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Content
1. Planning
2. Safety precautions
3. Overhauling & calibration procedure
4. Spare parts used
5. References
1. Planning
Information requested prior to survey
1. Refer class status report
2. Consult technical manager and discuss intended procedure
3. Check spare parts inventory and order if necessary. In this case it has to be
taken into account R.O.B after finishing the job too.
4. Inform master work schedule, Discuss with chief officer and arrange any
support if necessary
5. Previous survey report, engine running hours when survey was carried out,
Details of recoded clearances, details of any possible marking on pin, bearing
condition.
6. Lifting gear condition including engine room crane and test certificates has to
be checked and make sure conditions are satisfactory in advance to prevent
accidents, unnecessary delays, damages and personnel injuries.
2)
Take immobilization certificate from port authority. This process may take
some times therefore early inform to authority will avoid delays
3)
Read the manual and have a toll box meeting with everyone involved in
the job. Discuss the procedure.
4)
5)
A risk assessment of all personnel doing the operation to be prepared and
documented
6)
7)
8)
9)
10)
Stop main engine lube oil pump after cooling down of engine
Open crank case doors of fore and aft unit
11) Open crank case doors of that unit in which maintenance is to be carried
out.
12) Put blower and ventilate the crankcase thoroughly as it is an enclosed
space.
13)
14)
15. Before start the job checked condition of high pressure hydraulic pump and
hoses always used proper safety equipment when handling the unit.
F.
6. Open cooling water drain cocks G and
H.
7. Shut off the control air and safety air
supply.
8. Vent the manoeuvring system through
the ball valve.
9. Also shut off the air supply on the
reduction unit for the
hydraulic/pneumatic exhaust valve, and
vent the system.
Generally, it is recommended to renew the springs when the sealing rings and
scraper rings are renewed.
The springs can be checked as follows:
Place the springs on the table, measure Lo
(Free length), and compare with Data. If a spring is extended more than 8% from
the value given in data, it must be discarded.
The wear limit for a cross head bearing shell is limited to 50% reduction of the oil
wedge length (L).[ L=10mm]
3. Turn the crankshaft down enough to give access to nuts and screws on piston
rod.
4. Mount two chain blocks on the top of the crankcase for suspending the piston
rod.
5. Loosen and remove the locking wire and screws on the piston rod foot.
6. Mount the lifting eye bolt on each side of the piston rod foot.
7. Turn the crosshead to TDC.
8. Hook the chain blocks to the eye bolt on the piston rod foot. And turn the
crosshead down so that piston is now suspended on the chain blocks.
9. Turn to BDC.
10.Mount the hydraulic jack on the crosshead bearing cap nut and loosen them.
[Pressure: 1500-1650 bars]
11.Mount the lifting attachment on the head of the connecting rod.
12.Suspend the two chain blocks from the lifting brackets in the athwart ship
direction.
13.Mount the 2 eye bolts on the top of the cross head bearing cap.
14.With the help of the two chain blocks lift the bearing cap. Take it out of the
engine and place it on a wooden base.
15.To check the upper bearing shell, remove the locking screws and push the
shell out.
16.Mount the chain blocks to the lifting brackets on the frame box wall.
17.Turn the crosshead up until the piston rod lands on the crosshead. Ensure that
the guide ring in the crosshead fits correctly in the centre hole of the piston
rod.
18.Do not remove the chain blocks or the lifting eye bolts.
19.Turn the crosshead to TDC and attach the chain blocks to the lifting
arrangement and haul it tight.
20.Mount the four supports for the guide shoes on the crosshead guide.
21.Carefully and slowly turn the crankshaft towards to exhaust side and make
sure the crosshead guide sits on the supports.
22.Turn the crank throw towards BDC slowly while following with the chain
blocks, thus continuously supporting the connecting rod.
23.In case it is necessary to remove the lower bearing shell, tilt the connecting
rod towards the door on the cam shaft side with means of chain blocks.
24.Dismount the locking screws and turn the bearing shell so far up that an eye
bolt can be mounted. Lift the bearing shell out.
Top clearance in crosshead bearing:-Max: 0.29mm, Min: 0.17mm
3. Compare this reading with the earlier reading in the record or the new bearing
reading.
4. Now disconnect the lube oil pipe line.
5. Turn the crank throw so that it is towards the exhaust side.
6. Now mount the hydraulic jacks and loosen the main bearing stud nuts.
7. Mount the lifting tool for main bearing keep and lift the keep using a pulley
and a wire rope.
8. Note the marking on the main bearing keep before lifting for correct direction
of the keep.
9. Guide the keep safely outside with a help of another chain block and place it
on a wooden base once it is out.
10.Mount the tool for lifting the upper bearing shell and place it safely outside.
11.Place the strong back (cross piece) support on the bed plate so that its ends
rest on the cross girders.
12.Mount the hydraulic jack on the cross piece placing it such that it lies beneath
the crank webs.
13.Mount a dial gauge on the adjacent main bearing so that the lift of the crank
shaft can be recorded.
14.Now with hydraulic pressure (1500-1650 bar) lift the crankshaft corresponding
to the main bearing clearance to the adjacent main bearing, and check the lift
with the help of a dial gauge.
15.Remove the lock screws from the lower shell.
16.Place the dismantling tool on the lower bearing shell such that the flap enters
the oil groove.
17.Pull the bearing shell round and up so that it lies on the journal and take it out
safely.
Part number
ROB at
biginin
g of
month
used
ROB
Cylinder Cover
O-ring
Gasket
Spring Housing
Gasket
Gasket
Gasket
Piston
Piston
Piston
Piston
assembly
ring No. 01
ring No. 02+04
ring No. 03
P90101-0173126
P90101-0173151
P90101-0173187
P90103-0004020
P90103-0004032
P90103-0004127
2
1
2
1
1
1
1
2
1
2
2
4
8
2
05. Reference:
MAN B&W MC-C Engine maintenance manual
Class NK CSM Survey guidance
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