-28 ‘MAN B&W Diesel A/S(aed Cylinder Lubrication 903-21 maw Testbed Commissioning Procedure 6. Tum the mode switch to BCU position and check that both booster pumps are running, Turn the switch back to AUTO position. TT on TTT 7. Check the connections to the lubricators by activating the lubricators one by one via the HMI panel connection test menu (start one booster pump from the HMI panel). Lub.xx | [oFF/on Cont Jes[Sou | fine Check the lubricator system by activating the pre-lubrication function. Press the ESC button and the PRELUB button on the HMI panel simultaneously. Check that no feed- back alarm is activated. 2 When refering to this page, please quote Procedure S803 21 Page 3 (8) MAN B&W Diesel A/S 2005-01-288903-21 Cylinder Lubrication (os) Testbed Commissioning Procedure may 9. Turn the engine to approx. 10° before TDC of cylinder No. 1. Continue turning the engine and check that the small LEDs on the MCU unit ~ desig- nated 088 (above J20) 090, D91 (above 4J22) ~ flash when the engine is turned and passes TDC of cylinder No. 1. ‘Also check that the LED on the MCU unit ~ designated D89 (above J20) - flashes ap- prox. twice each second. MCU Board TOC Cyl. 1 Page 4 (8) When referring to this page, please quote Procedure S903-21 2003-01-28 MAN B&W Diesel A/SCylinder Lubrication $903-21 Ban Testbed Commissioning Procedure 10. Check the engine stop signals by simulating un and stop condition from the governor side. Check that LED D80 (above/tight J30) on the MCU and LED 038 (above Js) on the BCU turn on and off accordingly z mo i 108. When referring to this page, please quote Procedure S90321 Page 5 (8) MAN B&W Diesel A/S 2003-01-288903-21 Cylinder Lubrication Testbed Commissioning Procedure Baw Engine Alarm System e @| Q| | et 12, ‘Aipba lap tst doe n MW. Check the common alarm connection by simulation. Follow the HM! panel menu in- struction to activate a common alarm from the lubricator system as shown below. Check the timing adjustment as described in Procedure $903-20. on [om r Page 6 (8) : ~ When referring to this page, please quote Procedure S803-21 2003-01-28 MAN B&W Diesel A/SCylinder Lubrication $903-21 Testbed Commissioning Procedure 13. Carry out the tests according to the testbed test scheme and fill in the check boxes 14, When the engine load is increased to 50% cee | = keel = TS Tao leases ees momar heise bemeganmt wee Seq femme) Sesee | ara Sez Es See Eee eee} ee fama | Sener E eres | =e ee eee oh 0 se load, calibrate the index transmitter at this | 14, load by means of the index transmitter ad justment menu in the HMI panel Follow the example in drawing 14.2, ono TTT voce fOONNOOUOO] When reterring to this page, please quote Procedure $903.21 Page 7 (8) MAN B&W Diesel AS 2003-01-28'$903-21 Cylinder Lubrication Testbed Commissioning Procedure Saw 14a Password Ww ESC enrer| ls [SETUP] »{_ PASS ]->[ in. AdS it le (Password) 15. When the engine load is increased further 10 100% load, calibrate the index transmit. ter at this load by means of the index trans- milter adjustment menu on the HMI panel. Follow the HMI panel menu instruction. 15. en sme NTT oo [OE voce OOOO] | i Page 8 (@) ~ When referring to this page, please quote Procedure $903-21 2003-01-28 MAN B&W Diesel A/SCylinder Lubrication saw Check of Injection Timing Baw Injection timing 1. Adjust the shaft encoder in accordance with Procedure 905-8.3, 2. Remove the lubricator timing hole plug from the exhaust side of cylinder liner No. 1. If there is no timing hole, remove one cylinder oil lubricating point non-return valve from cylinder liner No. 1 3. Turn the engine to BDC Cyl. 1. Check that the timing hole is clean. Turn the engine ahead unt the upper edge of the top piston ring becomes visible. Note! Compressed air is coming out of the tim- ing hole when the piston is turned upwards. Use eye protection. 4. Note the crank angle-on the turning wheel 5. Compare tie angle obtained with the angle stated on the test sheet in the lubricator control unit. if the reading is not within the folerance stated on the test sheet, correct all angles in the test sheet with the ob- served difference. Programe Fisten ‘ins ‘Apu tet doe logcton ange ow one 2m ons When relerring to this page, please quote Procedure 590320 MAN B&W Diesel A/S Page 12)903-20 Cylinder Lubrication Check of Injection Timing gan ;OoQUHCTOOCOOOONC0 eo om — (SCORN Navigating in the HMI pane! menu is done : as follows - PoooeAOOoTAT + [ENTER] goes forward (right) in the menu or changes a set point. 6. Run the engine at steady load. Read all in- jection angles: on the HMI panel. + [ESC] goes backwards (left) in the menu, + [4] goes up in the menu. + [Y] goes down in the menu. 7. Read all injection angles in the HMI panel, starting at the [diSP] menu and follow the sketch Check that the angles correspond with the angles on test sheet. (| ees ies | oo i : 8. Incase the angles are not within the stated tolerance, adjust the common offset value in the HMI panel SEtup menu. See the sketch. 8 Possvord TW & Esc enter >{ ess} TnsAdu (Posewora) Lol ving indeoF 0) 9. When the Injection offset [InJ.OF] is checked or adjusted (if adjusted) press [ENTER] (the HMI panel will display [SAVE}). Return to the main menu by press- ing [ESC]. Page 2 (2) When referring to this page, please quote Procedure 5903-20 MAN B&W Diese! AISSz1g88L0 NOUWSASISNT e020 e RUBLE TT FeT PSL wy | iv 195810, MBG NY | ‘pou oun oi x2ea pu noi 3 padueD 98 MU meee — — "sla Sin wontes O1ny u 291s os ve» aU OH sips i suet | vu poe eb ieuee & Soie eee x Ae fay orenjon now aue waists sayy 10) EA suo equ enue yaino wy | pote i | ame eaves dors sudue ears pete con eee eer utes | | I I [ | iaved non wre vaca nerarg| PemOwmRvouueD | ¢ xX | xX xeall| X_| snes rseomestee | Meh dew tinaisewinng [end iaguen eonetoa| ® | Tx ‘me au puns er (eR) | bei 440 dun eeu cs, une fess . pongo | naw nt noapnT hon wa ony gees ‘rien 9901 vonaung BiRaiRo mae Fe ‘uiogoe 1s01 60 pogieal OSHA BUSTYCylinder Lubrication 8903-22 Baw Dock Trial Commissioning Procedure 1 Commissioning Procedure 1. Disconnect the connections to the HMI pan- el. (HMI panel side) 2. Check the power supply for correct polarity before connecting the power to the ALCU control box terminals. Check both Main A and Main 8, 3. Check the HMI panel power connection for correct polarity, and connect the HM panel. | 4. 123 2 + Ext owe, SI ae (ea 24Vv 0c | ° L+ oo —— ~ ou e| Se Sain ° | [ets e aoa Is = bwain'’a [ES SSS] | = | 2 When referring to this page, please quote Procedure S903-22 Page 1 (4) MAN B&W Diesel A/S 2003-01-28$903-22 Cylinder Lubrication (ead) Dock Trial Commissioning Procedure gan 5. Check the adjustment of the angle encoder. ‘Turn the engine until the LED on the encod: er junction box lights up, and check that the crank angle reading is 0° on the flywheel (TDC cylinder 1). See Procedure 905-8. Adjust the BCU pick-ups, as described in Procedure 905-7. 6. Check the connections to the lubricators by activating the lubricators one by one via the HMI panel connection test menu. Follow the HMI panel menu instruction. 7. Check the lubricator system by activating the pre-lubrication function. Press the ESC button and the PRELUB button on the HMI panel simultaneously. Check that no feed- back alarm is activated. 3 e Page 2 (4) When referring to this page, please quote Procedure S903-22 2003-01-28 MAN B&W Diesel A/SCylinder Lubrication 903-22 maw Dock Trial Commissioning Procedure 8. Turn the engine to approx. 10° before TOC. of cylinder No. 1 Continue turning the engine and check that the small LEDs on the MCU unit — desig- nated D&B (above J20) 090, D91 (above J22) ~ flash when the engine is turned and passes TOC of cylinder No. 1 Also check that the LED on the MCU unit — designated D89 (above J20) ~ flashes ap- Prox. twice each second. {EE mh MCU Board 23 ee ee eee When refering to ins page, please quate Procedure S903 22 Pages (@) MAN B&W Diesel A/S 2003-01-28$903-22 Cylinder Lubrication Dock Trial Commissioning Procedure gan 9. Carry out the external connection test ac- cording to the dock trial test scheme and fill in the check boxes. [ronton tbe [norm nnber] om [ cu | ecu [ecuin| cy ] ecu | sow [creer] rest Ie estoy sptoweon | ton ims | port | per [eon] it | SSH | Se eaenataacm | Onmonecing xt lcrangeoroacy | x | x x |x spomones | fwnante Jon 2 [eremaiaam | Ossonnesingxt | a0vasea [BCU ponertiam | x x x [x Jsonscroans | Pwn tr | > [enonesiop | Simuaung Stop signat |Mcu LED O80 above som Jnse-atne | Siva ge sp nat om ene cone sen pa toma = [aveaancem | Sinaaing aso jucu LED ore above | Smsne Aso na am erie cna oystom la one ps J or E @ [resbrcaton —[Smsaing pe tue re wrctan ‘Sinai pre orion eqn Kom eps cenel atom soo Es Jequnce 6 [sinaroure [Suiningmacir nine] (a)+48 [Sanbymmpoans | x 7 [ocvisieover loscomeaingpigm| + lormgeonrmacu | x x x | x Jasncty pomp [oomuvnesrrs tone eons nando Jsrtond one [erence emp st, So lu down err (rogged alo in cutee Page 4 (4) When referring to this page, please quole Procedure 8903-22 2003-01-28 MAN B&W Diesel A/S.21188820 NOILONSLSNT €20 20 € ey var [Te | 158 9 O29 vanes O ny 3 Ie an o> we | sweeney X9'5 94 osemuos now pue wereke nor" 04 118A x | xX x x ” ‘ X oro ° = ri t X ‘aoe ramon _ [precios 7 oreyg} oe [908 vous ston fae se ‘Sndino Wise PANN Buia yD Ise) Hen WOR TOWANAT LETTindex Operation Commissioning Maintenance Components Electrical Wiring(a) SAFETY PRECAUTIONS X | Stopped engine X_| Block the starting mechanism X | Shut off starting air supply X | Engage turning gear Shut off cooling water Shut off fue! oi! ‘Shut off lubrication oil Lock turbocharger rotors Data Rel. Deterstion D-1 . Nitrogen pressure ~ inlet accumulator D-2 Nitrogen pressure ~ outlet accumulator D-3 Plug screw = tightening torque When referring to this page, please quote Data D10302 Edition 0020 MAN B&W Diesel A/S 25-30 bar Cylinder Lubricators Data Standard Tools: See Section 913 ZS, Value Unit 1.8 bar 30 Nm 103-2 Page 1 (2)103-2 Cylinder Lubricators Data Baw ‘Spare Parts Prat - tom No. Descipton oy Page 2 (2) When referring to this page, please quote Data D10302 Eaition 0020 MAN B&W Diesel A/SCylinder Lubricators Baw Checking Check of Oil Injection: With stopped engine and normally when the system has been disassembled: 1. Press the ESC + PRELUB.-button on the HMI control panel, and check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lu- bricator. 2. If the cylinder cover or the exhaust valve is removed, check inside the finer that all lu- bricating points are working properly. A “‘eaosa Otherwise, remove the covers for scavenge port inspection, BGEEE Turn the piston to BDC and check inside the liner with a minor and a powerful light source that all lubrication points are work- ing properly, With running engine: 3. Check that all lubricators are operating cor- rectly by watching the LEDs on the interme- diate boxes for each lubricator The LEDs give signal when oil is injected. | Check the pressure shocks from the injec- tion of the lubricators on each lubricator pipe by feeling with a hand I in doubt, disconnect the pipe at the cylin der finer to observe the oil flow. When referring to this page, please quote Procedure M90302 Edition 0236 Page 1 (10) MAN B&W Diesel A'SPage 2 (10) Cylinder Lubricators Checking Check of Accumulators: 4, Measuring the nitrogen pre-pressure can only be done with stopped engine and pres- sure-free lubrication system. Stop both oil pumps. Close the inlet valve and open the equalizing valve on the re- spective lubricator. The nitrogen pressure in the inlet accumu- lator (0.7 litre) can be checked without dis- mounting the accumulator. For use of the pressure setting tool, see Step 5. 5. To measure the nitrogen pressure in the outlet accumulator (0.16 litre), the accumu. lator or the lubricator with accumulator must be dismounted. See Procedure 903-2.2. For nitrogen pressure in the accumulators, see Data. 6. Use of Pressure Setting Tool Assemble the pressure setting tool as shown in Figure 5, and mount the reducing valve on the nitrogen cylinder. If necessary, use a threaded adaptor. Mount a 0-60 bar pressure gauge on the fill ing valve when the inlet accumulator (0.7 li tre) is to be checked, and a 0-10 bar pressure gauge when the outlet accumula- tor (0.16 litre) is to be checked. When referring to this page, please quote Procedure M90302 Edition 0236 MAN B&W Diesel A'SPage 4 (70) Cylinder Lubricators Dismantling Dismantling of lubricators: The engine must be stopped and blocked be- fore dismounting a lubricator. Stop the cylinder oil pump station 1, Close the supply valve for the lubricator and open the equalizing valve (turn both han- dles to.a horizontal position). Remove the upper shield, if installed. Disconnect the electrical plug on the side of the lubricator. 2. Unscrew the three screws in the bottom of the lubricator and disconnect the cover with pertaining pipes. 3. Unscrew the four screws on the side that secure the lubricator to the hydraulic block, and remove the lubricator. Special running It is possible to change a lubricator while the engine is running if a spare lubricator with O- rings and the necessary tools is available. The change should be done in a maximum of 15 minutes. + Reduce the engine load io below 40% of MCR + Let the lubricator pump station run + Dismount the lubricator as described in steps 1-3 + Mount a spare lubricator as described in Procedure 903-2.4, When referring to this page, please quote Procedure M90302 Edition 0236 ‘MAN B&W Diesel ASCylinder Lubricators Baw Checking rar 7. Before mounting the filling valve on the ac- cumulator, check that the accumulator top is clean, Mount the filling valve on the relevant accu- mulator with the union nut. Check that valves C and F are closed, Loosen the plug screw in the accumulator using a ¥%" square drive handle in socket E. It is now possible to read the actual nitro- gen pressure in the accumulator on the dial gauge on the filling valve. 8. If the accumulator needs to be refilled with nitrogen, open valve A and increase the outlet pressure from valve C on spindle B to 1-2 bar above the pressure stated in Da- ta. Open valve C until the accumulator is filled to the correct pressure. Close valve © and tighten the plug screw with socket E to the torque stated in Data Release the pressure in the filling valve at bleed screw F. Unscrew the filing valve from the accumu- lator. Retighten the plug screw to the torque stated in Data. Remount the accumulator. 903-2.1 When referring to this page, please quote Procedure M90302 Edition 0236 Page 3 (10) MAN B&W Diesel WIS.Cylinder Lubricators 903-2.2 gan Dismantling Dismantling of accumulators: 4 4. The engine must be stopped and blocked ae before the accumulator is dismounted. = Stop the cylinder oil pump station. 7 Close the supply valve for the lubricator and ra stot nitrogen pre-pressure of 25-30 bar will remain in the accumulator. 4 Carefully unscrew the accumulator to re- lease the remaining oil pressure in the sys- tem. Remove the accumulator from the hydraulic block. When referring to this page, please quote Procedure M90302 Edition 0236 Page 5 (10) MAN B&W Diesel A/S903-2.3 Cylinder Lubricators Overhaul aaw 1 Place the lubricator in a bench vice with soft “jaws”. Remove the adjusting screw with bushings. Unscrew the oil accumulator. Discard the O-ring from the adjusting screw. Remove the screws from the cylinder block. Pull up the cylinder block. Remove the spring and actuator piston with plungers. Remove and discard the O-ring from the cylinder block. Remove the cover for the non-return valves. Take out springs and balls. Remove and discard the O-rings. Page 6 (10) When referring to this page, please quote Procedure M90302 Edition 0236 MAN B&W Diesel A/S(ses) Cylinder Lubricators man Ban Overhaut 4, Remove the cover from the terminal box, and disconnect the wires for the feedback (pick-up) sensor. Remove the terminal box. Carefully, unscrew the feedback sensor and remove and discard the O-ring Clean the housing with diesel oll or kero: sene and dry with a non-fluffy cloth. 5. Inspect the plungers, actuator piston and cylinder block for wear, using a magnifying glass Check that the balls from the non-return valves are in good condition, Check the seats for the non-return valves. BRT When referring to this page, please quote Procedure M90302 Editon 0236 MAN B&W Diesel W'S Page 7 (10)903-2.3 Cylinder Lubricators Overhaul Baw | Sotencis valve Feedback censor 3 ie 6. man Before mounting the feedback sensor, check that the sensor is flush with the sen: sor housing. Mount the feedback sensor or a new one, if necessary, with a new O-ring. Check with an object with a straight edge (e.g. the end of a calliper) that the end of the feedback sensor does not protrude into the actuator piston cylinder. Mount the terminal box. Connect the wires and mount the cover on the terminal box. Fit the cylinder block with new O-rings. Assemble the non-return valves in the eyl- inder block. Mount the cover the three inner screws. Check with a small screwdriver that the springs are correctly centered. Page 8 (10) When referring to this page, please quote Procedure M9002 Edition 0236 ‘MAN B&W Diesel A/S.Cylinder Lubricators Baw Overhaul 8. Fit the cylinder block with a new O-ring. Pre-assemble the cylinder block with the actuator piston and plungers to ensure the correct guidance of the plungers, before fi- nally assembling the cylinder block unit. Mount the spring and press down the actu- ator piston with plungers. Mount an M6 x 60 screw with a washer to keep the spring compressed. 9. Mount the cylinder block assembly in the cylinder housing, Mount the screws and tighten the block to the housing, Remove the M6 x 60 screw with washer. 10. Mount the adjusting screw fitted with a new O-ring and the distance bushing, Mount the oil accumulator. 11. If the lubricator is not to be mounted on the engine immediately after overhauling, cover all openings with plastic to prevent dirt from entering the lubricator during storage. Coat all surfaces with a thin layer of oil 5 | | TTT When referring ta this page, please quote Procedure MQ0302 Edition 0236 Page 9 (10) MAN B&W Diesel AS903-2.4 Cylinder Lubricators Mounting gan an) Before mounting the accumulator, check the nitrogen pressure, see Data. Mount the accumulator. Mount new O-rings on the hydraulic block and on the cover with pipes Mount the lubricator and tighten the screws on the hydraulic block. Tighten the screws in the bottom of the lu- bricator to the pipe connection, Close the equalizing valve and open the supply valve (handles to be in a vertical po- sition) Mount the electrical plug. Check the injec- 2, tion of cylinder oil on the feedback LED on the terminal box for the specific lubricator. E ; I 3. H So’ Rist ig Page 10 (10) When referring to this page, please quote Procedure M90302 Edition 0236 MAN B&W Diesel A/SCylinder Lubricators Ban Checking Check of Oil Injection: With stopped engine and normally when the system has been disassembled: 1. Press the ESC + PRELUB.-butlon on the HMI control panel, and check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lu- bricator, 2. If the cylinder cover or the exhaust valve is removed, check inside the liner that all lu- bricating points are working properly. Otherwise, remove the covers for scavenge port inspection, ‘Turn the piston to BDC and check inside the liner with a mirror and a powerful light source that all lubrication points are work- ing properly. With running engine: 3. Check that all lubricators are operating cor- rectly by watching the LEDs on th diate boxes for each lubricator ‘The LEDs give signal when oil is injected. Check the pressure shocks from the injec: tion of the lubricators on each lubricator Pipe by feeling with a hand. If in doubt, disconnect the pipe at the cylin- der liner to observe the oil flow. When referring to his page, please quote Procedure M90302 Edition 0237 MAN B&W Diesel A'S 903-2.1 Page 1 (10)903-24 Cylinder Lubricators Checking Baw 4 Check of Accumulators HE 4. Check of inlet Accumulator Checking the inlet accurnulator can be done ——| with running engine, D-1 {S32 gum | Close the valve that connects the accumu: lator to the distributor block. Fa nes Mount the special hose on the minimess ul ra For use of pressure setting tool, see Step A A 6. For correct pressure, see Data. Hl — 5. Check of Outlet Accumulator 3 The outlet accumulators are to be dis- mounted while the trogen pressure. is checked. FO) dismount tne outlet accumulator See Procedure 903-2.2, Check the nitrogen pressure, using the Pressure setting tool 6. Use of Pressure Setting Too! Assemble the pressure setting tool as shown in the Figure, and mount the reduc- ing valve on the nitrogen cylinder, If neces- sary, use a threaded adaptor. ‘Mount a 0-60 bar pressure gauge on the fill ing valve when the inlet accumulator (0.7 li tre) is checked, and a 0-10 bar pressure 6 gauge when the outlet accumulators (0.16 litre) are checked. le e Page 2 (10) _ When referring to this page, please quote Procedure M90302 Edition 0237 MAN B&W Diesel A/S,Cylinder Lubricators Checking 7. Before mounting the filling valve on the ac- cumulator, check that the accumulator top is clean, Mount the filling valve on the relevant accu- mulator with the union nut. Check that valves C and F are closed Loosen the plug screw in the accumulator using a %4" square drive handle in socket E. It is now possible to read the actual nitro. gen pressure in the accumulator on the dial gauge on the filling valve, 8. If the accumulator needs to be refilled with nitrogen, open valve A and increase the outlet pressure from valve C on spindle B to 1-2 bar above the pressure stated in Da- ta Open valve C until the accumulator is filled to the correct pressure. Close valve C and tighten the plug screw with socket E to the torque stated in Data Release the pressure in the filling valve at bleed screw F, Unscrew tne filling valve from the accumu: lator. Retighten the plug screw to the torque stated in Data, Remount the accumulator. When referring to this page, please quote Procedure M90302 Edition 0237 MAN B&W Diesel AIS Page 3 (10)903-22 Cylinder Lubricators Dismantling” Baw 1 Dismantling of lubricators: Both lubricators can be dismounted with run- ning engine, one at a time. If the engine is run- ning when a lubricator is dismounted, it is important to check that the other lubricator is doubling injection frequency. concerned, using the special tool. The out- er valve is for lubricator marked A and the inner valve is for lubricator marked B. ia) 1. Close the supply valve for the lubricator Let the lubricator inject oil until the feed- back LED stops flashing. Disconnect the electrical plug on the front of the lubricator. 2. Unscrew the three screws in the top of the lubricator and disconnect the cover with pertaining pipes. ] iS 3. Unscrew the four screws on the front that secure the lubricator to the hydraulic block, and remove the lubricator. Dismantling of accumulators: 4. Inlet Accumulator ff es Close the valve that connects the accumu- A lator to the distributor block Mount the special hose on the minimess coupling and drain the oil out of the accu- mulator. Unscrew the accumulator. If the engine is running, a new or checked accumulator should be mounted at once. Page 4 (10) Wien referring to this page, please quote Procedure M90302 Edition 0237 ‘MAN B&W Diesel A/SCylinder Lubricators Baw Dismantiing 5. Outlet Accumutator Close the supply valve for the accumulator concerned, using the special tool. The out- er valve is for accumulator marked A and the inner valve is for accumulator marked B. Let the lubricator inject oil until the feed- back LEO stops flashing, If space conditions permit, unscrew the ac- cumulator; otherwise the lubricator must be dismounted, see Step 1. When referring to this page, please quote Procedure M90302 Edition 0237 MAN B&W Diese! A'S Page 5 (10)903-2.3 Cylinder Lubricators Overhaul Bay 1 Place the lubricator in a bench vice with soft “jaws” Remove the adjusting screw with bushings. Unscrew the oil accumulator. Discard the O-ring from the adjusting screw. Remove the screws from the cylinder block ie Pull up the cylinder block . Remove the spring and actuator piston with e plungers. 2. Remove and discard the O-ring from the cylinder block. Remove the cover for the non-return valves. Take out springs and balls. Remove and discard the O-rings. a T | i Page 6 (10) 7 When relerring to this page, please quote Procedure 90302 Edition 0237 MAN B&W Diesel A/SCylinder Lubricators 903-2.3 Baw Overhaut an 4. Remove the cover from the terminal box, and disconnect the wires for the feedback (pick-up) sensor. Remove the terminal box. Carefully, unscrew the feedback sensor and remove and discard the O-ring, Clean the housing with diesel oil or kero- sene and dry with a non-fluffy cloth, 8. Inspect the plungers, actuator piston and cylinder block for wear, using a magnifying glass. Check that the balls from the non-return valves are in good condition. Check the seats for the non-return valves. When reterring to this page, please quote Procedure M90302 Editon 0237 MAN B&W Diesel A/S. Page 7 (10)903-2.3, Cylinder Lubricators Overhaul Ban Be Solencid valve BN (brows) {Br tea | reeavock sensor 2 Page 8 (10) 6. Before mounting the feedback sensor, check that the sensor is flush with the sen- sor housing Mount the feedback sensor or a new one, if necessary, with a new O-ring, Check with an object with a straight edge (e.g. the end of a calliper) that the end of the feedback sensor does not protrude into the actuator piston cylinder. Mount the terminal box. Connect the wires and mount the cover on the terminal box. 7. Fit the cylinder block with new O-rings. Assemble the non-return valves in the cyl- inder block. Mount the cover with the three inner screws, Check with a small screwdriver that the springs are correctly centered. When refering to this page, please quote Procedure M0302 Ealtion 0237 MAN B&W Diesel A'SCylinder Lubricators Overhaul 8. Fit the oylinder block with a new O-ring, Pre-assemble the cylinder block with the actuator piston and plungers to ensure cor- rect guidance of the plungers, before finally assembling the cylinder block unit Mount the spring and press down the actu: ator piston with plungers. Mount an M6 x 60 screw with a disc to keep the spring com- pressed, 9. Mount the cylinder block assembly in the cylinder housing, Check that the spring pin engages correctly with the cylinder block assembly. Mount the screws and tighten the block to the housing. Remove the M6 x 60 screw with disc. 10. Mount the adjusting screw fitted with a new (O-ring and the distance bushing. Mount the oil accumulator. 11. If the lubricator is not to be mounted on the engine immediately after overhauling, cover all openings with plastic to prevent dirt from entering the lubricator during storage. Cover all surfaces with a thin layer of oil When relerring to this page, please quote Procedure M90302 Edition 0237 MAN B&W Diesel W'S Page 9 (10)903-2.4 Cylinder Lubricators Mounting Baw Page 10 (10) Mounting of Lubricators 1. Mount new O-rings on the hydraulic block and on the cover with pipes. Mount the lubricator and tighten the screws. on the hydraulic block, Tighten the screws in the top of the lubrica- tor to the pipe connection. 2. Open the supply valve and mount the elec- trical plug. Check the injection of the cylin- der oil on the LEO on the terminal box for the specific lubricator. For checking injection timing, see Proce- dure 905-8.1. Mounting of Accumulator 3. Mount the accumulator. Remove the drain hose from the minimess coupling. Open the valve that connects the accumulator to the distributor black. Check the oil injection, See Procedure 903-2.1, When referring to this page, please quote Procedure M90302 Edition 0237 MAN B&W Diesel A'S.(ba) Gan SAFETY PRECAUTIONS [xxx] Data et, Da D2 Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil ‘Shut off ubricating oil Lock turbocharger rotors esedpion Vaiue Unit Tacho pick-ups for governor system ~ check distance 320.5 mm Tacho pick-ups for Alpha lubricator = check distance 3840/1 mm Regarding distance: Always refer to manulacturer’s instructions. When referring to this page, please quote Data 010507 Edition 0004 MAN B&W Diesel AS Data Tacho Pick-Ups Standard Tools: See Section 913 «ZE, 105-7 Page 1 (2)105-7 Tacho Data Baw Spare Parts Prat —hom No Oestpton ay Page2(2) When relerring to this page, please quote Data 010507 Edition 0004 MAN B&W Diesel A/STacho Pick-Ups Baw Checking The engine is equipped with two sets of pick- ups: + Governor system pick-ups + Alpha lubricator system pick-ups. Governor system pick-ups: 1. The tacho pick-ups are placed next to the turning wheel. 2. Check the distance between the tacho pick- ups and the turning wheel, see Data. H necessary, adjust the distance. If the tacho pick-ups are renewed, note down the wiring to ensure the correct re- 1 mounting e p Turing whe A ame When reterting to this page, please quote Procedure M90507 Edition 0203 Page 1 (2) MAN B&W Diesel A/S905-7.1 Tacho Pick-Ups Checking Ban eed) Alpha lubricator system pick-ups (backup system for angle encoder) 3. Turn the crankthrow for cylinder 1 to TDC. Check the TOG of cylinder 1 against the mark on the turning wheel, 4. The pick-ups are placed next to the turning wheel, see the sketch. 5. Check that the upper marker piece edge is in the centreline of the pick-ups. Check the distance between the pick-ups and the marker piece on the turning wheel, Adjust the distance if necessary. See Data, If the pick-ups are renewed, note down the wiring to ensure the correct remounting. When relerring to this page, please quote Procedure M90507 Edition 0203 Page 2 (2) MAN B&W Diesel AVSaan aw SAFETY PRECAUTIONS Stopped engine Block the starting mechanism Shut off starting air supply =[=]x]=] Engage tuning gear Shut off cooling water Shut off fue! oil X |] Shut off lubricating oi! Lock turbocharger rotors Data Angle Encoder Data 105-8 Ret. Description Value] Unit When referring to this page, please quote Data 010508 Edition 0007 MAN B&W Diesel WS Page 1 2)105-8 Angle Encoder Data paw ‘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. P0951 refers to chapter 909. Hem No. Description Page 2(2) When referring to this page, please quote Data D10508 Edition 0007 MAN B&W Diese! A/S.Angle Encoder 905-8.1 Ban Checking 1. Turn the crankthrow for cylinder 1 to TDC. Check the TDC of cylinder 1 against the mark on the turning wheel. 2. Check that power is supplied to the inter- mediate box. ‘The green indicator should now light. For adjustment of the angle encoder, see Procedure 905-8.3. When referring to this page, please quote Procedure MS0508 Edition 0204 Page 1 (4) MAN B&W Diesel AIS905-8.2 Angle Encoder ze Dismantling Ban Remove the inspection cover. Cut the cable tie which holds the rubber damper around the coupling, in the end nearest to the engine, and loosen the cou- pling. Loosen the three adjusting screws on the front flange, and remove the angle encoder and the coupling, Screw out the flange screws and remove the encoder housing. Take care not to dam- age the guide pins. Page 2 (4) When referring to this page, please quote Procedure M90508 Edition 0204 MAN B&W Diesel A/SAngle Encoder aw Adjustment 1. Tum the crankthrow for cylinder 1 to TDC. Check the TDC of cylinder 1 against the mark on the turning wheel. Check the TOC position with the pin gauge on the crankthrow, cylinder 1 Note! 905-8.3 Before using the pin gauge, check the measurement from tip to tip with the value stamped on the pin gauge, and/or the check-marks stamped on the fore end of the cylinder frame. 2. Loosen the adjusting screws which fasten the encoder to the housing. Slowly turn the encoder until the green indicator lights on the intermediate box. Tighten the screws to secure the encoder in the correct position I When referring to this page, please quote Procedure M90508 Edition 0204 MAN B&W Diesel AS. Page 3 (a)905-8.4 Angle Encoder AN Mounting saw TT Page 4 (4 3 Mount the encoder housing. The two guide pins indicate the correct positioning of the housing. Tighten the screws. Mount the angle encoder and the coupling Tighten the coupling, and mount new cable ties around the rubber damper. Adjust the angle encoder according to Pro- cedure 905-8.3. Note! The adjustment will be easier if mounting is in the same crank position as disman- ting Mount the cover. When referring 10 this page, please quote Procedure M90508 Edition 0204 MAN B&W Diesel A/SAlpha Lubricator System $903.2 Check and Adjustment of Index Transmitter acd Check and adjustment of index transmitter [w When referring to his page, please quote Procedure 5903-25 The following guidelines are relevant for the adjustment or replacement of the in- dex transmitter on engines in service. Adjustment of index transmitter Adjust the index transmitter electrically until: The minimum index trom the engine side control console corresponds to 4.5 MA. ‘The maximum index from the engine side control console corresponds to 19.5 mA, See instruction $903-21, Testbed Commissioning Procedure. Calibration of index signal Adjust the fuel rack on the engine side control console to an index corresponding to 50% load at testbed conditions (rele- vant values can be found in the shoptest report) Navigate, via the HMI panel, to the Index Adjust menu. Choose either the generator curve or the propeller curve, depending on the meas- urements obtained on the testbed, vanes] seein Adjust the fuel rack on the values can be found in the po ease} mle (Passwore) Navigate, via the HMI panel, to the Index Adjust menu. Choose either the generator curve or the propeller curve, depending on the meas- urements obtained on the testbed, Select 100% in the Menu, and press [ENTER] The index transmitter has now been adjusted. These settings are only 100% valid when running on diesel oil. When running on heavy fuel there can be a minor offset, which can be compensated for by adjusting the mechanical connection from the fuel rack to the index transmitter. "Page # (1) MAN B&W Diesel A/S, Copenhagen, DenmarkIndex M ANI Baw Operation Commissioning Maintenance Components Electrical WiringCylinder Lubricator Assy Plate mas P390307-0008 When reterring to this page, please quote Plate P90307 Edtion 0008 Page 1 (2) MAN B&W Diese! A'SPlate Cylinder Lubricator Assy 90307-0008 san Item D . [item tt vcripti nae Item Description He Item Description 700 | Screw 018 | Accumulator membrane 031 | Shim 043 | Distributor block 055 | Studs 067 | Nut 079 | Coupling, minimess 114 | Ball valve 126 | Coupling 138 | Distributor block 151 | Stud 175 | Spring pin 199. | Lubricator 209 | Screw 222 | Accumulator membrane 234 | Shim 258 _| Distributor block 271 | Plug screw 295 | O-ring 317 | Non-return valve 329 | Disc 330 | Cirelip 342 | Plug screw 366 | Terminal box, complete 378 | Screw 391 | Cable 401 | Oring 413 | Inductive sensor, complete 437 | Steel ball 449 | Spring 462 | Screw 474 | O-ring 498 | Coupling 508 | Adjustment screw 521. | Spacer 533 | Cover 545 | Cylinder block 887 | Cover 569 | Cylinder block 570 | O-ring 582 | Spring 594 | O-ring 616 | Screw 628 | Screw 653 | Plunger 665 | Cylinder housing 677 | Actuator piston 690 _| Solenoid valve, complete Page 2 (2) When referring to this page, please quote Plate P90307 Edition 0008 ‘MAN B&W Diesel WS.Cylinder Lubricator - Intermediate Box Plate Baw 90308-0010 O13 When reterring to this page, please quote Plate P90308 Edition 0010 Page 1 (2) MAN B&W Diesel A/SPlate Cylinder Lubricator - Intermediate Box 90308-0010 aan may a Item Description em Item Description : at iP Ne cription 013. | intermediate box, complete 037 | Electric enclosure with cables 049 | Printed circuitboard 062. | Light emitting diode Page 2(2) When referting to this page, please quote Plate P90308 Edition 0010 MAN B&W Diesel A/SCylinder Lubricator Unit Plate MAN B&W Diesel 90307-0035 When referring to this page, please quote Plate P90307 Edition 0035 Page 1 (2)Cylinder Lubricator Unit Plate 90307-0035 MAN B&W Diesel | fe Item Description ae Item Description | 018 | Ball valve | 031 | Stud | 043 | Hydraulic block 055 | Nut | 067 | Plug screw | 080 | o-ring | 092 | Intermediate pipe 414 | Adjustable elbow coupling 138 | Ball valve 451 | Stud 175 | Lubricator, complete 199 | Hydraulic block 209 | Gasket 210 | Membrane accumulator 234 | Screw 258 | Adjusting screw art | Oring 283 | Spacer, tubular 295 | Cover 305 | O-ring 317 | Non-return valve | 329 | o-ing | 330 | Cylinder block | 342 | O-ring 354 | Spring 366 | Plunger 378 | Actuator piston 391 | Straight stud coupling 401 | Screw 413 | Screw 437 | Cylinder housing 449 | Solenoid valve complete 450 | Screw 474 | Membrane accumulator 486 | Gasket 498 | O-ring 508 | O-ring 521 | Inductive sensor 533 | Cable 545 | Cable gland, complete 569 | Housing 570 | Plug 582 | Plug 594 | Screw Page 2(2) When referring to this page, ploase quote Plate P90307 Elion 0035Index Operation —_ Commissioning ee Maintenance Components Electrical WiringArrangement of Angle Decoder Plate Baw P90503-0017 228 170 182 204 When referring to this page, please quote Plate P90503 Edition 0017 Page 1 (2) MAN B&W Diesel A/S.Plate Arrangement of Angle Decoder 90503-0017 lan nan a Item Description ead Item Description 013. | Measuring instrument, axial vibration damper 037 | screw 049 | Angle encoder 050. | Housing 062 | Screw o74 | Shaft 096. | Intermediate box 098 | Coupling 108 | Damper plate 121 | Cable tes 145. | Tools 157 | Packing 169 | Screw 170. | Spring tock 182 | Spring pin 204 | Shaft 228 | Packing 241 | Washer 253. | Shiold 265. | Packing Page 22) When referring to this page, please quote Plate P90503 Edition 0017 MAN B&W Diesel A/S.i“SEG TEE) f) )o) Gao GSa0= Se sleiste][g]é ao Fees alle © nes © nin ae] osir | [ewe ar lp © | [e[eprfor>e ] w]e on ar ur - | © er er ter zee vee © | © © as ne © vert =a ozS=ZOS Veco, waivsTea ew OAL eS ewmanvaren| ETS] aT ewe WES SIO Ter Er sus nves seriyonnnn09 anes @27oatese a [-2esrere] aman |[Seemaive nen] eB SOE eee =e Rear aee wa) avs sciaet nya4 FLOSPELO] maT Taw OATS gE premcnneen TT TE Tee Re py Ze j ase 77 Pa i =a pag ; t ies 2] ers | ee cers] | fees eszese? er ets 8s Bs 28 Perri eesyas Perr Se Bet ae 18 i; GE Fea Eee ee ce ea 24 ii # ge Soe s TTT ripe tae ea 2d eles Sm gy Soggy! 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SANKYUK 2-DONG, BUK-KU DAEGU(702-012), S-KOREA TEL : 82-53-384-4894 FAX : 82-53-384-0030da » 1, Slate 2. A711] wey pa ° 30 & 2 He + 0 abe 0 o + on Hi z s we i a oA a = ° 4 on & BD iy Ae ® Hh om 9. HA] gl Ses let ae, 10, S201 INDEX SPECIFICATIONS GENERAL CONSTRUCTION OF YURIM TURNING GEARS MAINTENANCE LUBRICATING OIL OPERATION PROCEDURE FOR MANUAL OPERATION REPLACEMENT OF PARTS DISASSEMBLE & ASSEMBLE | INSTALLATION MAINTENANCE BRAKE ASSEMBLY DRAWING SPARE PARTS & SERVICING PROCEDURES1. SAlAret 2.2 Kw,63 440V,60 Hz ‘OC 90 V BL 1/1151.8 121+ :0.998 R.P.M. 25 :2000 Ko-M (4% 2700 Ka-M (21CH) 2. 7/12] aebay 2s SBE Ete 7101S (OSE “Elst D101 2k t) ZRSH| EWS VO! OVA SoH At INS SH MND ATMO SOL 2s SIG1 2.3.4 TS DOA LASOHAL, 2 EF QSD SS BRU HOI TIO Ari ator BS “RAS BRIO SHSM O1ROLAICE S252 sige a WADE Se! ay Dis OFC 2 HOS DSAMS HAI VAIO 18 DEYSH UPAS NG SA 10121 EN SAS Sede FNS WAG DAD OSANS A BRS + USS PES USM HUOU Bea EAS wa Se Sse 2 ANBMO! AS SAMS SEA AWM S Bure APSSECIOF SICH ABINAS BA SSA OMA AB SSL sae Nee BAI AOA SAS A SS AMA 4 UC TaD Be S23 oA NBS ASE ASN ewe HOt RA WC OSS 4B Ss, EUS + OIC} AI SMS] SerOlH O10! Bel= ML 7101 *tSAL91= HAND WHEEL(YU~ S0MC~C-28)@ {SAI Bu B31 LOCK LEVER(SOMC-C-45)3 S402 AS OS LOCK BRACKET(S0MC-C-44) ol LOCK PIN(YU-SOMC-C-52)3 dl DEA2! SOO! SHC} 1. SPECIFICATIONS 1.MOTOR 2.2 Kw,6P 440V,60 Hz 2. BRAKE DC 90 V 3.REDUCION RATIO:1/1151.8 4.0UT PUT SPEED :0.998 R.P.M 5.OUT PUT TORQUE:2000 Ko-M (NORMAL) 2700 Ka-M (MAXIMUM) 2.GENERAL CONSTRUCTION OF YURIM TURNING GEARS YURIM TURNING GEAR(hereinatter referred to as TURNING GEAR) is first reduced by R- oller chain and sprocket as shown Assembly Drawing. The reduction of next stageltrom 2nd to 4th) is getting in the gear box. T- he construction of Turning Gear consists of planetary gears which has simple, high precision and reduction ratio. The output shaft can be rotated either clockwise or anticlockwise, Each gears is manufactured in high precision with good materials and optimum heat treatments(hardening). Also, Turning Gear has device to relief first i- mpulsion when it is started up. Even if y- ou are an unskilled operator. you can han— dle it easily. however, An improper handl~ ing may be caused an unexpected trauble,t- herefore you must read operating manual o- ertainly and carefully before starting Tu ring Gear. All the time, Turning Gear sho— uld be used at normal condition. it is ri~ ght. if only it can be used momentary at Max.tourque condition may cause the life of Turning Gear to be shorten, resulting in the damage of E-Motor & Bearing. When operating the HAND WHEEL (YU-50MC-C-28) which, operates the pinion gear which is fed up in the flywheel gear of the engine main body certainly after making stand LOCK LEVER(YU-50MC-C-45) with hand weaving, after fixing LOCK PIN {YU-S0MC-C-52} certainly in LOCK BRACKET(YU-SOMC-C-44), must operate.3.474] BE BL ANE Woge sae FFD Z2Sei Uo] Sa Aas S402 = BE x JO 2B eg NBA NA S50 SSS SASH PT HOS oAtol act BCS Bel gt 4 SOILt Bees HAS a2) ERE 250 2 4.287 Eves OHS] DOr A LHe D101 SetoH S16 BM SHO NBD Sea Mow DE WH HERS DeA SA0oi AS SU. Oe WAS SRE DPSS #8 Sno Sec NOMA WFO SBS ANS ASO! SAL HD SE O10! Amst Sao1 Badal DO! SENGIA SPRL DOH S1SLOL 2 AFSIONOF CSI FAS AAO AA 1 HBO! Ia] BEe SRarcior sch DOA LHSES] NOH SAIS Sat 140 18] DHS SS| SS AAA ABS HL AWS SHS UWA SMCS OB DIC! DASFOLOF SICH (OVA UFOS BE MAS TO] Ba S101 26.) 35a! Bele ze 4.8 21(YU-S0MC-C-01) BOA, SUES SSO MM Sees FOSCh OL GH DEOL A LHSEOH BID WHA MESS AUS AIC 3.MAINTENANCE Tighten loose bolts & nuts and adjust the tension of roller chain. Check the level of gear oil and supply oil if necessary. Pay attention to noise, vibration and abn- ormal rise of temp. during initial start. The temperature of T/G casing may rise mo- re 10% to 40 than that of ambience, but it wilt be kept up the optimum temperature when T/G is reacheo a constant running. in the event of excessive heat. noise and vi~ bration during running, stop immediately and check it. Try it again alter repair Apply the grease and lub.oil to the outsi~ de moving part from time to time. 4,.LUBRICATING OIL The cif supply method of the intemal pa ts of gear box is self-lubricating(oil b~ ath system) and Roller chain is adopted by Grease method. Kinds of oil & grease and the times of exchanging oil follow “LUB O- iL LIST’. Gefore operating, supply the de- signated lub.oil so that oil level is just above the indication line of the oil gauge Apply grease to roller chain once a mon th at least. Renew gear oil once a year, However, renew gear oil once a half year under the severe condition or in order to remove foreign particles after initial ru~ nning. (The magnetic bar is attached in t~ he gear box to remove foreign particles) Exchanging oil 1. Loosen drain plug.(YU-SOMC-C-01) 2. Drain out the oil throughly. 3, Retighten drain plug after sealing the screw with Teflon 4. Loosen the air vent plug.(YU-SOMC-C-01) 5, Renewed the oil into the gear box through the pipe.euy o! mal] LUBRICATING METHOD AND INTERVAL, we : ] information) BE eevee | ow ay - | guentityor |“ method of pea ain | quantityof | fitvitating | _—_‘interval position | Wb. | | ase | wig tA Us i Worst Wise | APPROX.IB£ | OW BATH =| ONCE A YEAR | Holo 1 BSH | i ao ed asx | 6 NBO Lal chain and APPROX. 150 ¢ - oa ane GREASE SIX MONTHS ASIS SBR Practicable application lub.oil MAKER GEAR OIL GREASE YU KONG | SUPER GEAR EP 680 Esso SPARATAN EP 680 GULF 1 EP LUBE H.0 SHELL ~ OLE SHELL TELLUS OILet Fertsol Ss oa a ASI ANZSI IM BAL DAS) O2 +5 Hi48S0i BOS HS 1S He ee co S~ sa ‘olor 2 a ag MASE = mua 5-2 Sa 01 318(YU-S0MC-C-56-Me)21 | AWS MNS SH ICE 5-3 2012 aX! SS(YU-50MC-C-56-810) 2NBNMY EOS Sei FIO, Ws(B3)O1 221(89)S SSAA Salo AI AIC 5-4 2) 2a ses YU-50MC-C-001 S20 FOS BAS AM BOI WSS AS SRO BSAlzt & Sect 5-5 FSEN0 VSS SHES ARIAS AZ AS SAA 5-6 agase (2tch 611 MOS HEA Sa} aH = S(YU-SOMC-C-56-810) 20S SAI WHOS Set a BBS) a014 31UH(YU-S0MC-C-56-M8) EA Ee sols S BSS D101 @ Re HBSS B 6-2 SE HORS BERAS ABPOE IHS SEC 6-3 2S MB Awol A(YU-SOMC-C-38) 0 = 0 2 lo lo ia BME BE S MoH 3 NABI: HAWS 2H 2! 6-4 QU YS TSHEEM NS 8201 OE DPI CHF SSO HS + woos 5. OPERATION PROCEDURE FOR MANUAL OPERATION Operate emergency method as follows wh- en E-MOTOR can not rotate well by damage or the failure of electric power. 5-1 Extract the fixing pin of handwheel. 5-2 Loosen and extract the bolts(4ea) of brake cover(YU-SOMC-C-56-M8), 5-3 By tightening the bolts(YU-50MC-C-56-810) to the clockwise, the pushing disc(B3) pushes the spring(B9) and the brake is released, 5-4 Turn the handle after engaging with ou- tput shaft as Drawing(YU-SOMC-C-601). Return to the original state in the op~ posite order after completing manual op~ eration 5-6 Check the contact between pushing disc( 83) and friction disc(B2) whether it is closely adhered(Before normal operation. the contact will be come close by tight~ ing bolts(YU-50MC-C-56~B10) to the anticl~ ockwise.} Operate 1/G after re-assembli~ hg the brake cover(YU-50MC-C-56-M8)certain oy. 5-7 Fix the handle of output shaft to the original state. 6.REPLACEMENT OF PARTS 6-1 As gears & shatts are of special design. contact us in case of their replacement. 6-2 Most of bearings are commercially avail— able because of using standard production 6-3 Should be noted that spaces(YU-SOMC-C~-38) are of special made by our company. Request to our company if necessary 6-4 With regard to the seal, A considerable deterioration may be developed owing to surrounding environmentsBNO! DUI BIA. Fe Hogs SLs A AOS DAsCh MM ALONS ASS EDI TILE DE BAYS UT SSS sce TI eal Nol He seMol Bre! iSO NG Baal Olas! # Haha za SYS Baa ODSHe 41 Le Ch SHOAL BSI 2 FBI ARS Bla Balore SAMoH Ue! See ect OO BeOS a HAS weld 21k BD.2M Mt as Hot SSA SBS Hs ua) st 2s S68 SAM Sos D. Se ech AS SHIA BOS SHS was SO PAS SEI Ose # CHA SHCh 110 (e a #0 yon Ol EE SCh S)EOHALON HALE 9 A) 1OMA LISS a Bein GSS SSNS UNOS E12 11 3tM(TAB WASHER) MBaICt 5) 2101 WIS UA S warn Sect wee THREE BONO NO. 1215 FORMA GASKET NO.2 SILICON BOND. BRE NOMA HOI Bet BAS UW SSG H Soro sce exe ace a (Ets) WOH #2 A1SLOIOE a sil gee a S19) F101 BSOML) S2 eo] AIS USS IC 2peret BASE STE 71019 +98 Box o2 38 + YOUNES Bue Bee Rae +6 ACh temperature and contamination of tub.oil & other reasons. Replace the oil seal with new one period— ically. Also, should be replaced the oil seal when the parts included oil seal are disassembled for some reasons or ethers. uring replacement. pay specially attention to the turnover of the lip and the direction of the oil seal as well 7.DISASSEMBLE AND ASSEMBLE 7-1 Disassembly 1)Disassemble T/G after reading over operating manual in accordance with Assembly 2)Make clear the purpose of disassembly in order to minimize parts disassembled 3)Disassemble Turning Gear after marking if there is no match mark on a part to be disassembled. 4)Neither strike parts strongly nor pull each part forcibly 5)Taps are provided covers and other parts to facilitate disassembly and transportation. 6)In case of any trouble during disassembly, Check the drawing carefully and try it again 7-2 Assembly 1)Always keep clean surrounding 2)Each parts should be completely washed out with cleaning oil and made assembly after applying grease or lub.oil to defective parts. 3)Check and assemble parts in order atter putting together the alignment mark. 4)Apply three bond or equivalent to threads in the gear box to prevent loose bolts from vibration and other reasons 5)Flenew cover gaskets when assembly. Gear sealing : THREE BOND NO.1215 FORMA GASKET NO.2 SILICON BOND. 6)Once assembly is completed, check if Turning folates smoothly 8.INSTALLATION Turning Gear should be installed on a strong bed and mounting bolts & nuts tightened throughiy. Should be noted that an improper installation may cause excessive noise or vibration. resulting in aconsiderable decrease in the life time and damage.7b sel i 9. Al Yt Sis ELE 9. PROCEDURE OF MAINTENANCE AND SERVICE es sds Aas | ZEA] OH | Fol aol sues | Y [Aide seh le |SUseel Woe se ve i — | plotsts | 2 2 |?! 800! | 2 I z r a eet, Se H91 Oe! De Se iM Sol se were | cee OWA 2] ee waa = = = TAZel BEI a oa AIS R71, olMlsh S eee wert ane pean « Be lala ZAslaeS erst All lsat | ag fo = 4, [Mel 282 oto 5 Ael* jaar seer ayme ORES! O27} st | oe | | PEE pita ote aren (HE BA or aa yaa ae, cae | — al | opaeet Ajolol 1B M(B,71 ol@al x71 oe ol 221 8.9 Bel a wa} IS] BAT SA SAN Salo 2x1 Aalst Bal Holajs mee 6g ib = Diol stout xIcbal - JIE} lagaiigiz go aSol 2 aa[ CHECK | VIBRATION vibration is present | CHECK ITEM | pont METHOD REMEDY | INTERVAL AND POSITION | la cunanry|OM#E4 8 OH16 tenn tne same oi. _—_joecasion i ! {demands | L t = —— nn | |Keep the temp.to 80° Stop 4. TEMPE- |Check the temp. of |T/G, len RATURE |G/BOX casing |Operate it again after remedy in |GET LUB jcase of abnormai rise. lees \Take sample oil from |Renew the oil in case of | CLEANN- |drain plug and check lincluding — ESS the contamination of ‘foreign particles or ieee foil ____ deterioration. ok Ollseatpateial input Replace oil seal and gasket with |& output shaft 1 LEAKAGE |G ees ar (08H &month sone in case of leakage casing cover | ssua ieee TGHTE- | Be IGWTE™ Check the bolts. _|Retighten loose bolts occasion BOLTS ! idemands ~ (Check the bolts | jAs DAMAGE |whether damage or eee een, occasion | of damage or crack | fine or | ge os ide 1 As TENSION [Gheck the tension of ees with loceasion CHAIN | Nee demands GREASE |Chain toler surface. Apply grease to chain roller. 6month eee es | Sane eee ee — 7 iCheck it whether |, Replace it with new | Friction discdamage or wear | one in case of excess— ‘6month jdown. | ive wear out or damage i BRAKE ite 2 ee 4 CLEARANCE {Check clearance of | Re-adjust gap of it [Pushing disc & coil, with fecler gauge. jf oe thers) 2 eee ere eg uae | Slookl/c wemediaiely,10.2] 0] 10-1 #2 Yt St E24 (YU-5OMC-C-56)2] TEE ALAloll S} 228 (B8)0l VE(BS)S UT VHS O}SEH(B2)2+ Bhil SAts|ol BS (Bs)oH Sfetof ASA) GSS SO} Bich. BA(B4)ol AHO] 7psHA/ Ol APEYo] way S10] UES SAM OSES afof SIMO] SASS 10-2 Beto] Fl ABD} OFAHEE Bet Afolol|= 0] BAO] So} JIA St % aOrStch 10-3 SAS) EH © 24 (YU-SOMC-C-56)0 A 44 £(87) 474 SOWA QHD wel Afols| Sal= 0.4 mim, 2B ELS MOE So ASa7} wa SA SIS Bt 2h 10-4 #E9) Dx OPES] OF IP ALSIILE SEES! AP Bit] S S}Of Of ShO4 AE EE AL Bal 2S HAS stork step ety 1.28 So (38) 10.BRAKE 10-1 Construction and Operation The pushing disc(B3) adhere closely tog ether with friction dise ordinary times. However, if electric power is supplied to the magnetic coil(B4), Friction disc(B2) is separated from Pushing disc(B3) by Ma~ gnetic power, So, the brake is released and T/G can be turned freely. 10-2 Pay attention to handling Check and keep clean the space of pushi~ ng disc, friction disc & coil. 10-3 Adjustment of Gap Adjust the gap of pushing disc and coi! to 0.6mm evenly 10-4 Replacement of parts Replace triclion disc wilh new ane when it wears out excessively. After exchangi- ng it, be sure to readjust clearance. 11.ASSEMBLE DRAWING (Seperately appendix) 12.SPARE PARTS {Seperately appendix)@ Humco INSTRUCTION MANUAL FOR AUXILIARY BLOWER WITH MOTOR HYUDAI MARINE MACHINERY CO., LTD. ne- CONTENTS-— i AUX-BLOWER A. OPERATION 1. PREPARATION FOR OPERATION 2. STARTING INSPECTION 3. TROUBLESHOOTING B. MAINTENANCE 1. T/C REAR SIDE MOUNT TYPE for B&W ENGINE 2. TIC AFT SIDE MOUNT TYPE for B&W ENGINE 8. T/C REAR SIDE MOUNT TYPE for SULZER ENGINE 4, INSTRUCTION FOR DISMOUNTING & MOUNTING OF IMPELLER @ ELECTRIC MOTOR A. OPERATION 1. PREPARATION FOR OPERATION 2. STARTING 3. STOPPING 4. CARE AFTER STOPPING 5. TROUBLESHOOTING B. MAINTENANCE - PERIODICAL MAINTENANECE CHART . MAINTENANCE AND REPLACEMENT OF BALL BEARING ON THE MOTOR |. DISASSEMBLY AND REASSEMBLY OF THE MOTOR, |. DRYING. TRIAL RUNNING OF THE MOTOR REFERENCEM@ AUXILIARY BLOWERA. OPERATION 1. PREPARATION FOR OPERATION Alter the fan is left at rest for a long time or subjected to dis~assembly and assembly, carry out the following inspection. (1) Make sure that there is no foreign matter in the casing. (2) Examine if there is a piece of cloth or another thing which may easily be sucked in, near the suction port. (8) inspect the rotating parts for any contact with fixed parts. (4) Check the power source (Voltage, Gycle). Don't supply different cycle, power source with motor specification. 2. STARTING INSPECTION After starting the fan, carry out the following checks, (1) Check to see if the rotating direction in corret. (This check is not necessary when no reassembling has been carried out.) (2) Check for abnormal noise (3) Check for abnormal vibration. 3, TROUBLESHOOTING When the fan is out of order, care for the fan according to the following table. No. Trouble Probable cause Remedy Inspect the impeller and related parts to locate the cause. Mechanical rastraint Replace with spare bearings. Impossible or Seizure of bearings Check for motor winding difficult to start nee Trouble of the motor disconnection, insufficient voltage, cable disconnection, faulty starter connection, etc.Trouble Probable Remedy Insufficient Dirt and other foreign Clean the impeller. capacity or matter attached to the motor impeller, overload Rotation reversed, Correct the rotating direction Air leakage. Check the air duct connections ect. Impeller damaged. Replace the impeller. Insufficient or Check the motor. excessive rotating speed. ‘Abnormal ‘Abnormal speed Check the motor. vibration Foreign matter Remove the foreign matter. and noise Loose installing bolts Tighten the installing blots. Bearing damaged Replace with spar parts. 4, IF YOU HAVE ANY DOUBTS, PLEASE DO NOT HESITATE TO CONTACT. HYUNDI MARINE MACHINERY CO., LTD. 602-15, GAJWA-DONG, SEO-GU, INCHON CITY, KOREA. (http://hmmeo.co.kr) TEL : +82 - 32 ~ 583 - 0671 FAX : +82 ~ 32 — 583 - 0674B. MAINTENANCE 1. T/C REAR SIDE MOUNT TYPE FOR 8 & W ENGINE (1) MOUNTING OF ELECTRIC MOTOR ON B & W AUXILIARY BLOWER. All item numbers refer to drawing No. H-REAR-01/02 1) Place the motor on a table or flat so that shaft is in a horizontal position and motor shatt is sticking out of the foundation. 2) Remove the groove from the motor. 3) Lubricate the motor shaft with oil or grease. 4) The sealing ring to be pushed over the shaft. 5) The motor to be bolted onto the motor plate. The motor blots should be packed carefully with teflon or fluid packing substance. Do not forget to placetheterminal box of the motor correctly in proportion to the drain hole. 6) Mount the gaslock~seal (item 11) in the stuffing box (item 7) the lip towards the impeller, If the Gaslock—seal has already been mounted~check the seal lip, 7) Place the Gasket (item 8) between motor plate and stuffing box (item 7) Carefully push the stuffing box over motor shaft and sealing ring without damaging. the Gaslock ~seal. The stuffing box will automatically centre and then be mounted by means of 6 bolts with washers made of carbon steel. Lubricate the lip carefully with grease from both sides. 8) The groove should be shortened to fit the projecting part of the motor shaft 9) The impeller should now be caretully pushed aver the shaft, while taking care that the groove and the key way are next to each other. -6-When the impeller cannot be pushed up any further, if should be pulled into right position by means of a bolt. 10) The impeller should be tightened by using a think washer(5~6mm),a lock washer, and a bolt. NB : The impeller has been dynamically and statically balanced from the factory and must not be damaged in any way 11) Th inlet cone to be dismounted. 12) The GASKET (item 5) to be placed in it's right position 13) The motor plate to bo lowered onto the fan hou \g and tightened by means of bolts with washers made of Carbon Steel 14) Mount the inlet cone. Take care, however, that the distance be ween the impeller and the inlet cone is the same all the way round. 15) Turn the impeller manually in order to check that it runs smoothly. 16) The motor nay now be started in order to check the fan for excess vibration and jarring sounds. with an accelleromter it should be checked that the motor has an effective frequency below 2 mm/sec. Measurements should be made horizontally and vertically on a level with the motor bearings The impeller has been balanced in accordance with ISO 1940 and with quality class Q better then 6.3. Testing period 15-20 minutes.OOWNH ava Y_10-e3y-H “war Zt zzc0 v0] @OQQQ® Xt Os Eat ir a (a 1 ASwemaetiey OONNH EE IV Z0-wvau-4 Ae Sry) |] i I | | q / /| dddbsd ds bbb dddss2. TIC AFT SIDE MOUNT TYPE FOR B & W ENGINE (1) MAINTENANCE OF B&W AUXILIARY BLOWERS, ‘The auxiliary blowers usually consist of the following main components which are shown on drawing No. H~AFT—01/02/03 1) Blowers 2) T-connection. 8) Electric motors. Your attention is drawn to the fact that some of the minor types of diesel engines do not require compensator and suction box. 1) Blower. The blower part consists of the following, Scroll housing made of heavy steel! plate. Impeller in special welded alu. ~ alloy. Suction cone. Tightening device, intended for pressure of up to § Bar Motor plate. Motor. 2 ‘T-connection. The T~ connection, which is made of heavy steel plate, serves as connection piece between the two blowers as well as connection to the outlet pipe of the air cooler. ‘The pressure opening surfaces of the two blowers have a parallelism better then 0.1 mm. The parallelism is maintained by 8 conical guide pine, which should be treated carefully when re~mounting. -10-(2) MOUNTING OF AUXILIARY BLOWER 1) The two fans have been mounted on the T~connection from the factory and should not be separated, 2) Lift the whole unit to its right place. Tighten blowers loosely onto diesel engine. Tighten all bolts properly. 3) Mount the suction pipe from the air cooler. 4) The unit is now ready to be put into operation. 5) During operation the mechanical seal, which consists of Sealing ring (item 10) and Gas lock seal (item 11), will leak a bit considerable leakages indicate that the Gas lock seal is worn out and should be replaced. During this replacement the Sealing ring should be turned so that the seal gets to work at another spot on the sealing ring NB : The fans are in right and left position respectively, wherefore the impellers must not be reversed. The impellers are marked with the serial number of the fan. -u-~ paidy uouDuL gegen OONNHG | LAV | ca a]V t0-uv-4 ae waMOTe “KNW 40 9MG TwNOUD3S aaa @ QQ800 8 | T T 0 oe L Aff /f 1 vA VA J // | | GSSSHOH O re‘Dalay UOuDu] i Zopgen OONNHSP| LAV * ayaa e/a a am B08 Baoan [Seb age amuaro| 27 £0°¥0| }_ _ et \ es oe amet —aseratr Soe | mre ! tome | a te id, ae ae | werea + poate _® ae worss | x09 ONUsUs| —L at Fon aa se] @ — ae Sy 28 ‘W/s'n0a| 6 a, + fase | es ar} 7 [She] as soo] 11 ae eral Sov eal Se | — aoe | oy | wow | ire WS'Twal 91 | oat | aera eat ate ee} wer oe [188 [Pa moved £23. T/C REAR SIDE MOUNT TYPE FOR SULZER ENGINE (1) MAINTENANCE OF SULZER AUXILIARY BLOWERS ‘The auxiliary blowers usually consist of the following main components which are shown on drawing No. H-WGH-01/02/03 1) Blowers. 2) Joint duct: 3) Suction box 4) Electric motor. Your attention is drawn to the fact that some of the minor types of diesel engines do not require compensator and suction box. 1) Blower. The blower part consists of the following, Scroll housing made of heavy steel plate. Impeller in special welded alu. — alloy. Suction cone. Tightening device, intended for pressure of up to 5 Bar Motor plate Motor. 2) Joint duct The joint duct consists of two mounting flanges. 3) Suction box. ‘The suction box consists of a heavy steel box direct mounting onto the main motor, plus and inspection cover. The function of the suction box is to combine outlet of the cooler with the inlet of the auxiliary blower, -15-(2) MOUNTING OF AUXILIARY BLOWER 1) Mount joint duct onto suction box. (Small flange towards suction box.) 2) Mount suction box onto diesel engine. 3) Lift the blower to it's right place and push it towards the joint duct. Tighten blower loosely onto diesel engine. Tighten joint duct onto blower so that it does not suffer any harm The unit is now ready to be put into operation. ~16-OOWNH HOM ‘ aaees ‘OOWNH HOM EV zo-Hom-H Nini 4 /f /| hb bs \ ee € \dausten OONNASS ; ‘EY £0-HOM-H = sang SAD TONGUNWR ne a zzc0'v9 a — “ = a4, INSTRUCTION FOR DISMOUNTING & MOUNTING OF IMPELLER (1) INSTRUCTIONS FOR DISMOUNTING OF IMPELLER ON AUXILIARY BLOWER In the following it is recommended to see drawing No. H-REAR-01/02, H~AFT~01/02/03, H-WCH~01/02/03 1) The electric connection of the motor to be dismounted 2) The bolt on the motor to be loosened, and motor, motor plate, and impeller to be raised from the scroll casing by means of a stable lifting device 3) The bolt on the motor shaft to bo loosened and removed together with the spring plate: 4) Dismounting tool~as shown on the enclosed sketch No. H-TOOL~01 to be mounted on the hub of the impeller by means of 2 bolts which are screwed into the belonging threaded holes. 5) A strong disk is to be placed between the motor shaft and the dismounting tool in order not to damage the threaded hole in the motor shaft. 6) The impeller to be carefully drawn out by means of tightening the middle bolt. 7) Under normal conditions the sealing ring remains os the motor shaft However, it comes of when dismounting the impeller, the motor plate must be dismounted from the motor and the sealing ring must be mounted on the motor shaft. The motor can now be mounted, however, please take care not to damage the sealing ting =20-(2) INSTRUCTIONS FOR DISMOUNTING OF IMPELLER ON AUXILIARY BLOWER FOR MAIN DIESEL ENGINES In the following it is recommended to see drawing No. H-REAR-01/02, H~AFT~01/02/03, H-WCH~01/02/03 Please note that the new impeller has been statically and dynamically balanced from the factory, and therefore the impeller must not be exposed to thrust or other overload, 1) Grease the motor shaft with oi. 2) The impeller to be pressed over the motor shaft by means of a bolt and a washer plate. Please make sure that the groove fire opposite the key groove. 8) The impeller to be held by means of the original spring plate and bolt 4) Motor plate to be lifted up carefully from the foundation and to be turned horizontally 5) The packing between the scroll casing plate and the motor plate to be examined for porosities and cracks. In case of a defect packing has to be replaced. Please use a corresponding quality. 6) Impeller, motor, and motor plate to be mounted on the scroll casing plate once more. Please or take precautionary measures in order not to damage motor or impeller resulting in unbalance. 7) The motor can now be electrically connected again. = 92-@ ELECTRIC MOTORA. OPERATION 1, PREPARATION FOR OPERATION If the motor to be operated has been at rest for along time or disassembled and reassembled, pay attention to the following. (1) Check to see that rotary parts such as fan are secured positively, motor installation is satisfactory, and there is no abnormality on the machine to be driven by the motor, (2) Check to see that terminal connections of the motor are sufficiently tight, and ingulation distance between dissimilar poles and ground is not badly small (3) Check to see that there is no contact between rotary and stationary parts. On such motor that has small gaps between the rotor and the stator, both may be brought into contact by wear of the bearing, and the stator coil burned out by the resulting heat generation, (4) Check to see that bearings are normal. (8) Check to see that there is no ingress of dust or dirt of foreign matter in the aparatus. (6) Check to see that there is no part of deteriorated insulation (7) Measure the insulation resistance. If the measurement is lower than specified, dry by proper method, (8) Check to see that the machiner to be driven by the motor is ready for operation. (9) Check to see that the direction of rotation of the motor is correct. If the rotationg direction is reverse in the case of the 3 phase motor, change the connection of wires for two phases with each other. = 24-2. STARTING After finishing the preparation for operation, contirm the load to be ready for starting. Then, turn on the power switch, and after signalling to the rotary part, operate the operate switch to start the motor points requiring attention during operation are as follows. (1) The condition of load, and temperature measurement. If the motor is provided with an ammeter, the condition of load can be known by use of meter. If no ammeter is available. Hear sound or know the temperature of the stator frame. Note that if an overload is sustained, the temperature of various parts exceeds the specified value. ‘Temperature Rise at AC Machine Stator Windings Rated below 1, Table 1 (co) TYPE OF MACHINE pute | MEASURE Not totally enclosed Totally enclosed MENT CLASS OF INSULATION F E B F E B i 75 55 60 80 60 65 NK (1979) R 90 65 70 90 65 70 ABS (1978) R 95 60 70 100 65 75 T 80 85 60 80 85 60 LRS (1979) R 90 65 70 90 65 70 i 75 585 60 75 ‘85 60 Nv (1980) R 90 65 60 80 65 70 ‘T=Measurement by thermometer R=Measurement by resistance(2) Sound ‘The sound of the motor gives a good indication of the condition of rotation, Especially, the sound of the bearing part is useful in determining troubles. To hear the sound of the bearing part correctly, apply a metal bar, one end th the bearing part and the other to the ear (3) Vibration ‘The vibration give another indication of the condition of rotation Abnormal vibration of the motor during operation is caused either magnetically or mechanically. Probable magnetic causes are an air gap unbalance between the rotor and stator which causes a magnetic attractive force to be exerted between cores resulting in a vibration of the rotor, ground or wire break which causes a current unbalance to develop, misalignment of magnetic center, ect. Probable mechanical causes are broght about a mechanical unbalance of the rotor, improper installation of the coupling between the motor and the load (improper centering), loosened motor mounting bolt, improper bearing part, ect. The rotor is fully balanced during manufacture, and with norm: r@ it should not be unbalanced. 3, STOPPING Confirm the load lobe ready for stopping, and after signalling, operate the operate the operating switch to stop the motor. 4. CARE AFTER STOPPING Alter stopping, pay attention to the point given in the paragraph " Preparation for operation.5, TROUBLESHOOTING Trouble Cause Remedy Disconnect the motor from the load. Try to rotate by hand and if it is difficult, the cause is a mechanical Mechanical restriction or restriction. overload, Disassemble and investigate. If the motor without the load can be started, check the load. Stator winding broken Replace with a spare one. Falling of Measure the motor terminal voltage difficult to and read the voltmeter on the start ‘Switch in poor contact switchboard. If itis lower then spreitied, raise Fuse blown out Replace with a spare one. Readjust contact part or replace Switch in poor contact with a spare one, Connecting wire broken Reconnect. Over current relay operated Remove the cause and reset. Bearing binding Replace with a spar one. Grease deteriorated or Overhe Replace with a spare one. contaminated of bearing Ball bearing damaged Replace with a spare one. part Misalignment Alignment. ‘Abnormal Belt too tightened Reduce belt tension. sound or Investigate the cause for overheating abnormal Heat conducted from other part of rotor or stator. vibration ~o7-Trouble Cause Remedy Frequency —_| Check and adjust the line frequency variation to the rated value Abnormal Load Check and adjust the machine. variation Abnormal sound or abnormal vibration Air gap part in contact Replace bearing with a spare part Check for bearing of shaft Ingress of foreign Remove foreign matter. Loosened Retighten. mounting bolt Misalignment Vibration of direct orrotor Realignment connected machines Unbalance _| Rebalance. Replace bearing with a spare part. Air gap in unbalance center bracket with frame. Beating due to overload Magnetic Check and adjust load. loosened sound Disassemble and repair Laminated core Corroision of ball with Readjust or replace bearing retainer Grease ; Replace with a spare one. Abnormal deteriorated sound Ball surface from damaged mall damage by —_| Replace with a spare one. bearing electrolytic corroision Ingress of foreign Clean bearing and repack with grease. matter 28 =Trouble Cause Remedy Overheating Overload Reduce load to or below rated value. Cooling fan defective Disassemble and repair. Ventilating hole clogged Remove dust or dirt accumulation: Friction between rotor and stator Replace bearing with a spare part Readjust air gap uniform by centering bracket with frame. Coil grounded Disassemble and repair coil Inundation Disassemble and water wash to remove contaminant, then reassemble and dry in| the case of inundation by sea water, wash and clean in hot water at 60 °C to 70 °C to remove salt, then reassemble and dry. 29 -B. MAINTENANCE 1. PERIODICAL MAINTENANCE CHART Standard checking Standard corrective Interval Checking of procedure measure If abnormal vibration, sound or bearing heating is noted, Check for vibration investigate the cause and Major motor in | and sound, and the Daily repair use temperature of bearing I overload or other abnor etc. by touching by hand. ality is noted, stop at once and remove the cause. Rotate the motor by If abnormality is noted, Major motor . hand and check for investigate the cause and not in use . abnormality, repair. Weekly Removal ‘ect Measure insulation If insulation is deteriorated electric resistance. Check or ground connection is im apparatus ground connection. and repair Measure insulation If insulation is deteriorated, resistance. investigate the cause and Motor and | Check stator and rotor _| repair. Monthly stater loosened connection Clean contaminated area Check lubrication Add grease and replace part. bearing. If the measurement is below the allowable limit given Electric Measure insulation below, dry or otherwise 3-monthly circuit resistance correct =30- (1) Circuit rated about 100V: 1 Mohm or greaterStandard checking Standard corrective Interval Checking of procedure measure ; (2) Circuit rated below Electric Measure insulation 3-monthly 100v: circuit resistance 1/8 Mohm or greater operation is abnormal, Check operation investigate the cause and ‘Apparatus —_| starter and accessory _| repair. Repair defective associated —_| apparatus. or burned part. with motor | Cheek contact If necessary, replace with -onnections. a spare one. Retighen 6-monthly loosened connection. Check for loosened bolt or nut in the Retighen loosened bolt or base mounting part nut Motor joint, cover mounting _| Replace defective blot or part, etc. and for nut with a now one, correction Measure air gap between stator and Replace defective bearing Motor rotor. Check —_—_for| with a spare part, Clean jbnormality shaft and bearing in bearing part. Yealy (1) Check with parts list. (1) Check the number. | (2) If insulation is Spare part —_| (2) Measure insulation _| deteriorated, investigate resistance. =31- the cause and dry or otherwise correct.2. MAINTENANCE AND REPLACEMENT OF BALL REARING ON THE MOTOR ‘The ball bearing with grease sealing plates is packing with grease during manufacture, and should not require addition of grease during operation, unlike the conventional open type bearing ‘The ball bearing requires replacement if it produces badly abnormal during operation. The procedure for bearing replacement is as given below, After disassembling the motor by the procedure given later, remove the defective bearing from the rotor shaft by use of a bearing puller. Anti-rust grease on the surface of the replacement bearing should be removed with a cloth. Mount the new bearing on by the shock During this procedure, be caretul not to give shocks to the sealing plate, as the searing plate may be deformed or dropped by the shook. However desirably the bearings may be in use, it is unavoidable for them to be damaged by fatigue. Nevertheless, an adequate operating method can reduce the fatigue or can prevent failures due to other causes. Besides, should a damage to be taken, the cause should be examined in view of the appearance and character of the damaged part. and care must be taken not to allow the same trouble to be repeated: It is very difficult to locate the cause of a trouble, which is usually attributable to a combination of several causes. aaaNo. Trouble Characteristic Probable cause Dents formed on the race face owing to careless installation. Low noise Dents formed on the race face by (rustle or rumble) external vibration while the fan 1 | Noise is at rest High=pitched noise Too small clearance Foregin matter included Intermittent noise Resonance due to careless assembly about the housing Insufficient clearance during ‘Abnormal 2 operation temperature Overload Too tight fitting ‘Axial crack on the or Uneven installing surface outer ring Housing deformation Circumferential crack Uneven installing surface 3 | Crack . on the inner or outer . Extreme overload fing Crack on the retainer or ball due Irregular crack to grease aging Indentation Knock during installation Indentation of the same 4 | on the race Great blow struck on the bearing pitch as the ball face with the fan is at rest Grease aging Retainer 5 Ball damaged damaged Rivet damaged by vibration Corrosion by acid or moisture local spots on the while the fan is at rest for a 6 | Rust race face long time Surface rust Incomplete contact (Faulty fitting) eae3. DISASSEMBLY AND REASSEMBLY IF THE MOTOR] To disassemble the motor, proceed as follows. (1) Disconnect the motor from the power supply. (2) Remove the direct coupling, and place the motor in a ares suitable for disassembling. (3) Remove the bearing cover and the oil thrower on the direct coupled side. (4) Remove the bearing bracket. (6) Pull out the rotor as a whole in the direction toward the fan, (6) Place the rotor on a cleam stand, and pull out the ball bearing with a tool Be careful not to contaminate disassembled bearing part, etc. with dust or dirt. Also, take care nat to damage the insulation when pulling out the rotor. The reassembly should be done by reversing the disassembling procedure, taking care to insure positive assembling of bearing part or other fits. 4, DRYING Before starting the motor which han been at rest long or is suspected of moisture absorption, measure the insulation resistance of the winding and if the measurement is below he limit given below, it is necessary to dry the winding by the procedure given In the following paragraphs. C Cireult rated above 100V:1 Mohn or greater 1 Cirouit rated below 100V:1/3 Mohn or greater (1) Hot air of external heating method Place a well ventilated sheet over the motor. ‘The insulation should not be heated about 90 °C. (2) Current method: With the rotor locked, apply a low voltage to allow a short circuit, current to flow in the winding. The winding is then dried by it's own heat generation. Start at low current, increasing the current gradually until the temperature approaches 90 “C, then keep the current - 34so that the insulation resistance reaches @ constant value sefely. 5. TRIAL RUNNING OF THE MOTOR The motor which has been dried or disassembled and reassembled should be cleaned thoroughly, checked for loosened screw, etc. and then placed in trial running. | the trial running is satisfactory, the motor may be directly coupled with the load, 6, REFERENCE (1) Insulation resistance test for stator winding Remove the cables from terminals and measure resistance beween earth and stator winding by D. C. 500V megger. ‘The resistance should be more than follows. Machine rated voltage x 3 Machine rated outout(kw) + 1000 Note : R : Insulation resistance for stator winding. If the resistance is too low ( less then 1 M@ ) it should be dried by the procadure of item 4. Typical trend of insulation resistance. ~35-\ Resistance becomes constant Insulation resistance hours Caution 1. During drying, carefully heat up to exceed 90 “C at any points of winding, 2. It should be continued to dry that the resistance measured are saturate. (2) Re-greasing Following grease should be used. Refer to the attached Table 2. Recommended Grease (8) Period of re~greasing Operate frequently Every 8 month Operate intermittentry Every 6 month ~ 36 -RECOMMENDED GREASE Insulation Class E. 8. Insulation Class F Manufacturer Grease Soap Grease ‘Soap NIPPON OIL MULTINOG NO.2 | _NITUM | MULTINOG WIDE 2 LITUM MARUXXEN OIL_| WR-3 NATRIUM| WR-3 NATRIUM DAPHNR GORONEK| IDEMISHUKOSAN} LITUM | DAPHNE GERASE BENTON GREASE NO.2 ESSO REACON NO. 325 | _LITUM | TEMPREX N2 uiTuM SHELL ALVANIA NO. 2 LiTUM | DOLIUM GREASE 2 PORIYUA CARBURETTING MOBIL MOBILUX NO. 2 LITUM | MOBIL GREASE 28 HYDROCARBON DAINAMIC GREASE! DAINMIC GREASE DAIKYO OIL LITUM uiTuM Mp-2 MP-2 ANTER, MULTISERVICE LITUM BP ENEREASE &P ENERGREASE BP uum BENTNITE Ls-2 HTB 2 REGAL STARFAL CALTEX PREMIUM NO. 2 CASTROL CASTROL SPHEEROL AP2 DURA-LITH CHEVRON uitum GREASE 2 TEXACO TEXACO, REGAL AFB2 GULF CROWN GULF uitum GREASE N2 TOTAL MULTIS TOTAL EP22 DIAMOND DIAMOND MISHUBISHI ote MULTIPUROPOSE | LITUM | MULTIPUROPOSE GREASE NO.2 GREASE NO. 2T t air OOW NHS (Gaicy woqau @0-1001-4 vy ey, "1001 ONRWSE | er | S/H 20 ova inoavn sas £00] aren eee b= we A Aiquassy (Z-+% = 38- Ajqwessy—ay (1-7 6urs09q Jo Ajqwiasso—a, puo fiquiassy (1@ NAME OF PARTS EXTERNAL FAN EXTERNAL FAK COVER EYE BOLT FRAME ROTOR COKE ‘STATOR CORE ‘STATOR COIL ‘BRACKET (FLANGE) ‘SHAFT END KEY END-RING FAK CABLE GLAND) TERMINAL BOX ‘SHAFT PRELOADED SPRING SEALED BALL BEARING # NAME OF PARTS EXTERNAL FAX STATOR COrL, EYE BOLT STATOR CORE ROTER CORE FRAME, END-RING Fan HOUSING COVER OPEN BALL BEARING ‘BRACKET (FLANGE) (GREASE RING GREASE NIPPLE ‘SHAFT PRELOADED SPRING GREASE NIPPLE (CABLE GLAND TERMINAL BOX j ‘SHAFT-END KEY EXTERNAL FAN COVERAIR COOLER INSTRUCTION MANUAL DongHwa EntecCONTENTS I DESCRIPTIONS I STRUCTURES Il OPERATION W MAINTENANCE AND INSPECTION DURING OPERATION V CLEANING Vi PURCHASE SPARE PARTS FOR MAINTENANCE1. Description ‘The Donghwa air cooler is a heat exchanger cooling the air supplied diesel engine to the specified temperature for improvement the performance of engine. It is called fin & tube type heat exchanger and used for MAN B&W and SULZER MAIN DIESEL ENGINE. ‘The heat removed from air is carried away by the cooling water (sea waler or fresh water). The cooling water flows on the inside of the fin-tube, while air flows along the outside of the fin-tube. We call a cooling water side as Water Side and fin-tube side as Air Side, The cooling methods of water side are differential into F.W(Fresh Water) cooling & S.W (Sea Water) cooling, and Central cooling system. I. STRUCTURES Air cooler mainly consists of cooler insert and casing. Cooler insert is made up of tube bundle and water cover. -1. Tube bundle ‘The bundle has several multi-finned tube block arranged in the direction of the air flow. According the cooler capacity, the number of block and size of each tube block are decided. Both ends of the finned tubes are installed in the tubesheets by tube expansion with mechanical tube expander. And special hydraulic ball expander is used for the preference adherence of fin and tube. Fin-tube block is immortally fixed at tubesheet ‘so that is unable to take apart each other. ‘The two side plates serve for protecting the finned-tube and for reinforcing the cooler performance by preventing air by-pass. ‘The channel cover is securely bolted to tubesheet and all bolt is tag-welded, while the reversing cover is only supported by stud bolt with clearance for absorbing thermal expansion of tubes and stud bolt is fixed with wire. At side plate, lifting bosses are welded on for eye bolt and these make easier handling of unit. The supporting bars bolted on side plate serve for supporting tube bundle and for preventing the damage from a abnormal vibration. And also all bolts are tag-welded to prevent unlocking.1-2 WATER COVER Water cover has water inlet & outlet nozzle, partition plate for controling water pass, air vent & water drain connection and chemical cleaning. And there is two jack bolt to easily detach cover from bundle for cleaning. Two water covers, the channel and reversing cover, are tightly bolted to corresponding tubesheet with gasket. Here water inlet & outlet nozzle detached cover is called channel cover and the opposite cover is called reversing cover. When the cooling medium is sea water, there is zinc anode or soft iron on water cover inside to protect cover from corrosion. ‘Ihe corrosion protecting medium, zinc anode or soft iron, is connected as flange type to exchange it when it was wear away and is bolted with gasket to water cover. I OPERATION II-1 Cooling Water Side ‘The bundle is to be filled with water and at the same time the air vent valve is to be opened so that the air in the bundle can escape through bubbles in the escaping cooling water (it means air vented completely and the bundle There is no more air has been filled with water), close the air vent valve tightly. If air remains in the tubes, which will not only deteriorate the performance, but also may cause accidents during operation, so that special care is required. After the cooler is filled with water completely, it may be O.K to operate the air cooler. When the pressure and temperature reach the normal operating condition, confirm that there are no abnormalities in regard to bolts, nuts, and gaskets. If water should be leaking from the gaskets, retighten the bolts and nuts. Continuously water leak even after retightening, the gasket should be exchanged for a spare gasket. ‘During operation, do not excced the permitted condition. If do excced, contact us and consider the operation condition. If you don’t, we don’t take the respunsibility of resulting problem. M-2 Air Side ‘Make sure that the operation on the cooling water side is normal, and then the cooler is fed with air. When the operating temperature has been reached, check on the air leakage. The charged air temperature inlet and outlet of the cooler is checked up and the cooling water quantity is to be corrected, if required. After operation startfor the air side, once more confirm that the connections of the cooling water side and the air side are secure. I-3 Operation Stop When stop the operation, first stop the air side and then the cooling water side. ‘When stop period will continue several days, open the drain valve in the cover and drain all water from the cooler to prevent from corrosion and freezing during the winter. I-4 Cooling Water Velocity Cooling water velocity is limited in view of erosion, corrosion, and fouling so that do operate over the minimum velocity. And the best tube inside velocity is staying the recommended velocity range. : Recommended velocity | Minimum velocity aes (ca/see) (a/see) Copper 10 ~ 15 10 Al Brass 1a ~ 20 10 Conper-Nickel (1) 18 ~ 25 10 Copper-Nickel (73) 24 ~ 35 10 Steel 15 ~ 80 10 ¥Note : Please never operate at the minimum velocity for the prolonged periods to prevent causing scrious fouling. WV Maintenance and Inspection during operation W-1 Cooling Management () With use for a long time, various contaminations are deposited inside of tubes ‘and fins. It cause to deteriorate the performance of the air cooler, so following items should be checked during operation + Temperature difference between inlet and outlet side of air and water + Pressure loss for air and water When a pressure loss has been doubled of initial condition, execute washing and cleaning. (2) When running the engine at part loads as well as during maneuvering orrunning in winter season, the temperature or the amount of cooling water passing through the air coolers should be regulated so that the air temperature at the outlet of the cooler does not drop too low. If the air is cooled down to a dew point temperature, considerable amount of condensed water will collect in the air receiver. If the charged air temperature is above the dew point, condensates will form only where the air comes in contact with surface whose temperature is below the dew point. At this time, it is advisable to control the cooling water source temperature by adjusting circulation valve but inevitably if the cooling water quantity for the air cooler is controlled, the outlet valve should be throttled. W-2 Electrochemical Corrosion Protecting Metal When the cooling water is sea water, a protection metal is installed inside the cover of the air cooler to protect the cooler from corrosion. In order to protect the electrochemical corrosion of the cooler, the anode plates are installed in the cover. When operation is continued after the protectional metal has ‘been used up, notable corrosion will occur for the cover in case of standard equipment or for the tubes and tube plates when the cover is equipped with anticorrosion rubber lining etc. so that this metal should be periodically and should ‘be replenished as required. The anode plate has to be exchanged for new one regularly. Generally the consumption of the anode plate in new cooler is very fast. So the first exchanging has to be done within 3 months. After that time the exchanging intervals are decided in accordance with the degree of the consumption on the last inspection, Care should be taken that the surface of the protection metal and the threaded part re free of oil, paint, ete. W-3. Cover Coating Management At the inside of the cover is coated with tar epoxy resin, neoprene lining, etc to protect the cover from corrosion by the cooling water, the inside coating should be inspected when the cover detached for inspection, cleaning, etc. If there is any damage, it should be repaired immediately. If you don’t, local corrosion will occur at the damaged part, and finally the cover will be destroyed.‘And also when you detach the cover, careful handling is required so that the surface will not be damaged. W-4. Use of the plug ‘When the tubes are broken because of corrosion or for some other reason, use the accessory plugs to plug both ends of the tube. The plug should be installed according to the followings (Q) Drain the water completely from the cover. (2) Detach the cover installation bolts and nuts, and detach the cover. When it is difficult to detach the cover from the casing, the jack bolts should be used. (8) Drive the plug into both ends of the broken tube. WV-5 Inspection Normal hydro test pressure of water side is 6Kg/cm’. And air side test is done during operation whether leak or not, and general test pressure is 3Kg/cm’. The holding time of air side and water side pressure test is 30 minutes. Only clean fresh water is used for the water pressure test of the cooler. Add soluble ferrous sulphate(HeS40, 7H20) to stimulate generating the protective film at new cooler. ‘The quantity of soluble ferrous sulphate is Ippm per hour. It takes a time to be generating the protective film at new cooler tubes. So it is very harmful directly to contact tube with dirty harbour water. If dirty harbour water contact, the dirt film immediately generate on tube and will hinder the build-up of a protective layer. V Cleaning Use the cooler for a long time, various contaminalions are deposited inside of tubes and fins. It cause to deteriorate the performance of the cooler. Check the cooler outlet air temperature and if it is increased considerably , and water side pressure loss is doubled when compared initial condition, you must execute cleaning. Water side cleaning of the bundle should be carried out, if a considerable increase in air temperature measured at the outlet of the cooler. Keep in mind that a slight fouling at the water side is too much influencing to air cooler performance. Air side cleaning of the bundle should be carried out if the pressure loss of the cooler hasbeen about double of the initial condition. V-1L. Water side Cleaning (1) Use Brushing Tools © Tum off the blower @ Close the cooling water supplying valves and discharge pipe valves © Open the drain valve so that the bundle is to be empty. @ Disconnect pipelines, and take off the both water covers using the jack bolts, if necessary. © If the unit comprises zinc protection plates or soft iron, these should be examined for their condition when water covers are detached. Damaged or wore down zinc plates or soft iron have to be exchanged new ones. The cover has to be sandblasted and given a new coat of tar epoxy, if the damaged cover area is large. Covers made of bronze or gunmetal don’t need protective coats of paint and zinc protection plates bul at that case soft iron is usually used for generating protective film on the tube surface. © Using the provided nylon brush tool, clean all tubes while they are still wet. @ Rinse each tube with water to remove the brushed off dirt. @® And then it is make sure that the tube inside is clean, and replace the covers and gasket after checking up the water side connections again. @ After completely reassembled, operate water pump and do hydrotest to check leaking. @ All work is done, open valves and operate the cooler. (2) Chemical cleaning ‘When it is impossible to remove the fouling with tube brush, it is effective to circulate chemical cleaning solution. But, it take a considerable cautions, because if chemical cleaning fails, the tubes and others will be damaged, resulting in shortening the life of apparatuses remarkably. After finishing chemical cleaning, circulate fresh water so that cleaning solution is not remain in the cooling water. If you have no experience in chemical cleaning, consult the manufacturer. Chemical cleaning should be carried out by circulating method as built-in or by dipping the bundle into some cleaning solution after pull out it from the casingor between the air ducts. Working methods are following © Tum off the blower @ Close the cooling water supplying valves and discharge pipe valves @ Open the drain valve so that the bundle is to be empty. @ Mix the chemical solution with water to specific concentrate, and sufficient amount as calculated water side volume. @ Connect circulation pump and chemical tank at chemical connection on water cover. And then run pump and circulate solution. ® When chemical cleaning has been done, stop pump and drain the solution through drain valve. @® After solution draining, add neutralizer at chemical tank and neutralizing the remained solution. @® Finish all of above steps, check again and run the cooler. v . The Air Side Cleaning (2) At moderation condition, it is possible to clean out by washing with hot water and compressed air. (2) But there are some deposits such as oil, grease, carbon, etc., it is preferable to clean it with steam blasts(3~7 kgl/em2, 150T of less) or hot water and compressed air. (B) It is impossible to clean by above, chemical cleaning must be carried out. Detach the bundle from the casing and dip it in cleaning solution. Chemical cleaning method is available as built-in by circulation of solution, when the cleaning system is equipped on board. After the bundle has been cleaned, it should be throughly flushed, dried, and properly reassembled. Consideration should be taken to choose the chemical solution and cleaning process and must follow the guidance of chemical supplier not to attack tube or fin material. (4) When all work is done, you should add neutralizer and dissolve the remaining solution‘V~-3. Recommended chemical agent and supplier Chemical Supplier | Drew Ameroid Japan Co., Led] Minato Ise Bldg. -1, 3-Chome, Kaigan-Dori coy Neke-be,Yokoheme-s WATER SAF-ACID eae Xanagwa-Ken, 231, Japan Phone : 045 ~ 212 ~A741 Faxsimile : 045 - 212 - 4754 |= Drew-Chemical FOR F Drew Ameroid Japan Co., Lia] AIR aces = Drew Chemical Co. SDE New York, USA % Please consult chemical supplier's description. ‘VI Purchase Spare Parts for Maintenance During operation period, exchanging from old parts into new ones is necessary for maintenance. For purchase, you know the detail structures and if necessary, refer to section II Structures and attached drawing. ‘The air cooler’s parts names are tube bundle, water cover, gasket or packing, bolt, nut, anode, anode cover. ‘The ordering methods are following 1) Sce the nameplate and write down followings SHIP NO., MANUFACTURE NO. MANUFACTURING DATE, CLASS If there is not name plate or hard to see, you can also find at left or right side of tubesheet. 2) Check 1) and numbers and names that you need parts. 3) Contact us by in person, mail, telephone, or fax and inform us. 4) Reconfirm your ordering Tel. +82 - 051 - 970 - 1110, +82 - 051 - 970 - 1114 Fax. +82 - 051 - 970 - LILMARINE ENGINE _TSUBAKI ROLLER CHAIN‘Tsubaki Marine Diesel Engin ‘TSUBAKI marineengine roller chain meets all British Standard roller chain standards. iis speci esigned to drive marine diesel engines. The use of higi quality alloy steel combined with the most advanced manufacturing techniques ensures that all chains ass the rigid inspection of Loyd's Register of Shipping, Det Norske Veritas (NV). Bureau Veritas (BV), American Bureau of Shipping {A8) and Nippon Kaiji Kentei Kyokai (NK). TSUBAKI marine engine roller chain is used by M.A.N. BAW, Sulzer and Mitubishi smong others, in the operation of the camshafts, fuel pumps and various auxiliary devices oftheir marine diesel engines, This jog provides all the information necessary to mainiain TSUBAK! marine engine roller chain, CONSTRUCTION Chain i usually deseribed by its major dimensions fitch (P. the diameter ofthe roller (R} and the inner wigth of the cole link (Ws. length ie ‘measured in terms of the number of links. So the length of the chain shown on the right is 5 links. The four main components of marine engine roller chain are the link plate, the pin, the bushing ‘and the roller. The link plate provides the tension: the pin and bushing form the bearing, and the roller acts as a shock absorbar for the bushing and protects the sprocket against west. Pt ink The components shawn on the right are used to form the pin lk and the roller link, The chain is a series of alternating roller links and pin links, Pin fo pate Polk plestrand chain Pn link of double strand chain Connesing pin nk CConnacting in tink Yor double sand chain fd ein ‘The pia lnk of single strand chain consists of two pins and two pin lnk plates. ‘The pins are press-fited to the plates. The pin link of multiple strand Chain alzo has an inner link pate To increase ther fatigue strength the in is firmly fixed t0 the inner fink plates Roller fink consists of two bushings which are press-fitted to the link plates and two rollers fited over the bushings just loose enough to rotate freely. The same roller ink can be used with both single sand chain and multiple strand chain. The number of roller links needed per link of chein is directly proportional ta the number of strands Connecting pin links are the same as lrdinary pin inks except that ene of the link plates is not attached to the pin. The inner link plate of a connecting Tink for multiple strand chain is sip-fitted ta the pin to make assembling it easicr ‘Special machining techniques ensure that it of as high quality 8s ordinary Bin links. The middle connecting pin Tinks for multiple strand chain are silver colored sa they can be easly distinguished from ordinary pia links.HANDLING and INSTALLATION Roller chain is flexible along its length bout nat laterally, so placing strain along its edge should be avoided. Remove the chain from the package in the ection indicated by the arrow. I the chain is removed vertically, for example by a rane, it may twist and bend under its own aveight causing the press fied parts to become loose. Fit is necessary to rernove the chain vertically. sland the package on its end so that the chain will be pulled in a vertical direction Chain should be store in its original packing, ie. oiled paper and a wooden case, in'a place where it won't be ‘damaged by chemicals. If chain which has been used is 10 be stored for any length of tee, it should be cleaned tipped in lubricating oil and wrapped in colle paper. All roller chains ae dipped in 9 hot ferolatum bath before packaging The petrolatum coating acts 95 @ lubricant and prevents the chsin from rusting. Do not elean the chains or apply other lubricants before installing A joint link is used to connect the chain ‘The inner link of joint links for multiple stand chain is silver colored to distinguish it from an ordinary link plate The spare pin link may be used 3s a ‘connecting lnk. 4) Place the chain on the sprocket. 3s shown in tkstation No. 1 Iustration No. 1 Cennact he chain on resting with te sprocket. 2} When connecting large roller cheins, use a crane to lit the chain up to 8 height about 40% of its total length Place the vertical portion of the chain fn the sprocket 2s shown in tustration No2 IMustration No. 2 ‘wrap the longer sie on sprocket. ° Remove tom package in he direction Indesied by the son, 3) As shown in Photo No.1, place the fends of the chain on a base plate and tap the pin ink plat into position with a hammer. Photo No. 1 4) When the Fink plate is level with the surface of the pin head, place a small pisoe of pine whose inner diameter i Slightly largor than that of the pin over the pin and continue tapping. See Photo No2 Photo No. 2 5) Rivet the pin in place with 2 round: headed hammer, ‘The head of the pin is not hardened to make riveting ease. Crossed riveting is recommended.{6} When connecting @ multiple strand chai, place the inner link plate in positon. Press the pin by hand or ‘with @ wooden hammer in the direction Indicated by the arow. ‘See Photo No.3. Attach the link plate in the same way as described in 3) 0n Page 3. Pin tk plate ‘When joining the joint pin link plate and the pin, do not change the tdamater of either the link plate hole or the pin in order to make the assembling job easier It will have an adverse ttfect on the performance of the chain, Single strand chains can be lsconnected at any lnk. Multiple sirand chaine should be disconnected at links with siver colored inner fink plates since such plates ae slip-fitted (on the pia to make disconnecting easier. 1) Use a chisel to shear off the ends of the rivets. File them down so that the pins can be removed without damaging the link plate. See Photo No. Photo No.4 2} Support the connecting link between two blocks and tap the heads of the {wo pins alternatively with a hammer. See Phata No, Photo No. 5 3) Once the heads of the pine are level with the sucface of the link plate, ‘use @ punch whose diamater is sightly smaller than that of the pin to remove the pins complataly, Photo No. 6 Fish by ae 4) Pin links should not ordinarily be roused. If they arethe ends of the pins should be finished with a file and 2 wet stone {See Photo No) and the re-calking shauld be done 3s showa in Photo No. Photo No. 7 inal eating 5} A special tool t0 disconnect chains alter the ends of the rivets are removed is available, See Photo Nos. Photo No. 8 Discomestng too! Specify your chain number when ‘eedering one since the tool size ‘depends on the pitch of the individual chain.LUBRICATION and ADJUSTING CHAIN’S TENSION Lubrication is essential in maintaining the high quality of roller chain and in minimizing their stretching {A forced feed lubsication system is ‘usually used for marine engine roller chain, The lubricant protects the ‘bearing surface between pin and bushing against excessive wear and forms a film between the roller, bushing land sprocket teeth which cushions shocks, reduces noise and acts as an insulator. The lubricant should be applied to the inner surface of the chain atthe point ‘where the chain and the sprocket’s teoth mesh. See ilustation No.3. The more points which are lubricated the better, Ifthe lubricant is applied to the outer surface of the chain, it wall be prevented from soaking through to the inner surface by centrifugal force. The delivery jets should be directed in such a way that the areas indicated in red in Ilystration No. 4 aro well lubricated. Two delivery jets should bbe used with single-srand chain, three jets with double-strand and four jets ‘with viple-stcand. See Hustration No. 5 ‘The volume of lubricant necessary depends on the type of chain, The rminimurn recommended volumes are as Fallows: Single-srand chain 2 gallons (10 liters} per hour per neh of chain Double strand chain 4 gallons (20 liters) per hour per inch of chain Trile-strand chain: 6 gallons (30 liters) per hour per inch of chain CO Mustration No. 4 Pin tin pate IMustration No. 5 i > 0 A special device should be installed on the drive of marine diese! engines in ‘order to adjust the chain tension, IF the chain i 100 loose it will swing free, and if to0 tight a stain wil be placed on the chain and shaft bearing ‘causing them to woar out quickly The chain may vibvate during operation because of the engine torque oF the vibration of the shafts. This vibration can be reduced by changing the tension with the special adjustment sevice, Follow the instructions of the engine manufacturer in seting the initial tension. The initial wension may be as 9 much a5 half the tension of the chain ‘during operation, It is essential that the adjustment device be attached 10 the slack side of the chain and used while the engine ison, Regardless of the care taken in ‘manufacturing and instaling chain, all ‘new chains stretch about 0.02-0.05% during the inital period of operation Take up the resulting slack by adjusting the chain tension. After the initial period of operation, the amount of stretching willbe minimized. Every 3,000-6,000 hours the chain should be checked for stretching, The initial slack is taken up after the chain is first test dren and again at the first port-of calMAINTENANCE The intemal wear of ordinary chains ‘wal cause ther to stretch gradually Until hey sip off the teeth ofthe sprockets High-quality marine engine rollr chain is built to more exact specifications than chin for normal transmission purposes. This ensures that less stretching occurs and that they can be ‘operated with complete safety under ‘noemal consition. ‘To realize the fll operating lie of 2 chain, it must be properly maintained. Stretching isa result of the pin and bushing surfaces wearing out Chains used to drive marine diese! engine will pot have to be replaced because of stretching for atleast ten years. The amount of stetching should be measured occasionally 19 estimate the expected life of the chain since these two factors are inversely proportional 1) Take up the chain slack with the engine running slowly and set the inital tension. Measure the length ‘of the chain an the tension sie. 2) Measure L1 and L2 as shown in Photo No, 9. The following equation gives the total length of the chain. Lis Ua tn case ot meosuing RSQEB RSOIS RSOLZ7ASOLA ASO ASIAN RSORNG ASIC ASIA RUE PRS aon) 608 65 72 68 1018 0 1624 18 W002 aaHe Lie aaa PY suse ues_r734_onza tare est sss oar me25 2209 PISA ona) 152A 1905 2206 2687 s0ed sm0 4672 EDA OG OSB fer ereye te” s.e8_toaa8 azam 2707 sm0a7 29672 weeoe ona e187 cake ‘Ae iowsy 240 S175 SEO 44aS $080 6950 7620 FBO 10160 11430 oe aabaaye fe aster sozze earn e117 ssa omtss_rraeo ome 10126 e035) FERIA aus $08 %62 688 1018 1270 W824 1778 2082 T2B6 sp ram shat 6426731097 102KD zBse 18 Id mH64 ZI ANE Gia) 1528 Was PE MER 310 A672 6334 GG ORE ESCEEIHS ota are zarae_ze00 ane 269 so98_ 16m ooLe Pew AO 3175 3610 aa45 $020 GSO 76 |! 10D 11820 FERRET OP 25705 amar sess7 saves siat_ot2ea 771.14 oto67 1a19 15872 > bo] dyes a 3) minimum chain length of 6 links ice should be considered in order 10 ‘minimize measurement errs 4) The length (chain pitch X links) of ‘and the maximum allowable length to which chain may be stretched are given in the following tables. Use the figures in Table | when the large sprocket wheel has fewer than 60 teeth and Table i when it has between 60 and BO teeth The maximum allowable lengths given in Table I are 1.5% longer than the corresponding original lengths and in Table I 1.2% longer. IF the sprocket wheo! has between £80 and 100 teeth the maximum allowable length is 1% longer than tho original length, the measured length exceeds the ‘maximum allowable length the chain should be replaced. However these figures very slighty depending on the number of teeth and the tooth profile, 5) The above figures apply to both single and molple strand chain | | |Because it is technically impossible to climinate all defects on the surfaces ‘ofthe pin and bushing some piting '5 bound to occur during the intial Petiod of operation. Such piting, however, cecurs only during the initial period and is no cause for ‘concern to the operator. When not being operated, chain wil ever break. However, ifthe fatigue strength ofthe chain is exceeded because of the chain vibration ‘curing during operation it may break Ifthe chain vibrates excessively, the link plates should be carefully examined for cracks, A crack appearing in the link plate is the first sign that the chain's fatigue strength has been exceeded. Since cracks usually develop slowly, accidents Can be avoided by carefully examining the link plates. All cracked whole chain should be replaced immediately. cea wich cracks are Tasty wo appear {ine shaded reas) Cracking in ink ate O14 Dien n won cracks row. “The impact which the roller must bear does not usualy cause any problems However, ifthe vibration is excessive cracks may appear in the roller. (See photograph below), The roler should be frequently examined for eracks, i) (racking roller To prevent fatique breakage, the vibration of the chain should be sliminated as far 35 possible Wit cannot be eliminated by adjusting the chain tension, the engines manufacturer should be eonsultad for their recommendations, Ifa crack is found in @ link plate i is safer to replace the whole chain since al links ‘were subject to the same svain, “To ensure thatthe lubication system Continues to function properly. the lubricating device should be checked frequenthy t0 see hat the feed pipe has not become clogged with lubricant for thatthe nozzle has not been bent.To check that the alles and sprocket teath are propery aligned, examine the narrow polished of slightly worn stip ‘hich will appear on the inside suctace fof the teeth afler a few hours of operation, If the sprocket teeth and chain are properly aligned, the width of the stip will be uniform, as seen in Fig, A and C. Ifa strip like that show in Fig, 8 appears, it means that the rollers and sprocket are not propery aligned and should be adjusted. Usually the rollers do not come in contact with the bottom of the gaps between the sprocket teeth However the worn-strip many appear Jn this 2¢ea if tension & applied to the slack side of the chain. Other strips ‘may also appear on the inside surface fof the teeth as shown in Fig. A. When using an "Idler" or “Tightner” the point of contact is usually the bottom of the gap between the teeth 35 indicated ia Fig. C.DIMENSIONS (mm) AND SPECIFICATIONS (kg/mt) bie 1 iE Pals Eo th cross sive snicte ouste TRPLE ‘SECTION view ‘STRAND ‘STRAND ‘STRAND TSUBAK gs ngs" ETB BSE ESR iin TEN ty | ORHAN ‘can No, On No Sues Bie Fates _Puses__ Fos | P ae fee a H c Aa et A TsuaaK! BS ko/me WS008S Does 1 -HA 1608 17100 839 310 Was 2568 a -a700 agi 2 RS4098 220/160. 2 2540 1585 1702 828 43) 210 O18 24d TB 672 8000 asm 522 RSGO8S 29/i60-1 3 2540 1580 1702 428 022 2103188 mAs 568904 194001288077 RSOTOG 24/7RGS 1 8175 1905 Taso 1010 v0 me Zs01 2928” 296 7200 8680359 RSA10G 224760 2 9175 1905 1950 1019 1024 24 9645 2801 2928 78113800 18160 706, AS6106 728/267 9 217 1005 1965 1019 1024 254 2645 79012924 1129 7040018740 1040, RSOIZ7 22W/26S 1 380 2840 asco 1463 AGB aa a a OT REAIZ7 220: 2 2810 N40 2540 1463 1468 334 4530. 8792 3820 TOD 21100 189601370 RS6127 720/210. 3 2810 2640 2540 1469 1408 594 4895 9702 38201498 _sCO_28940 1960, RSO147 BiW/2BS 1444S 2701 3000 1800 Tes 308 “aaso” 460 6371400 19160 420 AS41467 725/260:0 2 ead 2794 3009 1500 1505 395 5050 4850 4085 1793 27800 6500 1600, RSOIA7 22707 3 444s 2791 090 1500 150 MRS 5880 4089 4006 1422 ALeKo saan 2450 RSO166 228/328 1 S080 2021 4099 1781 1780 396 4557 4585 627 19000 17240 a78 RSA166 224300. 2 5090 2021 090 1781 1788 MMe USS 4557 aBH8 1212 9eTKO 3kaB) 1720 RS616G 22q/s00-7 2 _som) 2021 090 178) 1786 386 SBE 4567 4885 1802 _S4am0 817207500 AS0206 aso 1 —e8s0 Gey 3810 M280 299625 BHT 8003 782” 0aI0 267701510 RS4208 728/400 2 6350 9097 980 2289 229 55 TAA ST Sos 1512 saTEO 5540 5020 S6206 229/400-T 3 6250 2037 aio 220 22m 825 Te su 86032289 _874E0 —eOSIO_a4eD RS0246 2040S 1 762 4826 KETO zO24 2029. 6887058 7009 987 BONO aDEND DED RSA246 220/48680 2 7020 4025 457 724 291 GLB 8121 TOSS 7089 1900 8BEO0 81650 A780 RSE246 220/407 9 7620 «a6 4572 2924 2629 698 9121 7056 7009 7016 128100 172470 _7OE0 RS0286 2a/s0BS 1880 SAO) GaN wae AST 77H wigan Tas e1000 S540 360 RS4286 70/5660 2 6800 S208 506 3422 3437 778 10600 O13) _BI71_7201_ 8500 110680 6ac0 RSO325 228/000S 1 T0160 e360 ose wad ale m0 “sam s2a6 1268 eo0m0 72580” 4700 | RS4325 228/0%0.0 2 1010 6950 6098 S040 904 900 11909 9202 8246 7470164800 145180 9840 RSOS66_228/720.5 1 1490 7239 eBS8 esas ass. 1050 Toast jot27 reaa 105000 e120 850 TSUBAKI marie engine oer chai ae rade pail nsec wi 85228 1970 {Shsh stondae spesieatons fr transit valley chainsDIMENSIONS (inch) AND SPECIFICATIONS (lb./ft.) Ke fe 1 aa =| 1B = hall hes bi 4] cxoss ‘ioe nici oust Tare SECTION, viEW STRAND ‘STRAND ‘STRAND Tue ggg ME Se E sa ER Cant onStin, Sick a eos tk & sum BS we RS0088 28/1685 1 1000 G62 0570 von 140810360 RS4088 224/160: 2 1000 a82s O87 ton 2616 1980 RS608B 224/1e5-T 3 _1000 0625 0870 ron 391022640 RSOTOS zaw/aweS 11280 07800779 e188 16870 RS4108 2/60 2 1250 070 070 isi 2096 90420 ASEI06 2w/x8T 31250 0750 0770 ist 4426 _ato00 RSov27 za28-5 F800 1009 1007 aot 2087 21250 RSAi27 nw/20-0 2 1500 1000 1000 rst 99724280 RS6127 228/287 3 1500 1.000 1504 5890 69450 6000 132 | RSO147 Dams 1178011001720 ais 2508 s1970 00068 | RS4147 228/208-D 2 1750 1200 0626 0628 1319 2345 1834 1845 4854 61.200 58000 110 | RS6147 z2e/700-T 91760 11001200 082 O6LH 1519 2045 1834 1887212 90400 _sPO00 163 RSO166 20/375 1 2000 1200 0701 0703 1589 1794-1806 «246941890 38000 RSAI6G zz0/2m.0 2 2000 130 1220 O71 OMS 1589 2205 1784 1805 4772 0910 16000118 RSO1G6 29/5201 3 2000 1950 1220 O7OI_aND 1569 2005 1708 1806 Poh THe7IO 14000 174 RS0206 229/«08-S 1 —2600 18801800501” 0909 2057 2186 22063079 eatao 50000101 RRSA206 720/408-0 2 D500 1860 1500 0901 0mC8 2067 2840 2196 2206 HHI. 129810 NACHO 3 RRSSZ06_z70/4007 3 2500 1860 1500 0501 ots 2067 2645 2195 2700 _a15 102880 177000 200 RS0246 2720/4885 1 3000 ve00 1181 1153 2512 +2778 «2791 «8886 98210 90000 161 34246 29/4000 2 acm 1600 1900 14511169 2512 3591 27% 771 _74B0 190700 TeOOHD 321 RS62AG 220/460-T 2 2000 1900 1800 1161 1189 2512 3601 2778 2761 11087 752410 DOGKO 476 S026 25/5555 | asco ave 2100 138i 138 30m 3202-9217 asoH Taaa@d 122000 728 | RSAZGG zan/san0 2 _3500_21z 2100 1361 1389 sous 4197 3200 717 a7 za0800 2440n0 457 RSOS25 e9/e48:S 14000 7=00 “2400 TssI 1859 “Sam Gar 17897016000 a8 SA325 z20/610-0 2 _4000_ 2800 2400 1861 1589 3543 4700 3629 3040 7a _sHasi0 e20mKD 628 RSO366 220/728-5 1 4500 2860 2700 1761 1759 4055 4087 4105 5685 231.480 202000 393 | "TSUBAK! marina engine roller chains are made precisely in accordance with BS228 : 1970 {eaush sanded speceations for tranarssion fle hein)TSUBAKIMOTO CHAIN co. Soe aStrafag Betriebsanleitung Druckschalter Mode d'emploi Pressostat sensors@>controls Instructions Pressure Switch Soe ioe 1) Betsiqung an Gentone ‘Sane mite two serene is) Use Sree EB een ” Trofag AG Tel +41 :1:922 3232 EmikStayb-Strasse 1 Fox +41:1.:922 32.33 atte 189 CH - 8708 Mannedori = Web. www. trafag.com H71261Druckschatter Pressostat Pressure Switch rom det Spate TAL ond er Sete Fonene ‘i ents Aas ig Stongrmighct tei 2% ay op cg en me E = ite epson, tm sa cites er a ‘aca2—Leiter Druck Transmitter trefeg 2-fils transmetteur de pression 2-wire pressure transmitter Bei Waseranonen ict der Anschluss ste —_Leconduit de connexionduréanoits'esu By water installations the connection is fon des Uructhuters 20 vermeicen, Bei Sumer tos thuctuations Se preston. stotertonk, core iz to Be. fokem that the ‘ee Soe Tron mi einen Recordingly long s0pply tubes oF damping Droctnsue” der Putationen sutra ntorepeoauresnoctsor pulsations aopsar oleiungen oder Dompfungerorecheungen Einstellung und Justionang Réslage et ajustement Setting and adjustement Geiss osteangsnen werden ion Work Talay AG suite Fétendue de céslace ate TRAFAG fas set the ange and the ze. point, Seantie" und NUCLPUNIET sbgesichen. ro selon lsoacticaions delocomimon ——_getandng tothe sonifcnin of onde tree Some en, mchtaghches Justices mt eau eas cs un requsioge ext nccesare an aeinona seiings aecesary it sponse ine tora tan botnet Sioa else cower eager ten. Sharmoung the tve to set he one ond 4.20 ma a Type 8202 | L_Variante mit Faston | vu, und klemme ven seem von] Emameter a 1 cea ad Belon, eo ooma me ie + Type 8202 wor erve yt Emameter H ~ 12.0 ma eingeorane: Giichsuom SEGA courant continy indépendant de N42 dtl curent lond independent fi Ausaarpiagealeoterndor aut dom Ker Muptave Ou wm oetcreuit de te sone shortceuit 220. MAY corvent OF 80 1090 Suetomeen (50 mat uct ut den usa une grandeur Se torte vee tb vlaye are (3.8 mA hertoutnomeces Ca covrrcttan de Cowan (230 mAyouls— Shortaireuit crrent eee aaa Sieur de courant vise (23.8 8. Toe 8260 seo 0 ma, Top 8202.c8, 32m, Type 3200 cow 80th 8202 cow S2mA, Pole os Gerst iat gegen Veveotiura gesehuteh vesten octigé conure poles remersée connection tne wrmisain, Fetter Pere 3 L002 BK de0,.70 0 Zero poten: <* 0.02 XK trom 0..70°C Nitipunks: 24002 9/K von 0..70°C Gomme, = £0.03 50% Jeonecenan la Rose SEGBS Meee Gen EMMI: EGER Stents ma Cinclnny. EB BI Stee Pema (OS rence ord eee 96% humidsre,3558C Hamidiey 9B, hamadity at $5 OC Terie o025 10 Fost bes 85.9¢ eogratce mbar 020°C bint temoertie 0 708E ‘Vibration: ‘geriss Gt, Kenniinie 2 selon characteristiqve 2 du Lioyd Germanique _characieratic curve 2 following German Liowd: 1-70722 mod.Types 8200 / 8202 Installations- und Bedienungsanteitung Instructions d'installation et mode d'emploi Installation and operating instructions trefag 2-Leiter Druck Transmitter 24ils transmetteur de pression 2-wire pressure transmitter 2.Leiter Druck Transmitter mi Halbteiter Widerstande-Messfubler Typ 8200, 2-Leiter Druck Transmitter mit Dannfilm -OMS- Messtuhler vor Typ 8202 4..20 mA eingoprigter Gleichstrom Gehivsedeckel_aboohmen, mit zwei ‘Schrauber bea eine ieste Unter Solern der Oruckanscis gonigond Direkt aut dem Drucktvoer Directly vo premure recone Druckanschtuss Beim Anschiiessen Verdrehen des Oruch. fave und Damsaura sie mt Was Trofog AG tel +41 19223232 EmilStoub-Strasse 1 Fox 441.1 922 32.33 (CH-8708 Ménnedorf www trolog.com 2Ailstansmetteur de pression ‘Sonde semi conductour rénstve Type 8200 2uits transmetteur de pression Sonde 3 jauge de contrainte Type 8202 4..20mA CCindpendant de a charge 2 Fixation 4 aide tie Eotver fe couvercl, tne a Presotat S'Taide de ux vis 08) we urn bose 1) Faation aie, Sabi do cont allt Schortvencwautung Raccord de la pression ipathe eau stagnomeh Cee Sete a at wire pressure transmitter Semiconductor-resistv-probe Type 8200 2.wire pressure teanemitter with thin film wire stain gouge Type 8202 4..20 mA DC load independent Dismount housing cover sere to 0d Sooo wth wo sees rd Abit Roteiveg Pressure connection 72.2-0 H-70722 dfe mod. 887Betriebsanleitung Instructions de service Instructions Industat/ Navistat alle Auvsfibeungen tout les éxecutions for all versions Drehbore Skala/ Echelle tournonte/ Revolving scale ‘Bei dr Montage dev Sholom Rasehen divfon| ‘unter de Kop dor Balestigungrchroubur M2 {Bylindorchrauten| Keine Unelogiecheben ‘ongebracht werden, Moninals Wandstnke nm For grosses Wondstrhen snd peril ‘erangese Achien ech, Fou. lo montage dy eniliveur ae foul pos wer, de onde sous ote des vs M3 LUepoitter de panneau mama et oe Pour des ponneaux d posniour pus grande i ou user dos ones specoun. For mounting ofthe bezel isnot allowed a wie ‘oy worhers under the head of the mounting: ‘ens M3. The mosimar panel thickness i enn Foe luing to heoviee pone special spindles ore ovodebe Umgebungsicinperatur/ Température ambionte/ Ambient temperature [Nicht temperctrkompensirie Regle nd in normale Roumemperaiur zu montecen. Eine Sore Erhohung der Rovnamperair hot on ‘Absinkon dor Regalrve eur Folge und tte Die Shoten snd ledighich Enstlbillen ue Kine Heine Abwechungen gegener dam Tenet aubweten Pozi Findelungen mien ‘it le eines Tovmenetersvorgenorema “rerden: Be qrosten Alweichongen sche unter Nachjvatieren! Scholtditlerens (Hysterese) Diltérentiel Switching difference {es egultours qui ne sont pos compensts pour ler vetotons deo tempéraire onbionte ont 3 vier dons use lempétoture ombiont do 15 8 125°C, Une howe es grande de lemprotre dla ite dy herons Boiss pot de coupure vice versa Einstellskolo/ Echelle/ Setting scale 4 Dai anes BS Lee cate Parone me Seen tc nents Fal Thermos wich ore no compensated shold bbe epereted ato canard cmbient lemparaue A substotaliereote in ambien! lemperoure sill cove lowering ofthe switching pon, ond The soles only on indication of the temperotsre nd con have @ small deviation from the orc wale, Foran accurate sing ‘ie 0 thermometer ond ci iMler- und Schuterohrmontoge ‘Montage de la sonde et du doigt de gont controls Instructions Picostat Massbilder / Cotes d'encombrement / Dimensions oe 765 bee Stckr / Conver / Pg Stcer / Comper / Po ont ahesb A OM stes0-a (0) (Zbhr 58/ Ace 587 Acer 58) Tabhir 59 Pacers 397 een 59) Schutzart / Protection / Protection GX P65” "nur mil vorchifsmasig montierter Kobeldose gig 5X1 1P51Y ——_velabe seulament avec ice forlle mane selon insructions provided femole connector is mounted according Io insrctions Elektrischer Anschluss / Raccordement électrique / Electrical connection DIN 3650-4, DIN 43650-A (GU) Scholter 20 AC_250V_10 12) A Schoher 28 AC_250V_S(I] A Schaller 89. AC__—30V__ 03 (02) Microrpleut 20 ne 20 o.ao.21a Microwpiew 28 ne anv 0310.21 — MCTONVPIN ES DC 75y 0.16 (0.11A Microswich20 PC 720 010.21 croswich 28 °C TIDY Geto aya Mieroswich 83 Soy weainau Mv OL) A mv SI) A Lebenidover mechoniach (Anzahl Lostpiele) Schaar 20 Scholor 28/83 Durée de viemechonique Nembrede cycles) Microrupleur 20. | Mio, Mieroruptour 28/8310 Mc. ‘Mechanical lifetime [Number of ces) Microswitch 20, Microswitch 28/83 Botriehstemperatur / Température de service / Operating temperature Type 980, 9K0 = BEC + BSC Type 90 Oe + are ‘Messstoft-Temperatur / Température de médium / Medium temperature “ype 980, 9K0 = 25%C .. + 120% ype M0 OC + Bore Logertemperatur / Température de stockage / Storoge temperature AOC. 80°CBetriebsdruck / Pression de functionnement / Operating pressure ‘Messbereich / Plage / Range Jos.s4] 0.4 | 0.6 | 1.10] 1.16 | 2..25] 4.40 | 6..60 ]10100] 14140] 25.250 beg ~~ Schelidff. Schalier 20 co. y) 03 [os | o3 | oF 16 Sh EGei steko zoe | os | G2 | as | os ie pg eee i |_| Messbereich / Plage / Range Tato | tate | 2.25 a 25.200] a.a00] | | Membrane Schabdiff. Scholter 20/28/83 ca!) 0.4.17) 04.17)1245]1.2..45) 4.16) 4.16 | Mentone sl ote 200 ssa |57| "| an) oat | G8 | Kolben _Scholidiff Schalter 20/28/89 ca jos_24}os.24| 2.6 | 2.6 | 5.15| 5..15 | 12.40 [Pave ‘Héchstzul, Betriebsdruck woo | 100 100, wo | 20 | 20 | 400 | 1 Scho abhangg vom eingesllen Sle /Dfretil en onto de la valeur de consigne/ Swichng diferent depending vpen he preset volvo 1}. Scholtif. Scholter 20 ca. / Diflérntelsuivont ype de micrrupleur 20 env. / Switching diferent swich 20 opprox. A Scholkif. Schaler 28/83 ca. / Diffrentiel suivant ype de microryptaur 28/83 ene. / Switching dilfrenial switch 28/83 opprox 21 Hochstul. Beiebsdruck / Pression maximum admisible / Maximum working prevsure Druckanschluss / Reccord de pression / Pressure connection 1) Antighdrehmoment: Couple de seroge: Torque moment: G 1/8": Mg= 18... 20m G 1/4: Ma = 32. 40Nm | al | ‘O-Ring || A | mig: 675178 : = 2 | ‘O-ring seat: 2 250bar Nitil 90°Shore = 250bor Nitil 70"Shore 3) Befestigungs-Schroube: Vis de Fixation Ms 4-3) Ondonche 1 esting sre Noesteeen, | pore) Hise eoeeice Fosighstlare dS Classe de vésisonce: 8.8 Property dass Anziehdrehmoment Couple de serrage: 4.5... 6Nm Mounting torque! SollwertEnstelling / Adjustage de la valeur de consigne / Preset value adjustment 1 centernen ‘nlever H: Hysterese abhingig vor cingeselien Solhwer, H: Hystéésis dependant de la velour de consign H: Hystoresis depending upon the 2 preset value Trofag AG Tel 44119223232 EmilStoub-Strosse | Fox +41 1.922 32 33 ate? CH-8708 Ménnedorf wirwirafog.com 4606000000" *! 2th tales AG 9/07 Were ep nl clone reg ey vera.trafag Betriebsanleitung 8244/8284 Mode d'emploi Picotrans sensors cont rols Instructions Massbilder / Cotes d'encombrement / Dimensions * TIT | a} | | 2} |S PD «91 8) C7 ar aie ee 4.7 Steckr / Connector / Pig Siecle / Comedie / ig On 236508 BN 43650. (60) (Dab 58 / Aces 38 Aceon 58) (Tabi 59 Aecessre 89 J Acenory $9) Elektrischer Anschluss / Raccordement électrique / Electrical connection Schomon [| P65" [Schaar 7] ES] ——Schuas 7 Ya Praca” —|— Praacios” —|— py Protein on Austoheung | “9650-4 Ausfihrung | 428508 ‘Ausfuhrung | 42650°4 Exscoion | 8244 Ghecsion | 8244 Ausgangstignal | Signal de sone ‘Avsgangssignel Signal de sorie | Signel de sorte Ee fle [sana 2 | wate) 1 | ae ates =| 4 | [Z | ere | 3 | La . Execution | a ® 1 ! Laanromntianen| © | sxavolis] DonceaNs/? | ° nur mit vorschrifiméssig monietr Kebsldose gig ‘oloble seulement avec fiche femelle montée salon inskucions provided female connector is mound according lo iasuctions 1 2 3 8 Ausgangssignal / Signal de sortie / Output signal Ouipor toad Tomine. L008) Ua 7 XA HK IH HK ar 20mA [Us 101/20mA 16%. save 19 o.. svoc 2 tho 2 18ma 10. 30v0¢ “ oO” wovoc |S 2k 220ma 15 30v 06 7 Vo ‘evoe ska E18 ma 12. 30v0e 16 0 mk = Ok 35mA 24 VDC 2208 20 Betriebstemperatur / Température de service / Operating temperature “DEC $B5°C Lagertemperatur / Température de stockage / Storage temperature “40°C .. +85°C o oe, Trafog AG tel +41 1 9223232 ae oe et” Mee Emil-Stoub-Strsse 1 Fax +41 1 922 32 33 tet 8 fe ae! oe, (CH-8708 Méinnedorf womirclag.com 4446644004" *e' 5Betriebsdruck / Pression de fonctionnement / Operating pressure h 0 10 Gherdrvck smo 3 ° 1s Surpression 3 Ronge 0 25 Over press 6 ber’ ° 40 tor 10 ° 60 6 0° 109 2» Oo 160 2 Oo. 250 20 Oo” a0 Ey oo 200 7. 1000 200 Oo” 1600 500 0”. 2500 500 0%, 4000 ‘200 0”. 6000 1000 Druckanschluss / Reccord de pression / Pressure connection pt { 2 250bor Niki! 90°shore ‘250 bar Niuil 70‘Shore } TE 4 Anziehdsehmoment Coop de serage Torque moment 88 Ne Onin 2 “60 Nm Jolt for Fetigheitlione Ging vesk Case de esstonce 8.8 Proper css 6.750178 | 8 ri t k cnflernen tenlevor a) * Dos Gera ist werkseitg kaiser und Decor boner weleren Einstlng, * Lopporel st ous & Nusine, un résloge Uriour niet pos nécescve, * The insrument has been factory clbrted, no further adjvsment i nonmaly required, Were thet male chentonsas chi pags my wo Trafog AG el +41 1 9225252 oe, EmilStub-Srosee 1 Fox s4l 1 922 32.33 stot 0h %, CH+8708 Mémnedort worwrahogcon $960 0668999" 16SINSTRUCTIONEMANUALE Heme FOR RESISTANCE BURB _ GMFR)) CMR KOREA CO., LTD.~ CONTENTS — Outline -~ Constitution ~ Installation & wiring - . Maintenance & inspectioin — (REMARKS) Specification - Construction ~ ‘The table of resistance value ----~1. Outline In general, the electric resistance of the metal is variable in proportion to the temperature. So, it is possible to tell the temperature by measuring the resistance, after Une investigation of the relation between the electric resistance and the temperature ‘There is detector used the theory of the resistance variation in proportion to the temperature of the platinum wire in this result, ‘and this detector is called PLATINUM RESISTANCE BULB. The resistance bulb consists of the resistance element (the resistance wire wound to the bobbin) the internel leading wire, the protecting tube, the terminals. ete. ‘This resistance bulb has the high pure platinum wire es the resistance element which is put in the steel tube in order to protect against the circumstance condition such as the moisture. the vibration and the shock. Moreover, it has the terminals for the connection of the wire and steel equipment for fixing the part of detecting the Lemperature This resistance bulb is produced so that it can demonstrate the good characteristics for the marine use, in order to be operated under the severs vibration and the shock on board 2. Constitution There are the resistance element and the internal leading wire inside of the resistance bulb, and the outside consists of the protecting tube, the bolls, the plugs, the terminal box, and ete. ‘The protecting tube ~ This tube is used for protection so that the resistance element and the internal leading wire may not touch the measured thing directly. ‘The bolts & plugs - There are the steel equipments for fixing the resistance bulb to the measuring spot. ‘The Lerminal box ~ This is the box to connect the resistance bulb to the outer leading wire 3, Installation and wiring Please pay your attention for the followings in case of the installation (1) It is necessary to choose the suitable place and the method for the installation which can transmit the temperature correctly and can follow the variation of the temperature as quickly as possible. Please take care not to bend the tube in view of the construction of the resistance bulb, (2) Please choose the suitable place which has the smallest vibration, the least dirts, and the lowest moisture. Then, please install the resistance bulb at the place which is convenient for the maintenance and the inspection, (8) In case of the connection of wires, please confirm the wire sign in order to avoid the mis-connection. On the treatment of the end of the wires, please connect the wires firmly by using the compression terminals to avoid the trouble such as the breaking-wire and the short-circuit.4. Maintenance and inspection 4-1, Maintenance items and maintenance intervals Maintenance / inspection | Initial interval | Normal interval Mechanical inspection 1 month 3 month * Blectrical inspection 1 month 8 month * Cleaning 1 month 1 year + Refer to the item 4 and 6. 4-2, The condition for opening (1) Turn off the switch of the electric source. (2) Do taping around the end of the outer lead-wire which is taken off, in order to avoid the mis-connection. (8) Never open the internal resistance element at the spot. 4-3. The order of opening (1) Take off the cover of the terminal box (2) Loosen the terminal screw of the cables. (3) Loosen the cable gland. 4-4. The necessary tools (1) A plus~driver. (2) & spanner. {3) A monky spanner (for the cable gland) (4) A radio pliers. (5) A circuit tester 4-5. The condition for the maintenance Prepare the spare parts4-6. How to keep good condition for the adjustment (1) Mechanical inspection Inspection points Inspection method Caution ‘a. Inspection of the looseness of the bolts, plugs and the outer tube. b. Inspection of the looseness of the terminals. ¢. Cable gland 4d. Temperature trouble Examine whether there is any looseness about the tightened part of the bolts, plugs and the outer tube. Examine whether all the terminals are fixed firmly oF not. Examine whether there is any looseness of the lead-in cable gland. Examine whether there is any breaking of the gland cover and the wiring, (2) Electric inspection Inspection of running Inspection method Caution a. Inspection of running of the electric source b. Insulation resistance test Examine running of the electric source with a tester. Examine the resistance between the terminals and the protection tube with DC S00V tester (more than SMQ). Whether the breaking not. (8) Cleaning Inspection points Inspection method Taking away the dirt attached with the protection tube for the high temperature, After taking off the resistance bulb, take away the dirt attached with the insert part Caution Avoidance of the error generation and the burning out.4-7 Presumption cause or investigation method about the trouble state ‘Trouble state Inspection method Caution Breaking out of the wire ‘Thermal vibration and shock | Short-cireuit Bad insulstion a. AS for the low Lemperature, the infiltration of the sea water, fresh water and the oil, due to the badness of the instruments. b. As for the high temperature the chemical change of the insulation, due to the high temperature. | Badness of the distance of the leading-wire. Exchange the bad one for the spare part. The pointer of the tester does ot move in case of breaking the wire and it shows less than 1M In case of the bad insulation, In case that the allowance increases gradually while using. In case that the allowance increases suddenly while using. a. Badness of the indicator. b. Badness of the resistance bulb (1) The increase of the internal resistance (2) The decrease of the internal resistance (3) The increase of the dirt attached to the protection tube. Connect the standard resistor instead of the resistance bulb, and find which of the measuring device or the detector is bad. Exchange for the spare parts. Take off the protection Lube and take away the dirt, ‘2. Abnormality of the measuring device b, Badness of the resistance bulb ¢. Bad connection of the wire, due to the looseness of the screw. 4-8 Method of repairing Exchange for the spare parts, (1) Do in accordance with the reverse order of that of opening (2) Concerning the one for the high temperature, the protection ‘against burning out should be carried out around the installation serews at the side of the engine. 4-9 Confirmation items (1) Confirm whether the leading-wire is connected correctly. (2) Confirm the tighteness of the cover. (3) Confirm the fixed part of the bolts, plugs. ete. (4) Turn on the switch for the electric source.SPECIFICATION FOR THERMO RESISTANCE BULB 1, Scope ‘This specification applies to the thermo-resistance bulbs which used to every part of machinery. 2, Specification 1) Element wire : platinum (Pt) 2) Nominal resistance value ; Pt 1000 at OC 3) Rated current : DC 10mA 4) Class : B (DIN 43760) 5) Resistance value of standard element : according to DIN 43760 6) Allowance against temperature : +(0.9+0.005t/C 7) Insulation resistance : it is to be the fcllowing table. Insulation resistance (Ma) Temperature range(¢) | ————___________ | Normal vemp. | Maximum temp | 200 ~ 100 5 | i] O~ 200 T 5 5 — 0 ~ 600 6 8) Dielectric strength : AC S00V 1 minute between conductive part to protection tube. 3. Environmental durability Vibrational durability It is based on the ship registers of every nation Approved certificates : KR, NK, LR, BV, DNV, GL.Specification of Type MPT100 1. Nominal resistance Pt 100 ohm 2 Class DIN 49760 05 MPT1oO 3. Regulated current 1OmA 4. Operating temperature : 0 ~ 200C | 5. Wiring 3-wires system are ot Measuring This MPT1OO Resistance Bulb is made up of internal element, protecting tube, and terminal box, and it has the advantage of following items at fitting state. Ter(1) It can do temperature Lest easily without box at fitting place. Loosen the nut like as following diagram, then, internal element can be pulled out trom outer protecting tube Item(2) The element can be changed to new spare one at fitting place, at this time, take off the cable from terminal box, and loosen the fitting screw of terminsl cover from terminal box, then element can be changed to spare one, fonnection of cable from terminal Bolt Complete Type : MPTI00 1. Fitting state, (Pig 1) a ____Protecting Tube Loosen the bolt 2. Temperature test (Fig 2) li | Internal element —- || Spore element 3. Change of spare (Fig 3)CONSTRUCTION ‘The temperature therminal resistance bulb is composed of a resistor clement, inner wires, production tube and terminal box. The resistor element is classified into two types; one for low temperature use and the other for high temperature use. The element spool for both types are made of oxidized alumina around which a platinum wire and inner wires are wound and welded for security. ‘The element spool for low temperature use is provided with an insulation tube at the inner wires which are welded to the terminals through the terminal board ‘The insulation tube and the terminal board use high quality ceramic as insulation material, while the terminals use selected material which is excellent instability against oxidizing and reducing atmospheres. The element spool for high temperature is enclosed in a sleeve type insulation tube (super-ceramic), thus it is fully protected against vibrations and shocks which may occur while in use The inner wires use nickel as material and welded to the resistor element. The material of the protection tube is based on the standard of SUS 304. ‘The lerminal box is made up from aluminal die~cast casing. the wire pads-through fittings are aluminal die-cast casing. the wire pass-through fittings are based on the standard of JIS FB601, 20a, Insutotion fing powder CERAMIC SUS_PIPE Construction for High Temperature Use COPPER PACKING ___ compere pron Exewent BORED POCKETTABLE 1 LATIONS TEMPERATURE/VALUE OHM 330 340 30 360 370° 380 390 22285 22617 22967 Bay | 73352 23865 | 237.00 330.19 | 2a0'37 243/53 | 24333TABLE 2 RELATIONS TEMPERATURE/VALUE OHM [ce ° Spool [sé 3 2 woo | 24708 247.38 297.73 248,76 | 249,10 749.79 | 28019 to | 043 25082 Ist.t6 | seta | 25259 25322 | 60/50 420 253,90 254.24 254,59 | 255.61 | 255.95 256,64 2 Sao | 357.2 | 25786, 2581 dsr | 229.36 | aad | 230372 | 281108 281.40 | 25282 | 262.78 | aso | 268,11 | 25445 26479 | 265.13 | 266,47 | 265,00 | 266,14 io | Gera | 25y'es 2017 250's0 | 2o8as | 269,18 | 2os'51 am | 2083 37133 | 2vs7 | 27220 | 272 | 272ie feo | eae Briss rat | eee Best | aso | 37736 31023 | 278156 | 27850 | ns56 1 500 | 250.90 20156 j 8223 | e289 sro | 288.22 2aaisa | 226.21 0120 sao | 26733 36.19 23851 3030 sao | 28083 3514s i 232.80, a0 sao | se 389 | 36.08 sso | 2979 29998 299.35 | Sorat | So2'e1 Soe'0 3 05.85 a9 H 03,03 abe nest nisza aise Bia 31982 | 320.63 331 322185 | 381 325.08 2503 | meas | as 3 220.14 331.40 nana uate Bee irr 3io.39 | 3s. 385, 388.35 gis99 38730 28.22 nea s0.07 , 320.38 351,30 351,91 | 353.14 | 393,45 sea Bsoe 35620, e651 aera 3800 gs025 3 360,37 361,07 362.29 | 362.59 35380 3ese0 , Sesto Seat, eset 355.82. 3ea82 | 367.12 | 3sea2) Hae: 3e.89 360.83 37013 333 Hiss i 372, 372.82 | 373,12 4 | 374,32 37461 ) 374,91 aco | a7sst 37581 , 37810: a7640 | 37670| 37700 | 377.29; 377.59 97789 B10 378.48 378,78 379,08 | 379.37 379,67 | 379.97 | 380.26 38056 380.85 820 381.45 381.74) 382.04! 362.33! 38263 | 38292 | 383,22 38351 383.81 839 | 3e1%0 Sado | Ses98 | 3es25 | Ges? | 38587 | 366,16 Sees e675 eco | 3573s 3e783| 387.92 | 358.21 | 3easi | Seee0 | eo.09 See's0 e808 teo_| Seo g5 2 | P| Ret | Re eee eeINSTRUCTION MANUAL FOR THERMOCOUPLE GMER)) CMR KOREA CO., LTD. 821-33 Myungjang-Dong, Dongrae-Ku, Pusan, Korea Tel. (051) 521-2835 FAX. (051) 521-2886 cemrkorea@thrunet.com— CONTENTS — 1. Outline ~ 2. Constitution ————————__--— 3. Installation & wiring ~ 4, Maintenance & inspection 4-1 Maintenance items and maintenance intervals 4-2 The condition for opening ~ 4-3 The order of opening ——— 4-4 The necessary tools —————— 4-5 The condition for maintenance —— 4-6 How to keep good condition —- 4-7 Presumptive cause or investigation method about the trouble state er 4-8 Method of repairing — 4-9 Confirmation items 5. Self testing — 6. Reference thermoelectromotive force of "K” —1. Outline When welding both ends of two (2) kind of conductors and giving tempera— ture variation to each end, a thermoelectromotive force generates between the conductors caused by flowing thermocurrent in the closed circuit. A point B point fic] free] | ——— | EMF. (Electromotive force) i bed ie HOT JUNCTION COLD JUNCTION Fig 1 In Fig 1, value of thermoelectromotive force depends upon the temperature difference between points A and B (Ti-T2 °C), that is, the temperature difference between A and B can be given by the value of thermoelectromoti- ve force by means of examinating beforehand the relation between the temperature difference and the thermoelectromotive force. ‘A thermocouple is the temperature detector using the above theory. In case of measuring the temperature of point A, it is necessary to add the value of temperature of point B on that which is measured by the value of thermoelectromotive force. For this purpose, a temperature compensa— ting circuit is attached to the circuit. Meanwhile, in case that the temperature variation at point B is large, the measurement, error come into large too. So, it is considered that the thermoelectromotive force to be measured at the place where the temperature variation is small (point C). But because, there is temperature difference between point B and C, a compensating lead wire which has approximately the same thermoelectric characteristics as the thermocouple is used for the wiring between points B and C.In case that the temperature compensation is carried out at point C, usual cables can be used for further wiring, An example of the tempera~ ture compensating circuit is shown in Fig 2 Cold juncti Cold junction eeaaca compensating circuit compensating resstonce 2 Thermeelectromtive force Thermocouple usual eable Terminal 2. Construction Inner part of the thermocouple consists of the element wire of thermo~ couple, and outside part consists of the protecting tube The protecting tube : This tube is used for protection so that the element. wire of thermocouple may not touch the measured thing directly.3. Installation and wiring Please pay your attention for the followings in case of the installation. (1) It is necessary to choose the suitable place and the method for the installation which can transmit the temperature correctly and can follow the variation of the temperature as quickly as possible. Please take care not to bend the tube in view of the construction of the thermocouple. (2) Please choose the suitable place which has the smallest vibration, the least dirts, and the lowest moisture. Then, please install the Thermocouple at the place which is convenient for the maintenance and the inspection. (3) In case of the connection of wires, please confirm the wire sign in order to avoid the mis-connection. On the treatment of the end of the wires, please connect the wires firmly by using the compression terminals to avoid the trouble such as the breaking-wire and the short-circuit.4. Maintenance and inspection 4-1. Maintenance items and maintenance intervals Maintenance / inspection | Initial interval Normal interval * Mechanicial inspection 1 month 3 month * Electrical inspection 1 month 3 month * Cleaning 1 month 1 year * Refer to the item 4-6 4-2, The condition for opening (1) Turn off the switch of the electric source. (2) Do taping around the end of the outer leadwire which is taken off, in order to avoid the mis-connection. 4-3, The order of opening (1) Take off the cover of the terminal box. (2) Loosen the terminal screw of the cables. (3) Loosen the cable gland. 4-4, The necessary tools (1) A plus-driver. (2) A spanner (3) A monky spanner (4) A radio pliers. (5) A circuit tester 4-5, The condition for the maintenance Prepare the spare parts.4-6. How to keep good condition (1) Mechanical inspection Inspection points Inspection method a. Inspection of the Examine whether there looseness of the bolts, | is any looseness about plugs and the outer the tightened part of tube. the bolts, plugs and the outer tube b. Inspection of the Examine whether all the looseness of the terminals are fixed terminals. firmly or not. c. Cable gland Examine whether there is any looseness of the lead-in cable gland. 4, Temperature trouble | Examine whether there is any breaking of the gland packing and the wiring. (2) Electrical inspection Inspection points Inspection method Caution a. Inspection of running | Examine running of the | Whether the of the electric source | electric source with breaking a tester. wire is or b. Insulation resistance | Examine the resistance | Pt test. between the terminals and the protection tube with DC 500V tester (more than 5MQ). (3) Cleaning Inspection points Inspection method Caution Taking away the dirt After taking off the Avoidance of attached with the thermocouple, take the error protection tube for away the dirt attached | generation the high temperature. with the insert part and the burning out.4-7, Presumption cause or investigation method about the trouble state Trouble state Inspection method Caution Breaking out of the wire Thermal vibration and shock Bad insulation a, As for the low temperature, the infiltration of the sea water, fresh water and the oil, due to the badness of the instruments. b. As for the high temperature, the chemical change of the insulation, due to the high temperature. Short-circuit Shortage of the distance of the leading-wire Exchange the bad one for the spare part. The pointer of the tester does not move in case of breaking the wire and it shows less than 1MO in case of the bad insulation. In case that the allowance increases gradually while using. a. Badness of the indicator. b. Badness of the thermocouple (1) The increase of the thermoelectromotive force, internal resistance. (2) The increase of the dirt attached to the protection tube. Connect the standard signal generator inst~ ead of the thermo- couple and find which of the measuring device of the detector is bad. Exchange for the spare parts. Take off the protection tube and take away the dirt. In case that the allowance increasrs suddenly while using. a. Abnormality of the measuring device b. Badness of the thermocouple c. Bad connection of the wire, due to the looseness of the screw. Exchange for the spare parts.4-8, Method of repairing (1) Do in accordance with the reverse order of that of opening (2) Concerning the one for the high temperature, the protection against burning out should be carried out around the installation screws of the engine side. 4-9, Confirmation items (1) Confirm whether the leading-wire is connected correctly. (2) Confirm the tighteness of the cover. (3) Confirm the fixed part of the bolts, plugs, ete. (4) Turn on the switch for the electric source 5. Selftesting (1) Visual control and polarity test. * visual control check conformity of product with customer's demand * polarity test check wires type (color code, magnetism) TYPE COUPLE COLOR MAGNETISM thermocouple K+ NO K- YES compensating KX + | Yellow / Green No cord KX - | Purple / White YESHANMI POWER AHP-2500 180 0001 MANUAL NO : AHP-2500-2.2(2005.03) INSTRUCTION MANUAL AIR DRIVEN HIGH PRESSURE PUMP MODEL : AHP-2500 HANMI HYDRAULIC MACHINERY CO., LTD. 718-14, Mora-dong, Sasang-ku, Pusan, Korea Tel. +82 51 305 2512-4 | Fax. +82 51 301 1721 E-mail : hm131@kornet.net / Hm132@kornet.netPAGE : 1 ap HANMI POWER AHP-2500 150 9001 HIGH PRESSURE PUMP UNIT CONTENTS A. SPECIFICATIONS enn — PAGE 2 B. OUTLINE OF THE AHP-2500 PAGE 3 C. OPERATING MANUAL ~ ~ PAGE 4 1, BEFORE CONNECTING THE PUMP UNIT PAGE 4 2, CONNECTION OF PUMP PAGE 4 3. START OF PUMP ~~ ~ PAGE 4 4, ENDING OF JOB ~ PAGE 5 5. DATA FOR HIGH PRESSURE en omeremeromnes PAGE § 6. CLEANING OF OIL FILTER ~~~ me PAGE 5 7. LUBRICATION INSTRUCTION ~~ ~~ PAGE 5 APPENDIX - ASSEMBLY OF BOOSTER (DWG NO. M10-2100-0.0) + SPARE PART (DWG NO. M10-2107-0.0)PAGE : 2 HANMI POWER AHP-2500 180-901 HIGH PRESSURE PUMP UNIT A. SPECIFICATION 4. MODEL NO. : AHP-2500 2. AREA RATIO 22774 3. ACTUAL AREA RATIO. 2266: 1 4, AIR CONSUMPTION : $200 LITERS/MIN. AT 7 BAR AIR INPUT 5. PUMPING SPEED : APPROX. 255 CYCLES/MIN. AT 7 BAR AIR INPUT 6. DISPLACEMENT PER CYCLE: 3.18 of 7. MAX. FLOW AT NO PRESSURE : APPROX. 0.81 LITERS/MIN. AT 7 BAR AIR INPUT 8 9. . TANK CAPACITY 6.5 LITER AIR INNER PORT 1/2" BSP FEMALE WITH INCREASE TO M42 ADAPTER, 10. LIQUID OUTLET PORT 24" MALE 11, APPROX. DIMENSION 450 x 341 x 400 12, WEIGHT 31 kg PERFORMANCE CURVES 10 o8 os iL FLOW (Luin) os 02 -— 0.0 8 B US 0B US UB VB OD CB OB OUTPUT PRESSURE BAR. (0) AREA RATIO ACTUAL AREA RATIOPAGE : 3 HANMI POWER AHP-2500 180 9001 HIGH PRESSURE PUMP UNIT B. OUTLINE OF THE AHP-2500 1, OIL RETURN VALVE 8. OIL OUTLET MALE COUPLING 2. AIR STOP VALVE (CYCLING VALVE) (HIGH PRESSURE OUTLET) 3. AIR PRESSURE CONTROL VALVE 9. SAFETY VALVE (RELEASE VALVE) 4, AIR PRESSURE GAUGE FOR PRESSURE CONTROL 10. OIL TANK 5, OIL PRESSURE GAUGE FOR WORKING PRESSURE 11. PUMP 6. AIR BREATHER (FILLER CAP) 12, OIL LEVEL GAUGE 7. AIR INLET (FEMALE COUPLING FOR AIR HOSE)PAGE : 4 HANMI POWER AHP-2500 HIGH PRESSURE PUMP UNIT 180 9001 C. OPERATING MANUAL This instruction has been made to facilitate the understanding of the working principles of the pump unit, The various control instruments and maneuvering handle are fitted with a number. These numbers are mentioned in this instruction and are also referring to the numbers found on the drawings showing the complete pump unit. Furthermore, these numbers are found on the instrument panel of the pump unit. Please, read this direction of use carefully before using the pump unit and follow the instructions given vary carefully. 1. BEFORE CONNECTING THE PUMP UNIT The tank Is filed with oll through the filer cap @ in the tight side of the top panel Hydraulic oil : ISO VG22 OF ISO VG32_ (MINERAL OIL) a) Open oil retum valve ( by turning anti-clockwise. b) The handle of the regulator valve @ should be turned 4-5 tums anti-clockwise. This is done to avoid the pump starting at a too high pressure level ©) Stop valve @ should be tured clockwise, to close the valve. This is done to ensure that the pump will not work at will when the primary pneumatic system is connected. 2, CONNECTION OF PUMP Compressed air is led through a flexible hose and is connected to the stud marked "air inlet” © on the right side of the cabinet, This stud has a 1/2” BSP female thread with a 1/4" BSP reduction, accepting either 1/2" or 1/4" hose. To avoid contamination of the Pump, it is essential that an effective air fiter and water separator is inserted in the air line. A lubro unit should however be avoided - see lubrication instruction on page 4. The hydraulic system is connected to the stud marked “high pressure outlet” (8) found on the left side of the cabinet. This stud has a 1/4" BSP female thread. The pump is now ready for use. 3. START OF PUMP a) Stop valve @ is tuned slowly anticlockwise, whereby compressed air enters into the ump unit, which commences to work. The stop valve @) is also acting as a regulator valve for the pumping speed. b) The regulator valve @, which is used for adjusting the pressure is now tumed Clockwise and the hydraulic pressute may now be read on the manometer for Pressure control ® This manometer shows the hydra high pressure in bar.PAGE : 5 HANMI POWER AHP-2500 HIGH PRESSURE PUMP UNIT 150 9001 ©) The oil return valve @ is closed by turning the knob clockwise and the oil will then run from the oll tank into the hydraulic system. When the hydraulic system has been fille. ‘and the pump has stopped operating, the high pressure reached can be read at the manometer for working pressure © found on the left side of the instrument panel. The pump siops automatically, when the required high pressure has been eatablished ‘and holds it infinitely ‘The pump starts automatically again if a pressure drop occurs in the hydraulic system. 4) High pressure may be relieved from the system by opening the oil return valve @ (to be turned anti-clockwise). The excessive oil the secondary high pressure system will thereby retum to the oll tank in the pump unit ENDING OF JOB To avoid oil spillage, precautions should be taken to see that the oll is taken back into the oil tank before the connections on the high pressure side are disconnected. This is done by turning the oil return valve @ anti-clockwise. ‘Simultaneously the pump should be stopped by turning the stop valve @ clockwise, and when this valve has been closed, the air hose may be removed and the pump transferred to another job. 5. DATA FOR HIGH PRESSURE The pump unit can deliver a maximum pressure of 1600 bar. At an air pressure of 4 bar a safety release valve is in the B+W standard version adjusted to release at a maximum pressure of 1060 bar. This pressure of 1060 bar (which is preset by the factory) secures the rest of the system from overload or faulty operation. The pump may be re-adjusted to blow off at any desired pressure, but maximum 1500 bar. ‘The release valve should be set at approx. 10% above the desired working pressure. 6. CLEANING OF OIL FILTER The filter in the filer cap @ is removed and cleaned when by reviling the oil starts running through slowly. 7. LUBRICATION INSTRUCTION WARNING : AVOID AIR LINE LUBRICATION. The pump has been pre-lubricated and a lubro unit will decrease the efficiency of the pump. Air valves should be lubricated periodically. Remove exhaust fitings and valve spool and apply a thin coat of hydraulic grease. It primary airdrive section is dismantied, always apply a thin coat of hydraulic grease to entire inner surface of cylinder tube plunger O-rings."0-0 eo g i Wa1S008 40 ATGNSSY 5 YY, Ze, © @®@ @ DOO®@MODEL AHP—2500 AIR DRIVEN HIGH PRESSURE PUMP DWG. NO. | M10-2107-0.0 MATERIAL SUPPLY PER SHIP S6 = 7 5 DRAWING NO, REMARK, (WEIGHT) Kg PLASTIC PACKING SEAL UHMWPE, 10-2117 -0 SPRING. SUS304 10-2124 -0 10-2139 -0 10-2142 -0 10-2143 -0 10-2147, =0 10-2148 -0 MANUFACTURER'S NAME HYDRAULI C MACHINERY CO., LTD. maraHANMI POWER VTU-1100N MANUAL NO. : VTU-1100N-3.3(2005.03) (FOR SLIDE VALVE) 150 9001 INSTRUCTION MANUAL FUEL VALVE TEST DEVICE MODEL : VTU-1100N HANMI HYDRAULIC MACHINERY CO., LTD. #700-17, Mora-dong, Sasang-ku, Pusan, Korea Tel. +82 51 305 2512-4 / Fax. +82 51.901 1721 E-mail: hmi31@kornet.net_Hm132@kornet.oetHANMI POWER 10 9001 A. SPECIFICATION 1, MODEL NO. 2. OUTPUT PRESSURE 3. AIR CONSUMPTION 4. MAX. FLOW AT NO PRESSURE 5. OUTPUT VELOCITY FOR FUEL TEST 1CYCLE 6. PUMPING SPEED 7. OIL TANK CAPACITY 8. WEIGHT DISCHARGE (L/MIN) PAGE VTU-1100N FUEL VALVE TEST DEVICE : VTU-1100N : 1300 BAR AT 10 BAR AIR INPUT 900 BAR AT 7 BAR AIR INPUT 60.5 LITERS/CYCLE AT 10 BAR INPUT 44 LITERSICYCLE AT 7 BAR INPUT AND NO OUTPUT PRESSURE. APPROX. 1.2 LITER/MIN AT AN AIR INPUT OF 7 BAR UP. AND NO OUTPUT PRESSURE. 172 06 APPROX. 60 CYCLES/MIN AT 7 BAR UP AIR INPUT 6 UITER ABT. 105 KGS. EMPTY PERFORMANCE CURVES 800 900 1000 PRESSURE (BAR) 1PAGE : 2 HANMI POWER VTU-1100N FUEL VALVE TEST DEVICE 180 9001 B. DESCRIPTION AND OPERATING INSTRUCTION THE TEST PUMP UNIT TYPE VTU 1100N FOR DIESEL ENGINE FUEL VALVES CONSISTS OF THE FOLLOWING MAIN SELECTIONS 1) PUMP UNIT : TYPE VTU 1101.2; DRAWING NO : AP 1100 WIDTH = APPROX 620 mm DEPTH APPROX 450 mm HEIGHT : APPROX 650 mm WEIGHT 155 KG 2) TABLE : TYPE VTU 602-2: DRAWING NO : AP 1104 WioTH ‘APPROX 880 mm DEPTH : APPROX 520 mm HEIGHT APPROX 850 mm WEIGHT 237K 3) FIXTURE = TYPE VTU 603-X : DRAWING NO: AP 1105-X WIDTH : APPROX 192 mm DEPTH APPROX 373 mm HEIGHT APPROX 785 mm WEIGHT 10 KG 4) HYDRAULIC HOSE : TYPE VTU 604-1: DRAWING NO: AP 11 LENGTH : APPROX 1000 mm DIAMETER —: APPROX 11.2 mm WEIGHT : APPROX 0.5 KGPAGE : 3 HANMI POWER VTU-1100N FUEL VALVE TEST DEVICE . OPERATION INSTRUCTIONS 1, BEFORE CONNECTING THE PUMP UNIT The tank is filled with hydraulic oil (viscosity7-10Cst st60° ) through the filler cap @ in the right side of the top panel. The tank will hold 6 ters. Open the oil return valve @ by turning anti-clockwise. The handle of the regulator-valve @ is closed by turning anti-clockwise. Compressed air is led through a flexible hose to the stud marked "AIR INLET* @ on the right side of the cabinet. To avoid contamination of the pump, itis essential that an effective air fiter and water separator is inserted in the airline. A lubro unit should however be avoided-see lubrication instruction on page 4. The regulator-valve @ is opened by turing the handle clockwise until the manometer indicates approx. 5 bar. Pumping of fuel oil through the whole system is now done for about one minute to make sure that no entrapped air is found in the unit. This pumping should only be done, when the oil vessel has run empty. Then the regulator valve @ is turned anti-clockwise, until manometer @ indicates 0 bar, when the oil return valve can be closed. 2. CONNECTION OF THE FUEL VALVE TO THE TEST UNIT ‘The fuel valve is connected to the pump unit through the stud marked "FUEL OUTLET" ® found on the left side of the cabinet. The fuel valve may be connected by means of a flexible high-pressure-hose. ‘The test pump is now ready for use. 3. CONTROL PROCEDURE (NOTICE : This type is not perform to atomizing) a) LEAK TEST AND VENTING FUNCTION The handle of the hyc’ operating valve @ is moved to position *OPEN*(48). The regulator valve @) is turned slowly clockwise until the manometer (and the manometer @® indicate approx. 200bar. The manometer will indicate approx. 30~85 bar by pressure reducer control Check that there is no leak at the atomizer. The handle of the hyd’ operating valve @ is then moved to position "CLOSED" (4A) and manometer © and manometer @ ate watched. At approx. 20-25 bar the slide valve of the fuel valve should open, which opening can be seen at manometer @ as an immediate pressure drop. b) OPENING PRESSURE The handle of the hyd’ operating valve @ is moved to position "OPEN" (4B). The regulator valve @ is turned clockwise until fuel oll is forced through the atomizing holes. Check that the opening pressure, which is read on manometer @ is correct. please refer to B&W motor instruction - Valve Section.PAGE : 4 HANMI POWER VTU-1100N FUEL VALVE TEST DEVICE ©) DIRECTION OF JET The regulator valve ) is turned clockwise until the direction of the jet is clearly visible. The fuel jet should pass through the holes of the jet template. After having finalized the test, the handle of the hyd’ operating valve @ is moved to position "CLOSED" (4A) 4) O-RING SEAL TEST il is pumped through the fuel valve until oil trickles from the venting hole. The venting hole is then closed by means of the plug. The regulator valve @ is tuned clockwise Until the manometer @ and the manometer @) indicate 100 bar. The handle of the hyd’ operating valve @ is moved to position (4A). The pressure should remain stable at 100 bar a few minutes. ‘Check that there is no leak at the head of the fuel valve. ) DISMANTLING OF FUEL VALVE Alter this test has been performed the regulator valve @ is tumed anti-clockwise until the manometer @) indicates 0 bar. ‘The valve “OIL RETURN’ @ is turned anti-clockwise and the hyd! operating valve @ is moved to position "OPEN" (48). The oil pressure has now been completely removed from the pump-system and the fuel valve may be removed. 4. DATA FOR HIGH PRESSURE The pump unit has a secondary high pressure output of 930 at a primary air pressure of 7 bar and has @ maximum output pressure of 1300 bar at an air pressure of abt. 10 bar. 5. CLEANING OF OIL FILTERS The mesh filter, which is found in the filler cap @D is removed and cleaned when the fue! oil has a tendency of slow flow. The oil filter @ which is found in the outlet from the oil-vessel is of the "throw-away" type, which should be removed and substituted by a new filter, when the old one has clogged, and the filter should under all circumstances be changed at least once every 6 ‘months. Please note that before removing the filter the oilvessel should be emptied completely, which is easily done by operating the pump unit without a fuel valve. 6. LUBRICATION INSTRUCTION WARNING : AVOID AIRLINE LUBRICATION. The pump has been pre-lubricated and a lubro unit will decrease the efficiency of the pump. Air valves should be lubricated periodically. Remove exhaust fittings and valve spool and apply a thin coat of the supplied grease. If primary air drive section is dismantled, always apply a thin coat of the grease to entire inner surface of cylinder tube and plunger o-rings.HANMI POWER Pos. Pos2 Poss. Posa Poss Poss Pos7 Poss PRESSURE RELIEF VALVE {Hit.vTU-5001) PRESSURE RELEASE VALVE (Hu-vru-6002) PRESSURE CONTROL VALV (HuvTu-6003) HYD OPERATING VALVE (Hu.vTu-s008) PRESSURE GAUGE (0-68a/6.0hpa) —_(HMLVTU-6006) PRESSURE GAUGE (0-10ay/.0Mpa) —_(#NVTU.6006) PRESSURE GAUGE (0-1000Bar/100Mpa) (HM-VTU.6007) PRESSURE GAUGE (0-16008e7160Mpa) (HM-VTU-6008) Poss Pos.0 Pos.it Posie Pos.ia Pos.ia Poss P0s.6 PAGE : 5 VTU-1100N FUEL VALVE TEST DEVICE STUD" AIR INLET ‘STUD * FUEL OUTLET FILLER CAP FILTER PRESSURE REDUCER PUMP faside VIU100N unit AUTO DRAIN FILTER OIL LEVEL GAUGE (du.vTU-£008) (atevTUs010) eamyTusor) (emevtusor2) caMvTU6013) (er2.1100.00) (aievTus0r8) (an-vtu-sore)OVERHAUL SPACE [080314] Revision of drawing no. [BOK DATE [REASON FOR MODIFICATION [REV'O|Seston 9-8 ‘F-o-aa rr Taaraa0)TYPE VIU-1100N FUEL VALVE TEST DEVICE DWG. NO. : M12-1008-0.0 MATERIAL, SUPPLY PER SHIP g ; DRAWING NO. | REMARK PLASTIC COMBINATION SPANNER HEXAGON HEAD PLUG WITH FLANGE AND GASKET SINGLE OPEN ENDED SPANNER + DRIVER MALE COUPLER COPPER MANUFACTURER'S. NAME p-052-05(Rev O} Te sores HYDRAUL C MACHINERY CO., LTD. AACoT Oza)FUEL VALVE TEST DEVICE TYPE _: VIU-1100N DWG. NO. : M12-1009-0.0 (1/2) SKETCH MATERIAL, SUPPLY \P OLD DWG NO, NEW DG NO. AP1100 -08 12-1109-0 SPACER AP1100, 11 12-1111-0 BACK-UP RING TEFLON AP1100 -12 fi2-1112-0 PACKING ‘SEAL URETANE AP1100 13 12-1113-0 ‘SUPPORT RING 12-1114-0 AP1100, -19 12-1119-0 P1100 21 12-1121-0 MANUFACTURER'S NAME (0P-052-05(Rev 0 (3) Biol 278 C MACH ERY CO., LTD. ‘aat210x207FUEL VALVE TEST DEVICE. E_: VIU-1100N DWG. NO. : Mi2-1009-0.0 (2/2) MATERIAL SUPPLY PER SHIP 3| 7 OLD DWG NO. NEW ONG NO. REMARK P1100 31 12-1131-0 AP1100 -32 12-1132-0 AP1100 -33 12-1133-0 P1100 45 12-1145-0 AP1100 ~48 12-1148-0 ‘SPRING AP1100 64 12-1164-0 MANUFACTURER'S NAME (OP-O5?-OR(Faw OF (2) S101 2 LIC. MACHINE ro() we SCHALLER AUTOMATION Industriering 14, D-66440 Blieskastet Industrielle Automationstechnik KG Tel: 06842/508-0 Fax: 06842/508-260 Declaration of Conformity EMC-Directive : 89 / 336 / EEC We SCHALLER AUTOMATION Industrielle Automationstechnik KG Industriering 14 0-66440 Blieskastel Tel.: 06842 / 508-0 Fax: 06842 / 508-260 declare on our own responsibility, that the products : VISATRON OIL MIST DETECTOR Type - designation VN 115/87-EMC — on andafter Ser.No. 11W-42202 VN 116/87-EMC — onandafter Ser.No. 11W-42202 VN 215/87-EMC — onandafter Ser.No. 11W-42202 are in compliance with following norms : EN 50141 , ENV 50204 , EN 55011, EN 61000-4-2 , EN 61000-4-3 , EN 61000-4-4 , EN 61000-4-8 D-66440 Blieskastel, the 09.01.1998 08. Ne. EGKONVNE.00CoO VISATRON VN 115/87 EMC, VN 115/87 Operating Instructions Article No.: 10024 Edition: 04U VN 215/87 EMC, VN215/87 VN 116/87 EMC, VN116/87 SCHALLER-AUTOMATION INDUSTRIELLE AUTOMATIONSTECHNIK KG y) : 0-65440 Blieskastel/Saar - Industriering 14 - Germany / SW Tel. ++ 49 (0) 6842 / 508-0 + Telex 44 685 » Fax ++ 49 (0) 6842 / 508-260Itis recommended to read this instruction manual before commencing the repair, assembly or commissioning of the oil mist detector system! CAUTION: The manufacturer’s warranty will become void if these instructions are not followed! ry Unless notified to the contrary, these operating “ instructions are applicable for: VN 115 /87- EMC VN 116 / 87 - EMC VN 215 / 87 - EMC VN 115/87 VN 116/87 VN 215/87 In case of an oil mist alarm, the oil mist detector (OMD) must be in condition to react within the next few seconds and shut down the engine, in order to minimise immediate or consequential damages! The corresponding relay contacts are instantly connected to trigger the alarm safety system! Safety Signs in general roo RemProduct Description Installation Commissioning Performance Test / Maintenance Failures and Corrective Action Repairing Spare Parts Service Facility Addresses Brochures, Leaflets, ete. General Information Notes Options,Product Description ‘Application il mist detectors of the VISATRON series protect large diesel engines of all operation classes against serious damages originating from crankdrive beating or piston component overheating, Functional Description The atmosphere of the crankcase compartments is continuously drawn out by means of headers and directed through an optical opacity measuring track, In this measuring track the opacity (turbidity) ofthe drawn crankcase atmosphere is determined by means of infrared light, Main Structural Components (see Fig. 1.01/ 1 to 1.01/3) 1. Base plate with air jet pump for generating the required negative pressure ( 1) and main connector plug (5) 2. Measuring head with electronic module, display window (2) and inspection cover (3) 3. Connection for headers (4 ) or individual pipes (6) Connection for headers designed as: VN 115/87, VN 115/87 - EMC ( see Fig. 1.01/ 1) Connecting box for connecting two header pipes (This type of oil mist detector may show an oll mist alarm, without identilying the individual compartment of damaged engine side ) VN 116/87, VN 116/87 - EMC ( seo Fig, 1.01/2) Valve box for connecting two header pipes (This type of oil mist detector may show an oil mist alarm, identilying in the valve box window whether a damage has occurred in compartments located either to the left side or the right side of the detector ) VN 215/87, VN 215/87 - EMC (see Fig. 1.01/3) Valve box for connecting up to ten individual pipes (This type of oil mist detector may show an oil mist alarm, identifying in the valve box window in which individual compartment the damage has occurred ) YN 115 /07-EMC vns16/87- EMC vw 215/87. Eutc vw 115/87 WN 116/87 vn 215/07 sony 4.0172 hows 12.95Technical Data Operating voltage: Electrical Data Power consumption: Electromagnetic Only VN 115/87 VN 116/87 vw 215/87 VN 115/87- EMC VN 116/87- EMC VW 215/87-EMC In addition Load to relay outputs: Sensitivity: ‘Switch position: ‘Atatm lovet:(% of opacity) of VN 115/87 - EMC ‘and VN115/87 ‘Alarm level: (% of opaciy) of viv 116/67 - EMC ‘and VN116/87 of VN 215/87 - EMC ‘and VN215/87 24 VDC +/- 25%, with reverse battery protection Maximum 3 & Wiring fas SO Het0 10 hte, 3V ofl. NOkHE to SOM, 1 Vol Etoctomagnati ft: GOH 16 200 Mie fol tength 10 V/m, Damped escilaon: 1 Mt RY, 400 pulses per secon Hit enray pss: gs 05 ule, SRV, Fi=500.9 Electromagnetic fiolds: 30 kHz to.1 GHz with 10 Vim, Acc. to IEC 801-3 ( ambient class 3, 10 V /'m, 30kHz - 16Hz ) Fast transients (burst ) ‘Acc. to IEC 801 - 4, (ambient class 3 ) Electrostatic discharge: Ace. to IEC 801 - 2 Maximum 60 V AC/DC, 2.A AC/DC, 60 W, 125 VA € ‘Ist row: switch position, 2nd and 3rd row: required ‘opacity for triggering an alarmTechnical Data Negative pressure measured: Driving air for air jet pump: Air consumption: Protection: Admissible operating temperature range: Admissible oll mist temperaturerange: Admissible storage and transport temperature range: Hum ity: Vibration: Dimensions: Weights: Pipe connections for __1.03 At least 60 mm, maximum 80 mm W.G. in Measuring Unit Pneumatic Data 0.310 0.5 bar Dependent on the number of suction points, however, max. 1 normal m?/h IP 44 O° Cbis +70°C. Maximum 470°C. Ambient Conditions = 25°C bis +80° C Maximum 90% refative humidity Maximum acceleration 6 g (see drawings 1.04 / 1, 1.04/2, 1.05/1) VIN 115/87, VN 115/87 - EMC 7.5 kg VIN 116 /87, VN 116/87 - EMC 9.4 kg VIN 215/87, VN 215 /87- EMC 9.6 kg ‘Mechanical Data VN 115 /87, VN 115/87 - EMC and VN 116 / 87, VN 116/87 - EMC Header ( two pieces, 0 22 x2 (id. 18mm) ‘maximum length: $m, R 1/2" and R 3/4" VN 215 / 87, VN 215 / 87 - EMC Individual pipes (maximum 10 pieces ) 014 x2 (id, 10mm ) maximum length: 9m 12.951.04_ Dimensions us VN 115/87 - ERIC eA Fl I « Oo} a |< vw 115/87 ous if Es 3 oii ©} : ST” | Uroral sl ald 7 O }.43,} }—140__} Irae 18 if tour eal was VN 116/87- EMC = | ——— moor omer HEH | IPL cuttOl] tt i ; 4 tl 3 is a J yd | BH | 9 a4| oe [] ees 7 t2.98 roar) Instailation General Its important to emphasize cleantiness during the assembly work! Clean pipelines and fastening parts before assembly, Lay pipes in a stress: free manner! Installation position of the device: Locate the oil mist detéctor in a vertical position! ‘Make sure not to install the device within the airflow of blowers or air dellectors. ‘Suction pipes VN 115/87 - EMC and VN 116 / 87 - EMC (see Fig. 2.1/1) Material: Seamless steel pipes, header (1) 22 x2mm (id. 18mm ), max. length: 9m suction pipes (2) 10x 2 mm (id. not less than 6mm ) Ascending to ihe device, ascending gradient 2% to 4%, without sagging, avoid oil collection (see Fig. 2.01/ 1) 2% to 4% 2011 Ascending Gradient 2% to 4%! Consider toavoid oit collection when laying the headers! Oil must always drain back to engine VN 115 /87-EMC VN 116 /87-EMC vw 115/87 vw 116/87 12.952.02 Sk Wiis Toro emc) Headers above suction points for: VN 116/87- EMC und VN 115/87 VN 116/87 without Pipe end- siphon Lay headers in ascending direction to the detector! Bear O Headers below suction points: with pipe end- siphon Lay headers in asecending direction {0 the detector! zovie @ Header pipe 622 mm x2 mm (id. 18mm) ® Compartment suction pipes to header 010 mm x2 mm (9, not less than 6mm @ Pipe end- siphon 100 rm with oil return back tothe engine, 0200 mm with ol discharge outside tho engine 1295SL 2.03 UN 215 /87- ENC VN 215/87 Lay suction pipes in descending manner! ~ Suction funnel 2.09/1 ()_ Suotlonpines viians 97 o, vi 215/a7 Material: Seamless steo! pipes, 14 mm x2 mm (id. 10mm ) Pipe Laying: Ascending to the device, ascending gradient 2- 4% (see Fig. 2.03/1) Siphon blocks Pipes can be ‘mounted horizontally v Avoid sagging or oil collection Suction funnet 2.0312 12.952.04 Pa ‘Suction funnel in the crankcase compartment, The suction funnels have to be fited in such a way that flooding by splashing bearing oil or retuming Piston cooling ol is avoided ( see Fig, 2.04 / 1) Caution: Make sure funnels are not interfering with rotating or moving parts of the engine. engine rotation bb £ ; i oO ‘Suotion rennet ‘Suetion funnet ‘Suction tunnel forsiphons and for sipons and only for engine wal connection engine wall connection engin wall connection oars ‘Suction funnel with alischarge labyrinth Senge of ‘engine rotation Pushin ‘suction funnel pipe firmly to the stop oN during assembly! aa Crankease compartment Oi return & Engine wall 2.0812 ‘Straight engine wal connection Engine wall connection LL- ype Observe mounting P position! Engine wall connection L- ype 1295 2.0813Installation of siphon blocks4-cylinders 5-cylinders 5- cylinders 6 - cylinders 7- cylinders @ Connection numbers to valve box Closed by © rain plug Connection tor © Suction pipe 1295 Suction piping of VN 215/87 - EMC Connecting flange, Valve box teft Fight Unused pipe connection bores in flangeare to be plugged with the supplied viton plugs.Suction piping of VN 215/87 - EMC. Connecting flange, Valve box tett right Unused pipe connection bores in flangeare to be plugged with the supplied viton plugs. S 2.07 7 - cylinders 8 - cylinders 9- cylinders 9 cylinders 10- cylinders Connection numbers tovaive box Closed by @ drain pug Connection for O Suction pipeNo back pressure and no oil collection is allowed in exhaustair pipe! Parts are not included in the scope of supply, but they can be purchased as an option! 295, Air supply 208/1 ® Discharge funnel © Dratt air connection set ® Exhaust air connection Pressute regulator unit consisting ot @® Throttle block ® Pressure connection 2 - 12 bar © Pressure regulator {f parts are not included in the scope of supply they can be purchased as an option 5 To avoid backpressure, lay exhaust pipes without any reducers (DN 22). € Avoid sagging and oil collection in pipes ( See drawing 2. 08 / 1 ) Electrical connection ( see Fig. 2.09 / 1) Connection: 2av 0c min. 18 max. 30 V Power consumption 3A Protection: 4 Awith semi time: lag When power is supplied by batteries, charging voltages of more than 30 V might occur. These voltages are not permitted. Device will go into failure mode. Voltage limiters must be installed! ( See Fig. 2. 09/2)Terminal Plan 2.09/1 Power supply connection for battery supply 20972 12.95oOCommissioning Adjust suction pressure The suction pressure must be calibrated by adjusting the pressure regulator when the engine is ata standstil. Make sure ventilation of the engine room is in operation (pressure ditference in room ). An increase or decrease of the pressure in the crankcase compartment during operation and its elfect on the flow velocity of the oil mist in the suction pipes, is largely compensated by the intemal restriction integrated in the device. (e.g., +25 mm W. G. in the crankcase compartment against the atmosphere account for an increase of the olf mist flow velocity in the suction pipes of approx. 8%; +50 mm W. G. of approx. 14%, a negligible figure). This is important because precipitation of minute oil droplets ofthe oll mist increases with a too high tlow rate, thus reducing the sensitivity of the device. Pressure regulator unit ® omen 3.011 1. Connect U-tube pressure gauge at inspection cover. (See Fig. 3. 02/1) ( Pressure gauge is included in the service box, available as an option ) 2._Loosen nut (1) and tum setscrew (2) in clockwise direction gently up to the stop. 3. Open safety cover (3 ) at the throttle (5 ) and manually turn setscrew (4) in clockwise direction gently up to the stop. eee oo oe 4. Switch on compressed air supply with inlot pressure ( range 2 to 12 bar) The pressure gauge should now read zero pressure. After adjustment, 5. Tum setscrew (4 } in counterclockwise direction until the U- tube remove U- tube pressure gauge indicates a nogative pressure of 80 mm W. G. pressure gauge 6. Close safety cover. and screw in the 7. Tum setscrew ( 2 in counterclockwise direction until the negative pressure previously removed is only 60 mm W. G. plug 8. Tighten countemut (1 ) 12953.02 1298 3.02/1 Filling of siphons Slide pump fing Pipe up tothe stop! 3.02/2 1. Remove plug ( 1 ) and seal ring ( 2), 2, Introduce filing pump (3) against the stop. 3. Secure filling pump with fiting and slightly tighten union nut 4. Pump 10 to 12 times with fast strokes. 5. After the filing process has been completed, remove pump and tighten plug (1 ) and seal ring ( 2), 6. Measure negative pressure in the last siphon. Apply power supply ‘Switch on power supply after checking the wiring,Oo Device Operation Control and display elements Alter the preparation work has been carried out ( commissioning ) the device sets itself to normal operation in approx. 30 seconds, after the power supply has been ‘switched on, This phase is indicated by a blinking LED No. 1. The device only needs to be controlled, if: - an oll mist alarm is recognized - a malfunction of the oil mist detector is recognised - the oil mist detector has to be maintained. ‘The present state of the device is indicated in the display window: Visatron Display Window Left side: LED No, error code) Right side: opacity in % (ashiight ) (steady burning light) No ‘Alarm LED. Alarm 14, Opacity display ( Opacity ) Test LED Ready LED ‘Alarm level switch 3.0371 12983.04 1295 only VN 116 /87- EMC VN 116/87 VN 215/87 - EMC VN 215/87 Display and function during normal operatior The basic state (ol mist opacity below alarm level ) is marked by (see Fig. 3. 08/1): = green READY LED is on = the percentage of change in ol mist opacity with regard to basic opacity is, shown on the opacity display = TEST LED is off = ALARM LED is off = READY relay switched on > ALARM relay switched off = RESET button showing no function = allvalves in the valve box are opened, sible by the symbols displayed in the oO inspection windows of the valve box (only VIN 116/87 - EMC, VN 116 /87 and VN 215 /87 - EMC, VN 215/87) Opacity increase beyond search run level The search run level is fixed to 10 % of the adjusted alarm level. Valves in the valve box are activated according to a defined algorithm in order to find the corresponding engine side or compartment showing an increasing opacity ( search run ). The search run can be interrupted by pressing the RESET button. Further opacity increase beyond alarm level marked b blinking cod ALARM LED ~ READY relays switched on = ALARM relays switched on © ~ 81d symbris inthe inspection window of the valve Box showing the enrine side on which the damage has oceured (only VN 116/87 - EMC, VN 116/87) ~ aed symbotin ho inspection window ofthe valve box showing the ‘compartment in which there is the highest opacity. (only VIN 215) 87- EMC, VN 215/87 ) ‘Alarm condition reset to basic state ~ By pressing the RESET button = It there is a dovice failure, . g. breakdown of driving air supply (READY LED is off )@® 3.05 Display and function in case of a failure A failure is shown by: = green READY LED switched off = the LED assigned tothe failure is blinking in the opacity display = TESTLED switched off = ALARM LED switched off = READY relay switched off + ALARM relay switched off = _ RESET button toggling from fault indication to opacity display and vice versa Oil mist opacity exceeds alarm level - TEST LED is additionally switched on Assignment of blinking LEDs on the opacity display showin device failure: LED No. Cause of failure 4. Negative pressure in the measuring compartment t00 lov 1B Infrared filer diny 2 Not assigned " ‘Ambient temperature < = 0° C 10 Ambient temperature > = 70° C 9 Electronics temperature < = 0° C 8 Electronics temperature > = 75° C 7 Reset button defective 6 Not assigned 5 ‘Switch for adjusting sensitivity defective 4 Infrared light track defective . a Flow control detective 2 Electronic module defective 1 Blinking for about 20 seconds ater the oil mist detector hhas been switched on ( warm-up phase ) To eliminate malfunctions see chapter “Failures”! 12.953.06 Modifications only permitted by consultation with the ‘manufacturer! Touch electronic ‘module only at exterior edges of printed circuit board! 1295 ALARM LEVEL Switch Meaning of switch positions: 1 = Highest sensitivity ‘actory-set sensitivity Lowest sensitivity To change sensitivity (this must be done by authorized personnel only! ): tc Pullout plug with RESET button - Unscrew measuring head casing ~ Remove electronic module (see Fig. 6.02/1) - Adjust new sensitivity at ALARM LEVEL switch by means of a screwdriver - Reinsert electronic module - Screw on measuring head casing - Reconnect plug with RESET button3.07 Function of relay outputs Function of READY relay {corresponding to the state READY LED ) (s00 Fig. 2.09/1) = The relay is switched on when the oil mist detector is in operation Function of ALARM relay The relay is switched on when the opacity exceeds the adjusted alarm level = Wire break monitoring by the alarm system is made possible by wire break resistors installed between contacts 7 and 8 as well as between 14 and 16 (33kO factory-preset ). ~ Toreplace the line break resistors the electronic module must be removed, ‘The resistors are located near the relay on the lowest printed electronic board (F222, R223), Attention: {In case of an oil mist alarm, the oil mist detector (OMD) must be in condition to react within the next few seconds and shut down the engine, in order to mini immediate or consequential damages 12953. 08 Performance Test Attention The engine is uncontrolled during this performance test! A performance test of the device without an alarm being indicated externally can be carried out as follows: = Open the cover of the measuring head casing ~ Wait until the READY LED is switched off after about 10 seconds ) and LED14 Search Run only: is blinking ( negative pressure in the measuring compartment too low) vw 116/87-Emc. _—_~ Daten the measuring rack with fter glass or another object ww116/87 ~ Search run (1s described in 3. 04) is started vw2is/e7-emc _~ TESTED lights up wien alarm level is reached vw 215/87 = Alarm reset by pressing the RESET button = Bypressing the RESET button once again the display switches over from fault indication to opacity display = Close cover again = Device is again ready for operation after about 18 seconds (READY LED is switched on ) Attention Take care that the cover of the measuring head casing is defintely closed after the performance test has been carried out in order to ensure that the engine is controlled again! 12.95‘When painting works are carried out near the device, the draft air supply to the device has to be turned off, in order to prevent the scavenging air filters from clogging. ‘Shut Down Stop driving air supply = Donot switch off the power supply Storage in closed rooms Tmin “25°C Tmax +80°C Maximum air humidity 85%Oo Oo Performance Test / Maintenance Performance test (To be preformed before the engine is started): = Pull out the main supply plug, green READY LED will go off = Re- install main supply plug, LED No. 1 is blinking for about 30 seconds, then: the green READY LED and LED No. 1 light up. Device is ready for operation + Open inspection cover at the measuring head, Alter about 15 seconds the green READY LED and LED No. 1 tum off simultaneously. LED No. 14 is blinking (meaning: negative pressure in the measuring compartment is too low ) = Close inspection cover at the measuring head again. LED No. 1 is blinking for about 15 seconds. ‘The green READY LED subsequently switches on, Device is ready for operation, Performance test with test vapour, e. g. vapour distillate from the Service box (to be performed only when engine is not running ) = Open crankcase - cover of a compartment in order to access a suction pipe or sampling funnel ~ Fill the plastic bag ( found in the service box ) with vapour = Alix the plastic bag to suction pipe or sampling funnel. = Allow the oil mist detector to draw in the distillate vapour for ‘a minimum of 20 seconds. = lt depends on the vapour density and suction time ( at least 20 seconds ) 1. whether an oil mist alam is triggered, or 2. whether an oil mist alarm is triggered, and a search run is started, or during the search run only one half or the engine or the affected compartment is indicated. (Ifthe amount of vapour is insulficient or the suction time is too short, a wrong compartment may be indicated in the display window of the valve box. ) ‘Search Run only: YN 116/87 - EMC VN 116/87 and VN 215/87 - EMC VN 215/87 1295Rough filter side outwards! Use cotton sticks only, otherwise the glasses may be damaged! 1295 manufacturer's liability expires. Maintenance work has to be documented. Monthly: Every 6 months: 4.0271 Check the negative sssure in the measuring head (sange 60 - 80 mm H,0 } Replace the sintered bronze filter in the measuring head. Attention: Filters cannot be cleaned, (see Fig. §.03/1) Clean the two fresh air bores in the measuring head (see Fig. 5.03 /2) Clean the infrared filter glasses in the measuring head GO (see Fig. 5..04/1) (only with siphon block assembly system, optional ior all OMD device types ) Inner odo so Cc Rlemove header pipes from the connecting box, (VN 115/87 - EMC, VN/118/87 ) or from the valve box of VN 116/87 = EMC, VN 116/87, or individ pipes from valve box of VN 215 / 87 - EMC, VN 215/87 (to ensure thatthe device is not contaminated dung the cleaning operation). remove siphon block plug, blow-clean the siphons with compressed air (max. 7 bat), mount the header or the individual suction pipes and siphon block plug, tighten accordingly Subsequently fill the siphon blocks with lubricating oil (see Fig. 3.02/1)Annually: Replace the sintered bronze filter in the pressure reducer (see Fig. 4.03/1) In order to do so: ‘Turn off control air supply, remove plug ( 1 ) with O- ring (2), detach sintered bronze filter (3), insert new fier, install and tighten plug ( 1 ) with O-ring (2) and turn on the air supply.Malfunctions Failures and corrective action ‘A malfunction in the operation of the oll mist detector has occurred if: = the green READY LED is off = an LED assigned to the failure mode is blinking in the opacity display A pending oll mist alarm is reset. Failure: No display in the inspection window, all LEDs of le cause: cP Breakdown of power supply r voltage toa low Fuse in the measuring head defective ( see Fig.6. 06/1) VO Should there still be no indication Remedy: ‘Check power supply by: pulling off the main supply plug Between terminals 1 and 2 in the socket (on the base plate, check if 18V to 30V is available. Push on main plug and lock into place. ‘Make sure that the power supply does not break down under the load of the oil mist detector. ( voltage not below 18V ) Replace fuse in the measuring head (2A, semitime lag) by: puling off the main supply plug. Detach measuring head ( 8 screws ) Replace fuse by a new one. Mount measuring head into position. Push on main supply plug ‘and lock into place. Replace the electronic module (see Fig. 6. 02/1) 12955. 02 Do not clean filters, but always replace by new ones! 1298 Failure LED No. 14 is blinking - negative pressure in the measuring head too low. Possible causes: Open inspection cover Close inspection cover Filter or water separator in the ‘Clean accordingly, empty if necessary air supply pipe clogged or filled Pressure reducer misadjusted Readjust ( see chapter 3. 01) by vibration Pressure restrictor misadjusted __-Readjust ( see chapter 3. 01) by vibration Sintered bronze filter in the Replace bronze filter pressure reducer clogged (see Fig. 5. 03/1) by: Turn off the control air supply. Release plug (1), remove O- ting (2), detach filter (3), insert new fiter (3), ‘mount O- ring (2), instal and tighten plug (4 ), Tum on air supply Sintered bronze fiers in the Replace sintered bronze filters measuring head clogged (see Fig. 5. 03/1) by: opening the inspection cover. Remove circlips. Mount new fiters (always on both sides, rough side outwards), inser circlips, close cover.Possible causes: Fresh air bores for flow contro! clogged Leakage at the device © Exhaust air pipe malfunction 5.0/1 5.03 Remedy: Clean both bores ( see Fig.5. 03/2) by: opening the inspection cover. Press cleaning pin contained in the service box into the left or right fresh air bore, respectively, The bores can be seen from the side of the scavenging air chamber. Close inspection cover. ‘Check all pipes and seats by: checking flexible expansion bellows (accessible after the measuring head has been dertached ) Replace damaged seals or expansion bellows. Eliminate blockage of the exhaust ait pipe, the air must flow without restriction, Needle lengty “Angle 11 5.0/2 12.951295 Failure LED No. 13 is blinking - infrared filter clogged - Possible causes: Remedy: ( see Fig. 5.04 /1) Infrared fiter clogged Clean infrared fiter by: opening the inspection cover. Soak cotton stick (plastic only) with alcohol. Clean intraféd fiter with cotton stick several times. Rub infrared filter ry by means of cotton stick. Make sure no fluff remains on the infrared fitter Close inspection cover again, I failure continues: Replace electronic module (see Fig. 6.02/ 1) s.04/1 Failure: LED No. 11 is blinking - ambient temperature below 0° C Possible causes: Remedy: Engine compartment ventilator Change blowing direction of ventilator, biows cold air onto the device. away from oll mist detector. Failure: LED No. 10 is blinking - ambient temperature above 70° C Possible causes: Remedy: Source of heat radiates Protect device against sources of heat fn the device. radiation, ensure an improved fresh air= Failure LED No. 9's blinking - electronic temperature below 0° C. Possible causes: Remedy: Engine room ventilator blows Change blowing direction of the ventilator to cold air onto the device. ensure that cold air itis not directed to the cil mist detector Failure LED No. 8 is blinking - electronic temperature above 70° C Possible causes: Remedy: Source of heat radiates Protect device against sources of heat fon the device. radiation, improve fresh air circulation. Failure LED No. 7 is biinking - RESET button defective Possible causes: Remedy: Blocked RESET button Eliminate blocking Failure LED No. 5 is blinking - OMD sensitivity switch defective Possible causes: Remedy: Switch defective Replace electronic module (soe Fig. 6.02/ 1) Failure LED No. 4is biking - infrared light track dofective Possible causes: Remedy: Infrared filter clogged Clean infrared filter ( see failure LED No. 13) {failure continues Replace electronic module ( see Fig. 6. 02/1) Failure LEDs No. 3 or 2 are blinking Possible causes: Remedy: Electronic module defective Replace electronic module ( see Fig. 6. 02/1) 5.05 12.95Replace fuse in the measuring head! 1295 5.0571©)Oo 6.01 Attention I these factory pre- settings (resistors) are replaced by those with other values, it must be ensured that a spare electronic module or the one in a replacement measuring head is also modified accordingly! Modifications have to be printed on the protecting cover plate on the rear side of the ‘measuring head casing, in the fields provided for this purpose, (see Fig. 6.01/14) Examine Module or spare when received from shipment. Myou return the electronic module, ‘ensure that the completed form “Why do you declare this unit faulty" Js included! Ifthe electronic module is replaced, take care oo“ that the same wire break resistors are used and that the Alarm Level sont ‘switch is set on the ‘same position! ‘The wire break resistors are located on the fist visible printed circuit board, Observe focks! Which is under the protecting cover plate, near the relays (Fi 222 and Ri 223)! ‘The resistors are designed as plug-in resistors and can be replaced without soldering! You find the ALARM LEVEL switch on the front display plate of the electronic module ( soe Fig. 3. 03/1) 12956.02 vw Procedure: ( see Fig. 6.02/14) * Pull off the main supply plug ~ Dismantle the measuring head (8 screws ) It the electronic modute is replaced or needs to be modified: = Remove protecting cover plate (3 screws ) ~ Remove the 3 hexagon distance bolts ~ Remove detective electronic module trom the casing, first pulling off the lateral flat cable plug from the socket in the casing = Mount new electronic module in reverse order ~ Install protecting cover plate, fasten 3 screws ~ Fasten measuring head, tighten 8 screws moderately = Push on main supply plug and lock it into place Bey senator batch elctonio ry ot (see chapter 401) Cs module! Examine Module or spare when received from shipment. Ityou return the electronic module, ensure that the completed form wny do you decare this unit faulty” oar fs included! C © _Dismantle cover plate by removing 8 screws ® Loosen 3 hexagonal screws of module ® Extract module Attention: The electronic module is equipped with components which are sensitive against electrostatic discharges. A replacement must be carried out by skilled personnel only! Do not touch infrared lenses or circuitry! Utilise grounding strap on your wrist. 1295Leaks or f ie of the valve box of VN 115/87 - EMC, VN 115/87 Remedy: (see Fig. 6.03/1) Disconnect header pipes on the left and right side of connecting box (1 ), push pipes aside to get ree access. Loosen the two serews (2 ) and (3) of the connecting box Detach the connecting box and remove the gasket On principle, use now Check if bores 1, 2 and 3 are free from dirt, blow them free with connecting box gasget! compressed air Clean the base plate cavity from oll Assembly in reverse order, utilising new gasket. fore t Bove 2 Bowe 3 YN 115/87 - EMC VN 115/87 6.09/1 Leaks or failure of the valve box of VN 116/87 - EMC, VN 116/87 Remedy: see Fig. 6.04/1) Dismantle the pipe connecting blocks with the headers on the Fight and left side Push away the header pipes for ree access to the valve box Unscrew the valve control cable plug and loosen the four screws (3), (4), 6) und (6 ) of the valve box. On principle, use new valve box seals! Detach vaive box and remove seal Check if bores 1, 2 and 3 are free from dirt, blow them free with compressed air. Clean the base plate cavity from oil Assembly in reverse order, utilising new seals and gasket 12.956.04 VN 116/87-EMC VN 116/87 On principle, use new valve box seals and gasket! YN215/87-EMC VN 215/87 1298 Boast Leak or failure of the valve box of VN 215 / 87 - EMC, VN 215/87 Remedy: ( see Fig.. 6.04/2) Assembly in reverse order, on principle, use new valve box seals and gasket. ( K Release the pipe connecting blocks ( 1 ) und (2) on the right and on the left side. Push away blocks with with individual suction pipes for free access tothe valve box. Unscrew valve control cable plug and loosen screws (3), (4), (5) und (6) of the valve box Detach valve box and remove seal Check if bores 1, 2 and 3 are free from dirt, blow them freé with compressed air. Clean the base plate cavity from oil, 6.0872 g ®® ©© Boe 1 Boe? Bore 3False alarm in the case of fire with smoke development in the engi Incase of a fre with smoke development in the engine room, a false alarm cannot be prevented since smoke may pass into the measuring track through the sintered bronze fiters in the measuring head. This condition induces an opacity which can trigger an oil mist alarm. Remedy: Install optional pressurised air scavenging system, available from the ‘manufacturer ( Press RESET button to reset the alarm ) Further possible failures Sudden false alarms in very warm or cold climatic areas can be triggered by "humidity (in the crankcase ) falling below the dew point: ‘ater droplets passing the measuring track or dew on the fiter glasses may trigger afalse alarm. Remedy: Check negative pressure and calibrate to 60 mm W. G., if required. Ventilation air fans, if any, blowing towards the device and its suction pipes. ‘Change blowing direction ( install deflectors ) of the ventilator to ensure that cold air itis not directed to the oll mist detector or suction pipes. ‘Check VISATRON heating system. (The heating element is located in the base plate and is hooked up with the connector plug to the 24 V power supply!) Furthermore, a measuring head heating system is available as an option (800 chapter “Options"),UO bebe 7.01 UN 115/87- EMC VN 115/87 VN 116/87- EMC VN 116/87 VN 215/87- EMC VN 215/87 1295Mem Description Article No, vw 115/87 Connecting easing 0202 2, Heating element 10051 3. Cable clp 10052 4. Lower VW part, 10032 5. Seal 10208 6. Connecsing socket 0033 7. Value bax seal 10049 8, Measuring head suspension, botiom 10019 9. Capseat 10054 10. Screwplug Rive" 10083 11. Cover lor meaiung head 10088 12, Scavenging ait iter 10042 13, Gitclipfor scavenging ac fiter 10044 vw 116/87 4. Vahebox VAl16 87 10302 2. Heating element 1001 3. Cable cp 10052 4. Base plate 0032 5. Oilretix seat 10306 6. Connecting socket 0093 7. Oitmist seal 10307 8. Sealforvatve box 10908 8, Measuring head suspension, botlom 10019 10. Screw plug R 14 10083 1, Seal com 10 10082 12, Cover for measuing hea 10088 13. Scavenging airfitor 10042 14. Cicip for scavenging ak titer 10041 15, Measuring head VN116/87 1001 215/67 1. Valvebox vi 215/87 10402 2. Heating element 10054 3. Baso plato 10032 4 Cablecip 10082 5. Oivetx seal 10408 6 Connecting soc 10093 7% Oimist seat 10407 8 Vale box eat 10405 9. Measuring hoad suspension, botiom 10019 10. Clamping plate for pipe connection 10409 11. Serew pag R vet 10083 12, Sealfortem 11 10082 13. Cover for measuring head 10088 14. Pipe connection, ett 10408 15. Scavenging ai titer 10082 1295 No. of pieces tem Description 4. 15. 16. Wr. 6 19. a 25, 26. 2. es 16. v. 8. 1. 20, 21 2. 2m, 2. 26, 21, 2. Article No, Measuinghead for VN115107 10201 Expansion balows 0023 Measuring head suspension, top 10018 Measuring head seat 10022 ‘Srew plug A 1/2" 10208 ‘Screw plug seal 10209 Protecting covertorE-madule «10084 Fastening screw for E-moduie 10085, Electronic module or VN 115/87 10203, Fuse 2A 10083 Fuse cap 10087 Expansion botiows 0023 Measuring head suspension, top 10018 Measuring had seal 0022 ‘Serow plug F172" 10208 ‘Seal for tom 19 10209 Pipe connection son2 ‘Seal for connecting casing rona Protecting cover for E-madule 10084 Factoning serow for Emote 10085 Electronic module VN 116/867 10203, Fuse 24 0042 Fuse cap 10087 Culp tor scavenging airfler 10041 Measuring head for VN 215/87 10401 Expansion bellows 10023 Measuring head susponsion. top 10018 Measuring head seal 10022 Pipe connection, right 10430 Drain pig or pipe connection 10412 Rubber siowe for pipe connect. 10411 Protecting cover tor module ‘10084 Fastening screw for -module ‘10085 Electonie modulo for VN 218/87 10402 Fuse 2, 10083 Fuse cap 10087 No.of pieces OO Oo dy 7.03 tem Description Asticle No. No. of Item Description Article No. No.of yw 115 /87- EM eee — 1. Connecting easing ro202 14. Measuring headlor VN 115/8-EMC 10601 2. Heating eloment t00s1 4 15. Expansion betows 100232 3. Cablectip 100521 16. Measuring head suspension, top «100182 4A Lower VA pant ro0s2 4 17. Measuring head seal ros 5. Seal 10208 18. Stow plug R12" 102083 6. Connecting socket 0033 10. Screw plug seal 102093 7. Vale box seat 100494 24. Protecting coverlorEmodue «10084 8, Measuring head suspension, bottom 10019 2 25. Fastening serew forE-modulo «10085 9. Capseat 0054 2 26. Electenic module, VN 115/87-EMC. 10603. 10. Screw plug R V3" 100831 27. Fuse2A to04s 1 11. Cover tor measuring heas to0ss 1 28. Fusecap 1087 1 12, Scavenging after tor 2 13. Girip tor scavenging ar filer 100412 vw 116 /97-EMC 1. Vane boxVN 116/87-EMC 10302, 16. Expansion bellows to023 2 2. Heating element roost 17. Measuring head suspension, top 100182 3. Cable clin 10082 18. Measuring head seat 10508 4. ase pate ro0s2 19. Screw plug R122 102082 5. Otel seat 10305 20, Sealtor tem 19 102032 ©. Connecting Socket ross 21. Pipe connection waz 2 7% Omit seat 10307 22. Seallor connecting casing toa 2 8. Sealfor valve box 030s 4 24, Protecing covertorEmedule 100841 9. Measuring head suspension, battom 10019 2 25, Fastening screw lorE-macule 100853 10. Serew plug A 4 e083 26, Electronic modulo VN 1161 87-EKC 10707 1 1. Sealfor item 10 0082 2 2. Fuse 2A 004s 12. Cover for measuring head 100881 28. Fuse cap 100871 19. Scavenging airtitor woo 2 14. Cicip for scavenging after «100812 1S. Measuring neag VN 116/@7-EMC 107061 215 /87- ENC 1. Vahabox vw215/87-EMC 104021 16. Ciclp or scavenging airfiter - 100812 2 Heating loment 100811 17. Measuring hoadVN 215 /87-EMC 10801 1 3. Base plate 10082 18. Expansion bellows 10023 2 4 Cable cp 1005821 19, Measuring head suspension, op 100182 5. Obretlx seal 104081 20. Moasuing head seat 105081 6. Connecting socket 100331 21. Pipe connection, ight 108301 7. Olmist seat row 22. Drain plug orpipe conection 108126 8 Vale box seat tots 1 23, Rubbersleovetorpipe connect 04112 9. Measuring head suspension, boom 10019 2 24. Protecting covertorExmodule 10084 t 10. Clamping plate tor pipe connection 104082 25. Fastoning screwiorE-modue 100853 11. Screw plug A 1 t0083 1 26. Electronic modo VN 215/ 87-EMC 10002 1 12. Sealtoritem 11 soos 2 27. Fuse 2a toms 4 18. Cover for measuring head ro08 28. Fusecap 10087 4 14. Pipe connecton ett 104081 15. Scavenging air fiter roo 2 12.957.04 Service - Box 1295,Designation Manual in English Quick connecting for U- tube manometer Gasket Wrench mounting of electronic module Filter for pressure reducer “Upper* spring for elastic mounting of the measuring head "Upper" distance bolt for elastic mounting of the measuring head Flexible clamp ring for distance bolts for mounting of the measuring head Lower" spring for elastic mounting of the measuring head "Lower" distance bolt for elastic mounting of the measuring head Oil return gasket VN 115 / 87 - EMC, VN 115/87 Bottle with alcohol Cleaning needle Cottonstick for cleaning of infrared fiters Bottle with stacked water Screwdriver for mounting of measuring head Screwariver for adjustment of alarmborder Coloured glas, 5% Sately ring for fresh air filter Fresh airfiter Flexible bellow for connection of measuring head with base plate Fuse 2A / semi time- lag Oil return gasket VN 116 / 87 - EMC, VN 116/87 Hexagon wrench for valve box mounting Oil mist gasket valve box VN 116/87 - EMC, VN 116/87, and ‘VN 215/87 - EMC and VN 215/87 LLockplug for not connected tube at VN 215 /87- EMC and VN 215/87 Rubberplate for tube connection at VN 215 /87- EMC, VN 215 /87 Mouth piece for cigarette burner Ring box end wrench Hexagon wrench for release of lockscrew at cover of measuring head Screwdriver 4 mm Pliers for mounting of safety rings for fresh air filters Gasket for valve / box connecting frame / connecting cover Plastic bag for cigarette smoke Clamp plate for tube connection at VN 215 / 87- EMC, VN 215 / 87 U- tube manometerVISATRON - Service Facility Adresses Australia CJA Marine Technology Division of C. Johow & Assoc. PTY. LTD. Unit 3 186 Cochranes Road Moorabbin- Victoria 3189 Phone-no: +461 -3-95 92 13.86 Telefax-no: +461 -3-95 92 1413 Brazil Teletronic Equipamentos Eletronics Lida. Av. Venezuela, 3- salas 602- 03-04 CEP 20081 Rio de Janeiro, RJ. Phone-no: 4455-21-23 6007 Telefax-no: +455 -21-5 16 1629 Croatia Lomaar Co. Bosnaska 4 21000 Split Phone-no: +4385 -21-584 325 Telefax. no.: +4385 - 21-584 325 Denmark J. Klitso AIS Hirsemarken 1 9520 Farum Phone-no.: ++45- 44-99 70 00 Teletax-no: +445 -44-99 70 10 Telexno: 3.3310 Germany Claus- D. Christophe! ‘Automations- und Elektrotechnik GmbH Georgswerder Bogen 7 21109 Hamburg Phone-no: +449 - 40-75 49 660 Telefax-no.: +449 - 40-75 49 68 24 @ 8.01 DIESEL ENSET PTE LTD 25 International Business Park, #01-55/56 German Cenive, Singapore 609916 “Tet: (65) 566 5567 Fox: {85} 565 7757 Emma diesel enset@achaler de Finland Schaller Automation Industrielle Automationstechnik KG Industriering 14 66440 Blieskastel Germany Phone-no.: ++49- 68 42/508 -0 Telefaxno.: +449 - 68 42 /508 - 260 Telexno: 44 685 France Sofraret “48, Rue de Rome 75008 Paris Phone-no: 4433-1 - 45224084 Telefax-no: +433 -1- 42949901 Telexno.: 260.430 Greece ‘Th. Mantanoviteh 8. A. 5-7 Aghiou Nicolaou Street 18597 Piraeus Phone-no.: +#30-1-4513868 ‘Telefax Nr.: +430 -1- 413 69.49 Telexno: 211771 Hong Kong Hua Xing Equipment Ltd. 117 F Hong Kong ‘Computer Centre, 4 - 62 Lockhart Road Wanehai, Hong Kong Phone-no.: +4852 - 8 65 68.03 Telefaxno,: ++852- 861 1470 Telexno: 65397 Naly International Marine Equipment and Services Ing. A. Cacciottoli Sas Via Cassa di Risparmio 6 34121 Trieste Phone-no.: +439 - 40 - 66 05 50 Telefax-no,: +439 - 40 - 66 06 20 Telexno.: 460209 12.951295 DIESEL ENSET PTE LTD 25 taternational Susiness Park, #01-55/56 i (65) S68 5657 Fax (65) 566 7757 Ermal deel ensat@schalerde Japan Nippon Vutkan Co. Lt. Nikko Building, 2nd Floor 3-972 Miyahara- Cho, Omiya Saitama- PFT, Japan 330 Phone-no: ++81- 48-6 5448 11 Telefax-no.: +481 - 48-654 48 10 Korea BUM- A Trading Co. Lid. Phone-no.: +#82 - 2-5 6633 40 Telefax-no.: +482 - 2-5 65.0064 Benelux Van Stigt B. V. Avelingen- West 30 4202 MS Gorinchem Phone-no.: 4431 - 183-6329 06 Telefax-no.: +431 - 183 -63 10 66 Norway Maxeta A/S. Porsgrunnsveien 225 3901 Porsgrunn Phone-no.: ++47 - 36 - 5977 55 Telefax-no.: +447 - 35 -5979 40 Poland P.P.H, Gdanpol Al, Niepodleglosci 739 A, 80967 Sopot 1 Phone-no.: +#48 - 58 -517241 Telefax-no.: +448 - 58-51 0855 VISATRON - Service Facility Adresses ‘Singapore 2262 Bond Instrumentation (Singapore) Pte. Ltd. 8 Gul Street 3 ‘Singapore 629265 Phone-no.: +465-861 4279 Telefaxno.: +465 - 8 62 40.62 Telexno.: 5.0650 ‘Spain Guillermo F. Mallet S.A. Boix Y Morer, 6 28003 Madrid Phone-no.: +434- 1-5 6491 05 Telefaxno: +434 - 1-5 3401 82 Bygap S.L, Rambla de Montserrat, 21 (08290 Cerdanyola (Barcelona) Phone-no.: +434-3-5 809444 Telefaxno.: +434 -3 -§ 8098 20 USA Diesel Monitoring Systems Inc. 4900 Mill Street Building A-4 Reno, Nevada 89511 Phone-no.: +#1-7 02-826 20.03 Telefax-no.: +41-7 02-826 20 04 United Kingdom Bond Instrumentation & Process Control Ltd. Drakes Lane, industrial Estate Boreham Chelmsford Essex CMS 3BE Phone-no.: +444-2 45-9601 91 Telefaxno.: +444 -2 45 -96 22.48 Telexno.: 996115 :@) OUie Brochures, Leaflets, etc.SCHALLER VISATRON OIL MIST DETECTORS SHORT FORM CATALOGUE VISATRON i SYSTEMS FOR DIESEL ENGINE #8 MONITORINGSCHALLER VISATRON OIL MIST DETECTORS PROTECT EACH DIESEL ENGINE TYPE IN MARINE + STATIONARY - MOBILE OPERATION ‘SHOWN BELOW ARE THE POSSIBILITIES OF APPLYING THE VARIOUS VISATRON DETECTORS AND SUCTION SYSTEMS, ‘The VISATRON 08 Mist Detectors the types VIN 11S and VN 116 ue a Header Suction ube Stem which combines crank: cease compartments for evacuating tha crankcase almospee whereas the VN 235 type uses 3 Single Suchon abe System {or indwidual compartment monteing. Should tbe impossible to make use the assembly arangements shown Below, ‘3 modified mouring version might possbly be provided lor upon request at out works. ‘SLOW SPEED TWO-STROKE CROSSHEAD DIESEL ENGINES ‘Partners ae oneal impor ‘nd therlore pon ‘Potion wil not causa ary appreciate tow of crankcase sim: he behween marisa is the casa for wunicpion stones “Ory ony aldup fot mt accra wn ein ts unless damages ocoutng, Therefor he ony sense VSATRON 219 ving a Sige satontibe Seon [lf ISickaly sulted to Montonog slow spead casshead engines A TPE Te Tee. VN 115, VN 116 VN 215 Bost model More senative model hy senate mode, isan copay Gearicace compannests where Eaton oe dana the damage has occu, aeae compan Nestea hechratonnbe esaiagontibe Marsan ma Sac max 5 single Seton ht ‘chon tes tt enon bes ah @ o eV (ale Liv coum aN cH SPEED Tana Header Sucontite Stan sale Sie Sxtonie Sen apts PISTON ORSEL ENGINES, INLINE for al medium and Tigh speed leet o'' macuin and sow speed died [AND VFORIM VERSIONS fcnginesespecaaly repacing engine gies whore in case of damage 2 have genera, unportioned compat. covigaaions where the ‘canietoe —unform spresding af he. Oh Mk ‘monts’nd he mst lrmod in case ct Sectone ate easetaly ynpartboned. ough the whole crankcase wil ke rae rap ahead Tehri comics tah more tun 1S snc ercasn Fe Sah a ete cries fa Pat the WTS and devs a2 Suey apn tosh ony mevISATMONypes compattie incase alangher sensi. Spec ae olrge megum speed Wiieand vac specongtteal — uayrequredttetpewniaiscanea —elgnes where he engl ser ‘et trough the whole cranieaoe shally be replaced by te VA 6 Irepocton doors of crankcase compar {ake mere than approe 15 see 2 10 Imeris han soarohng be te Weblo ‘eo, espectiey may be someaunt agag ise ae HE 48S NI S3HMUW34 TVOINHOSLVISATRON x Faery Oran say wating sei Os tp entra chet meted OUR VISATRON OIL. MIST DETECTORS ARE 2 Z SELGERE Tees FSSSSSSRSSS — ecaronming cauciat FUNCTIONS IN we ST igsstosotswiesy MORE THAN 15000 APPLICATIONS ——— ovmrm caermeataeeergeeete SI THROUGHOUT THE WoRLO EENALLER AUTOMATION » wetrite Automaccrntectnik KB. esting 14__0 G20 techs! Germeny——Te: 96542) SO Fox: O6B.Ag} SC8.-260___Teees 4a00S. VISATRON OIL MIST DETECTORS MEET | VISATRON OIL MIST DETECTORS FULFIL | VISATRON DETECTORS THE 3 FOLLOWING BASIC MAIN REQUIREMENTS | FURTHER IMPORTANT REQUIREMENTS ‘Sosa ntneeaedtnicntitementt | ema eer eecead er Soca neanematna ‘sloumnaaes euaom at , et a ‘Srey once as sana tonay ene men ener ease et te Canna he ee ee ARSAFECONIMOL wa Scotoy Kam ~twefsgatng hltemt es m | SMELESTREPARARLIY cet nose crn dtm YEA Doser — miro ieomecey ser os gsc pe ‘SE MEAS Fon LUNN FALSE ALAS — ned an (Huei Snr dna Sa eS BS 2Airport Seerbracken Telex: 44 68S 508-0_____Fex: [06e.42] 508-260 SLINA wercemcsmen | OL, A aes mana mM [OTS NA TAL OS BTE a ee ive | oars wenn oro ons nN | Coe Ren 10H 7H 01 -oN aunuyganan eno. aon), on68 .9.82— newnaum uae wenn pun atm 201 «2,9 ub amd ura fy A402. | ommawnrs) ym gaia tuner a sammy. ts eo Sie ete es i ae Sr ee eal i a ae at ohne fe LP LORE tents ‘SRESSTEaSed" Ms au oe Dee Se nano ‘im 2 tet) ie un ay 0 ar (ems) 2 mar WS4VeNS os HoH EHO HE “UNTY -HomOD HeNOL R88 2 1 wane) endo meg aS ci eee! te ‘037 Aa dade wuts, now BE SH g = TaN ERE RL TS ESSE 2 ie Seirus actu a owes 2 ‘exo ing coy 5 YU 0 ten ne He Sy css o to na ea tit Go a 5 _ sowo le "guano or ‘henumo $e no Was 3 0 srasag um wcziney 200% 2 3 \ , , eee seeusien : ore seni wrene vac muna ul ey dos eta sss earn gh ‘nan 3 z 8 ma onee oie TLL » aes ws Sass & _ulttaws fo 2 |, ssanevan anipaioee a fan SCS TaD WH FEW ATE GRR SRG wm NRT 2 RTE TEN OE A g |= GLIARSNGS Laue "waure "ye new eins BseeeD ‘yr eee woune ye ve aun Baten sign SER | soe Le oe eS = : TaN a SP ~ ee = eee oe ee eee 5 me a ne eons hs 2 Teocousraara sou ov eton B “(SH NA NOWAIHOSSO 431¥e 5 YUN BON). AipRdD BBz TON UAT ‘sh z le ea Toa wT BATT 38 aaciamseaan cman ute opeee | oEnn a imoBa ew ony as 2 BEB OO ; i 5 s i i g j i 2 yD iB) SCHALLER VISATRON § REPRESENTATIONS in the following counties: * Senice assistance posite Our range of BIEMOS products comprises: (Dlesel Engine MOnitoring System) @ FUMOS vay ery of varus maa OG hey oy vicang of Mycrautc of c ™@ BEAROMOS ‘monitoring of main bearings at combustion engines @ walomos determination of water content Reavy os, lubsoaling ol, hydrauc ois | WAING-ADAPT limiting value control for water content in cil, oll temperature, oi! filing level SCHALLER AUTOMATION Industrielle Automationstechnik KG Induseriering 14D 66440 Bleskastel + Germany ‘Tel (069.42) 508-0. Telex: aa 685. Fax: (O68 42) SOO-260 PO. Bax 1200 ‘Commercial Arpore SeerbrockeneS)General Information Recycling Forms: Error descriptionsSCHALLER - AUTOMATION ne Industrietie Automationstechnik KG ») 66440 Blieskastel, Industriering 14 Tel. 106842) 508.0, Fax (06842) 508-260 Why do you declare this unit faulty Please fil out this form sheet when replacing electronic card, measuring head or complete OMD and add the issued sheet to the unit when shipping it to SCHALLER Automation or Repesentative. Thanks in advance | You can send this information sheet also by Fax or mail in case the VISATRON oil mist detector is ‘malfunctioning. We will reply immediately giving you technical advice. Pleas write tis particulars, Name: [You have on hand: fgseelbent Manual, Art.No 10028 =O) ‘Phone = ~ ‘Service Box, Art. No. 10055 (] Telex: Installation instructions Art No. 10055 o 1) ReadyLEDOFF Yes [] No (1 If Yes mark with a cross which LED on the LED chain (red LED's from 1 to 14) is blinking: Please insert data to enable identification: [Oil Mist Detector Type: VN 115/87] , VN 116/870] , vN215/87() [Serial No. : ( At label of measuring head ) example: 11S-11111 OO0-DOO0D ee numbers, 1 alphabetical letter, dash(), 5 numbers) [Oil Mist Detector is installed at : Main Engine] Aux. Engine [1 Engine manufacturer: Engine type: Replace Sintered bronze filter Clean fresh air bores( on both sides) ‘Check / adjust suction pressure (60-80 mm water column) 4, ds Adjust aie pressure ‘Chan otntvshal bores seagure air vacuum a detector Malfunction still present Yes L] NoO 1.2) _In case LED No. 13 is biinkins Clean the infrared filter glasses on both sides with cotton sticks and alcohol or detergent. [Malfunction still present Yes) NoO) [Above described procedures performed Yes () No(] IF "no", due to the tack of : spares (C1, tools CI, time C] Please tum page~ SCHALLER - AUTOMATION penne Industriel Automationetechnik — KG ») Soi sie oe, © Tel. 1OG8a2 509-0, Fax (OSTA) SOB-260 2.) Condition of Reset Button: Button mechanically damaged: [] No response when button is pressed () 3.) Valve box working properly (if present) YesO NoO 4.) Condition of cables of device, OK ? Yes) Nol 5.) Condition of plugs , OK 2 YesO Nol 6) — NoLEDis illuminated at all Yes No 1 Check power supply at terminals 4(+) and 2() with volt-meter Minimum is 18 V = Maximum is 30 V = vate: 10] v 7.) Problems with performance: Emergency shut downs caused by Oil mist high concentration alarms without obvious reasons. 7.1) Device is giving oil mist alarm occasionally [], or permanently [] During: Engine start 0 ‘Warm up Oo increasing load Qo decreasing load a shut down. QO various condition 7.1.2) Engine crankcase checked Yes (] Nol] If¥es damages found Yes No (] water leakage found Yes No condensed waterfound Yes [] Nol} 7.1.3), Suction pipes and pipe connection box / valve box of device checked Yes (I NoQ If Yes: lots of oil found Yes) NoQ condensed water found Yes) NoO 7.1.4) Open control cover and check inside lots of oil found YesO NoO condensed water found YesO NoO 7.1.5) Check suction pressure with U-Tube Manometer (see previous page) Measured vatue: LLL) mm we (normat: 60-80 mm Water column) 7.1.8) Position of Alarm level Switch $1 (At display) [] [Your additional Comments: Yours truly , Schaller Automation Please tum pagef Notes 11.01UI1295Options List of Options for VN 87 ‘As an option, the following device extensions can be supplied for the oil mist detectors of series 87: tem Description Protecting cover Pressure control unit with input throttle ‘Typhoon fer ‘Measuring head heating system Pressurised air scavenging ‘Analog opacity indicator ‘Siphon block assembly systems Noor oena Description of the individual items tem 1, Protecting cover The protecting cover can easily be mounted on the four provided threads on the base plate of the VN device. It serves to protect the device against mechanical damage and contamination. fem 2, Pressure regulator unit The pressure reducer unit consists of a pressure reducer and a throttle block. Both parts are mounted together on a frame whichis fastened by 3 screws, MB, ‘The pressure reducer device is especially designed to supply the draft air to the VISATRON ( VN ) device. The throttle block ensures that the negative pressure in the VN is limited and does not surpass 25% above of the calibrated negative Pressure, should a failure occur in the pressure reducer ( €. g. rupture of the diaphragm, etc. ) {n addition, the throttle block is equipped with a fier to retain impurities ‘from the plant air supply.Item 3, Typhoon filter The typhoon filter serves as a pre- filter for supplying fresh air to the scavenging air chambers of the VN device. ‘The typhoon filter is laterally affixed to the protek ‘The fiter outlet and is joined to the air inlet at th by means of a flexible hose. 19 Cover of the VN device. 'spection cover of the VN device ‘The typhoon fiter considerably increases the service if ofthe fresh air fitter (sinter bronze ), in particular, if the power plant is operated under contaminated ‘ambient air conditions, such as dusty air, orf the plant is operated in regions where the air humidity is high. The typhoon filer is fumished with a fier cartridge Which can be cleaned with compressed air ( blowing from inside outwards ) or, if required, be replaced with by unscrewing the top cover. The typhoon fiter consists of: ~ a complete fiter ~ a special inspection cover for the measuring head = a connecting hose tem 4, Measuring head heating system ‘A standard heating element is installed in all the VN 87 series, in the base plate. This heating unit might not be sufficient to cover all cases ( cases of extreme humidity in the crankcase, higher water content in the lubricating oll or tower than ‘normal ambient temperatures ) ‘The measuring head heating system serves to warm up the top of the measuring head and the crankcase gas flowing through the VN device, in order to avoid condensation of water, especially in climatic zones with high humidity or low temperatures. Condensation of water may trigger a false high oil mist alarm when ‘small droplets of water are detected by the optical measuring track and shut down the engine. ‘The measuring head heating system can be mounted on top of the measuring head and replaces the heating system in the base plate. The power supply is ‘connected in the same way as the heating system of the base plate by means of a plug under the main Harting plug on the base plate.ey tom 5, Pressurised air seavenging By means of driving ar scavenging itis possible to provide filtered air to the scavenging air chambers independent of the ambient ai. This option is recommended to prevent false alarms with consequential engine shut downs due to a fire with smoke development in the engine room. The smoke may reach the VN device, entering through the fresh air slots in the inspection cover, passing through the fresh ar filters (sinter bronze filters ) to the optical measuring track, triggering a high oil mist alarm. The pressurised air seavening receives the air thtough the nozzle of the draft pump which is connected with a hose to the special inspection cover on the measuring head. The air flow is metered by special jets located in the nozzle and inspection cover. Item 6, Analogue opacity indicator The analogue square shaped opacity indicator may be utilised for all VN 87 devices. lis dimensions are 96 x 96 mm and itis appropriate forthe installation into switchboards or panels. The analogue opacity indicator is connected to the terminals 9 (+) and 10 (of the VN 87 device. The relative distance to the adjusted alarm level is indicated on a scale from 0 to 1, meaning 0% to 100% beeing away from the alarm level Example: Ifthe measured opacity has reached a value corresponding to 50% of the adjusted alarm level, the analogue opacity indicator wil display the value 0.5 tem 7, Siphon block assembly systems Siphon blocks are devices which enable to drain the accumulated oll rom the oi mnist suction pipes, directly back to the engine crankcase. The siphon blocks allow ‘a horizontal suction pipe installation, from compartment to compartment. Conventional suction pipe systems, without siphon blocks, require to be installed with a gradient of 2% to 4% ascending to the VN devico, in order to drain the precipitated oil back tothe engine. itis imperative to drain the oil to the crankcase and avoid potential clogging. ‘Special engine-oriented assembly systems in modular design are available for VISATRON Oil Mist Detectors for a large number of two- and four- stroke engine types of various manufacturers.WAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ (for MAN-B&W engines) (Electric driven) 9 Feed revised on Dec.20, 2004 | + Power Supply : 440V, 3Ph, 60Hz Page Safety Warnings é | Specifications “ ee 2 Legend 3 Installation of Shock Absorbers: Shock Absorber Wear-down Installation of Shock Absorbers: | Positioning of shock Absorbers Installation ~Grinder/Machine rest:-------~ Grinding Feed | Recording Cutting Feed:-~ | Preparations & Precautions beforelwhen commencing Grinding Operation: "1 | | Grinding of Valve Spindle (1)-~ » 12 i | @ 13 eee 14 | @) is | | (4) | Grinding of Valve Seat(1)~ 16 a ee "38 | Grinding of Bottom Piece, 98MC/MC-C/ME engines-~ 18 | | How to verify Grinding Angle upon completion of grinding: 19 | | How to verify Total Run-out and Surface roughness 20 | | How to verify 30.0 degree Grinding Angle 2 | | i | | Grinding Angle Adjustment Device (1)-(2) - 22-23 | | Dressing - 24 | | Maintenance + 25 | Replacement of Timing Belt-++--~ 26 i Timing Belt for Rotation Gear | i Timing Bett for Grinding Spindle | Parts Lists | | Rotation Gear Parts: 27 | Grinding Spindle Parts 28 I | Angle Feed Assembly Parts 28 ' Control Box (100/110V AC, 200/220V AC) ot | | Electric Diagram (100/110V AC, 200/220V AC) es | Spare Parts ea Tool List: : 34 | Ordering of Wakefield products and consumables | WAKEFIELD CORPORATION HEAD OFFICE: Call: +81-(0)45-780-6120 | 1-8-24, Fukuura, Kanazawa-ku Fax; +81-(0)45-780-3392 i Yokohama 236-0004 Japan e-mail: info@wakefield.co.jp http://www. wakefieldcorp.comWAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ Safety Warnings © Carefully read instructions prior to Operations © Always protect your eyes when grinding. Use Ear-mufflers. Grinding Motor sound level 85dB at 3 meter radius. Take care, Rotating Parts. Clean and oil bare parts after use of the machine. When operating the machine stay clear of the area not to be contacted by the rotating components. Always wear eye-protectors, ear-muffiers and hand protections when carrying out the grinding and lapping operations. ‘The electric motors should not be exposed to extreme heat or wet and humid surroundings. Ensure the correct voltage is supplied to the motors and that cables and connections are proper.(Aa ‘Wakefield TYPE ‘SEG’ Specifications for VALVE SPINDLE STEM DIA for BOTTOM PIECE OUTER DIA ELECTRIC POWER: DRIVING MOTOR: GRINDING MOTOR GRINDING SPINDLE SPEED GRINDING MOTOR STARTING CURRENCY: MACHINE WEIGHT SIZE MACHINE REST WEIGHT SIZE ‘The Valve Spindle is secured in the machine, perfectly aligned by the Centering Chuck and Securing Chuck. WAKEFIELD EXHAUST VALVE GRINDER ‘The SEG Grinding Machine is designed for grinding of Exhaust Valve Spindles and Bottom Pieces for 2-stroke engines. 30~ 108 mm 202~660 mm 440VAC, 3ph, 60HZ 90 W, 0-20 min’? Reversibie Direction 1400 W 4,200 min 458 180-235 kgs H; 1200-1400mm W, 1000-1200mm D; 750mm 25 kgs HxWxD 600 x 800 x 800mm ‘When grinding the Exhaust Bottom Piece, the Seat is centered and secured in the Chuck ‘The Grinding Angle is fixed as per the Engine Makers instructions, however @ Grinding Angle Adjustment Device is incorporated in the SEG machine to allow for checking and changing of grinding angle if so recommended by the Engine Makers. ‘The Driving Motor speed can be adjusted to slow down during the final stage of grinding operation to achieve a good finish of the gas sealing surfaces on the Valve Spindles and Valve Seats. The cutting feed and grinding feed are manually fed ‘A Roughness Template is fitted to the Angle Piece for the purpose of comparing the Valve Spindle and Seat surface with the required roughness Only original Wakefield parts and Grinding Wheel should be used. ‘A Working Stand for dismantling of the Exhaust Valve is supplied optionally.TYPE ‘SEG’ Legend WAKEFIELD EXHAUST VALVE GRINDER BASE FOR MACHINE WELDED TO FLOOR STEEL CHANNEL 75 X 75 X9 HOLE SIZE: 12MM 1 _[ Synchro Pulley L (Rotation) 1] 49 [Driving Motor (electric) i 2 | Synchro Pulley § (Rotation) 1 [20 | Grinding Drive Assembly 1 3 | Timing Belt for Drive Gear + [21 | Grinding Drive Cover 1 4 [Belt Cover 1_[-22 | Securing Chuck 1 5 | Bearing Cover 1_| 22-4] Securing Chuck Cant 3 6-1 | Grinding Feed Handle 1_|-23 | Grinding Wheel 1 62 | Cutting Feed Handle 4 | 23-4] Grinding Wheel Cover 4 7 | Gear Box 1 | 23-2| Dresser Assembly 1 [Angle Feed Piece + [23-3] Dresser 1 8-1 | Securing Bolts for Angle Feed Piece 4 | 24 [Lock Grip 1 ‘9 [Angle Feed Slide 1] 25 | Control Panel Box 4 10_| Cutting Feed Slide 1 [26 [Bearing 1 11_| Vertical Pipe 1_[27_| Shock Absorbers 46 12_| Support 1 [28 | Base 2 13__[ Frame Plate 1 [29 | Synchro Pulley L (Grinding) 1 14_[ Grinding Spindle 1_[-30_| Synchro Pulley S (Grinding) 1 15_| Bracket 1_[31_[ Timing Belt (Grinding) 4 16 | Machine Rest 2 [32 [Angle Adjustment Device: 1 17__| Centering Chuck 1] 33 [Angle Indication Plate 1 17-4] (oreonn pies 4 | 34 | Angle Setting Bar 1 17-2) 2 ee 4 | 35 | Roughness Template 1 78_| Grinding Motor (electric) 1_[40_[ Cable Gland 205 i® 7‘) WAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ F\iciteld _ Installation of Shock Absorbers In order to be able to use the Grinding Machine while the ship is under way it is recommended to install the Machine with the Shock Absorbers (27) positioned as described herein Shock | Guantiy of | Dimension (mm) Engine | Absorber's | | Shock tye type | ‘PartsNo. | Absorbers | A} B|C}D)H|h| | o ja}tts 26-35MC | EC400T | apes. | 63 28|30|28} 35] 6 |45|32| 8 | 22/17 ‘az60Me | ECHOT | — 6 pes. 70-80MC | Ecapoa | 4° 87 | 41 | 50 | 42 | 45] 85] 4.5 | 3.2 | 10 | 25 | 20 0-98MC | ECagon | OPS Wakefield Exhaust Valve Grinder Type SEG has been tested suitable for use when vibrations from other machineries are present. However, if the Grinding Machine is to be installed in a place where extremely heavy vibrations and/or shocks are present it may be required to install WAKEFIELD brand Air Spring Dampers, which are available upon request.® (hi WAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ Shock Absorber Wear-down The Shock Absorber manufacturers recommend that the shock absorbers should be replaced when showing the following defects. 1) The rubber is found cracked more than 5mm in depth. 2) The rubber is detached from the metal parts. 3) The rubber is compressed and inflated more than 30%. 4) The rubber has become moist and swollen due to contact with oil® (hb WAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ Id Installation of Shock Absorbers 1s 2] 3 4 Welding seam width 6mm, to be welded by shipyard. BiEWE 6mm 5 ERAPTRRICTHBHBOCE. Floor The Base to be welded to Floor. A-AILRITBEOCE. Engine types: 26MC-60MC_ JOMC-98MC 1 Nut & ve Mio \Spring Washer [Machine Rest 3. [Shock Bridgestone [Bridgestone [Absorber (E4001 lec4o02 4 ute Ina imio ISpring Washer 75 x 75 x 9mm 5 Base Steel Angle Welded to floor The above 1-5, to be supplied by Wakefield Corporation,ee WAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ Positioning of Shock Absorbers At the time of delivery form the factory, the Grinding Machine has been assembled with the Shock Absorbers positioned for installation of the machine FORE — AFT DIRECTION. The Shock Absorber direction can be changed by loosening the nuts, both upper and lower end, and turning the Absorbers 90 degrees, then re-tightening the nuts. For 26,35 MC engines For 42,46,50 and 60 MC/MC-C engines For 70,80 MC/MC-C engines For 90, 98MC/MC-C engines STARBOARD® 7 Y) WAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ Installation — Grinder / Machine Rest | Machine Rest [Securing Bolts between Grinder and Mi Grinder Rest mola] >) Machine Rest foundation bolts (4 or 6 pieces)® 7 Y) WAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ eld GRINDING FEED The feed of the Grinding Spindle and Grinding Wheel (23) over the seat can be achieved manually using the Manual Feed Wheel (6-1) fitted to the Angle Feed Slide Bolt. 23 6-1 9 sa 32 8 6-2 10 33 6-1 [Grinding Feed Handle 62 [Cutting Feed Handle 8 Angle Feed Piece 9 Angle Feed Slide 10 Cutting Feed Slide 23 [Grinding Wheel 32 Angle Adjustment Device 33 [Angle Indication Plateee WAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ RECORDING CUTTING FEED In order to monitor each increase of the cutting feed, fit a Dial Gauge magnet base on the Feed Assembly Post with the Dial Gauge Feeler on the Angle Feed Piece (8). Each increase of the cutting feed can then be recorded by the Dial Gauge readings. SE pea ReWAKEFIELD EXHAUST VALVE GRINDER TYPE ‘SEG’ PREPARATIONS & PRECAUTIONS BEFORE/WHEN COMMENCING GRINDING OPERATION The following points should always be checked before grinding operation. As.a long period may have elapsed since the Grinding Machine was delivered from Wakefield until used for the first time. Precautions before commencing of grinding operation 1. All rust prevention coating should be washed off and removed from moving parts and from the Chuck surfaces. 2. All Shaft Gears should be well greased and oiled 3. All Shaft Gears should move smoothly when manually operated. 4. Ensure that the correct voltage for the electric power is supplied to the Grinding and Driving Motors. Check that the electric cables are properly connected. 5. Check that the grinding wheel is tightly secured in the grinding wheel hub. 6. Timing Belt tension to be checked Precautions when commencing the grinding operation | 1. Check that the correct power source is applied, condition of electric wiring and switches. 2. Check the Grinding and Driving Motors revolution. 3. Check that the Timing-Belts are properly stretched to ensure a smooth rotation speed of driving and grinding gears. 4. Ensure the Grinding Wheel is properly dressed. See Dressing. If the vessel is rolling or listing heavily, the grinding work should be suspended. The operator should always wear protective clothing and eye-goggles when grinding work carried out, "