MTU_F_A_771903_(2).pdf

CORPORATION @ nrtu

FRI EDRICHSHAFEN

DETROIT DIESEL

USCG CPB Project MTU-F A. 77190a

Shaft to Engine/Gearbox Plant Alignment Instructions (revised 02/07/00) 8V 396 TE 94 w/ BW 255

Alignment Survey Report for the 87 foot Coastal Patrol Boat

REFERENCES

Calculation of Shaft Bearing Loads for 2 Shaft Bearing System Arr.DWG, Engine 8V 396 TE 94 wi BW 255 Gearbox* Arrangement, Engine Mounting, Free-End* Instructions for Crankshaft Transportation Locking Oevice* Instructions for Engine Mounting Locking Oevice* PropulsionShaft Details General Informationon Resilient Mount"Drift Limit* ZF Marine Alignment Procedure Acceptance Letter dtd 4/28/99

17 SEP 98 encl. (1) 556002 81 01 encl. (2) 555007 1423 encl. (3) M060464 encl. (4) M060430 encl. (5) 87 WPB 243-001 encl. (6) encl. (7) encl. (8)

*j~tTU Reference Documentation

ENGINE ROOM AND PLANT FOLJNDAnON GENERAL RECOMMENDA nONS

When applicable, engine room access openings must be dimensioned and arranged to permit introduction and positioning of the engine, if necessary complete with flange-mounted gearbox, on the foundation using suitable lifting equipment.

The installation opening covers should be bolted (not welded) in position. No permanent superstructures should be erected above the installation openings.

When possible, in the case of multi-engine plants, lifting equipment should be installed in the engine room, which is capable of lifting a complete engine (if necessary with flange mounted gearbox) to an adequate height to facilitate introduction of the engines and to simplify their maintenance.

If no lifting equipment is installed in the engine room, a sufficient quantity of adequately dimensioned and correctly positioned lifting eyes must be arranged in the deck for the attachment of lifting slings, jigs, etc.

Machinery, equipment, pipework, cable conduits, channels, etc. must be so arranged as to insure that the engine is freely accessible from all sides for monitoring and maintenance operations as well as the removal and installation of complete subassemblies.

The machinery foundation must be a torsionally-rigid and vibration-resistant construction so that:

-The individual subassemblies and machinery plant components can be precisely aligned relative to each other (important for trouble-free operation).

- The propeller thrust and gearbox reactionary forces can be accommodated without torsional det1ection.

- Ship's torsional det1ections to sea movements, loading, unloading, etc. are not transmitted to the machinery plant.

- Machinery vibrations are, to a great extent, absorbed and not transmitted to the ship's hull.

The engine and gearbox supporting faces must be flat, precision dimensioned, geometrically arranged and torsionally resilient. Where possible the foundation plates are to be so designed as to allow the incorporation of transverse and longitudinal thrust-bolt blocks (stoppers) to facilitate engine and gearbox alignment. The thrust-bolt blocks are to be supplied by the shipyard.

The securing screw holes are to be drilled, with the engine and/or gearbox in position and aligned, using an angled drill. according to a preset pattern or using a drilling template. before tinal installation. .

Foundation angle must take into consideration the permissible engine, and gearbox inclination whereby the anticipated positions of the vessel in the various operating modes is of major importance. The inclination data, to be provided by the shipyard, determines the amount of oil in the oil pan and thus the markings on the dipstick.

MACHINERY INSTALLA nON

Prior to machinery installation:

Clean foundation-supporting faces.

Remove crankshaft transportation locking device - *ref.M060464 Remove all traces of corrosion inhibitors, dirt, grease, burs, paint, etc. from engine, gearbox and universal shaft flanges.

Check the propeller shaft, see Page 5.

Position the engine and gearbox on the foundation and align them relative to the propeller shaft, see page 6 & 7.

Prerequisites for alignment are:

That the ship is in the water, with 50-75% of the liquids on board (fuel & water) properly stored and distributed in the tankage areas, but not in contact with ground for at least 24 hrs prior to the alignment procedure.

The resilient mounts are blocked as delivered by MTU.

Thrust-bolt (stopper) blocks are mounted to the machinery foundation. These should. if possible, be installed after completion of "rough" alignment.

A.

T904116bO

1 Thrust-bolt block 2 Engine or gearbox mount

3 Packing plate 4 Foundation

Fig. 1

On completion of machinery alignment, install adequately dimensioned preCISIon packing elements between the mounting brackets and the foundation.

Page 3 0f 8

Suitable materials for the packing elements are:

Sheet steel Cast steel Casting epoxy resin

When using sheet or cast steel:

Tightening torque for securing screws(3): 500 Nm (369 ft-Ibt) Lubricant: Engine oil

When using casting epoxy resin:

Observe manufacturer's instructions regarding casting methods, hardening periods and permissible area load limits.

Before casting coat mounting bracket adjusting screws (4 and 5) with grease.

Tightening torque for securing screws (3): 8V 396 Timing end: 90 Nm (66 ft-Ibt) Lubricant: Engine oil Lock securing screws with spring washers

KGS

Fig. 2 - Front (Section) View Engine Mount 8V396 TE 94

After securing the machinery plant to the foundation:

Move the thrust bolts (stoppers) into even contact and tighten the lock nuts.

Back-off mount adjusting screws (4) to 54 mm (2.126") dimension and tighten the lock nuts.

Check engine and/or gearbox alignment.

Propeller Shaft Check

The propeller shaft shall be checked for axial and radial shaft flange run-out in accordance with Dwg 87 WPB 243-001 prior to installation. As an alternative the shaft may be checked after installation in the vessel and prior to alignment to the gearbox with the shaft supported by an alignment cradle as described below.

Check the axial (a) and radial (b) shaft flange run out.

:r I

I I I 1 p

I I

I

I

I

T 904 352 bO

Fig. 3

Max. Permissible run-out deviations:

a = 0.025 mm (.001") b = 0.025 mm (.001") [dial gaugedet1ection=0.050mm(.002" Total IndicatorRunout {TIR})]

For gearbox PTO flange dimensions, see MTU Installation Documentation.

Engine with Flange-mounted Gearbox~ \-

I) To align the gearbox. raise the propeller shaft on an alignment cradle until it is centered in the stem tube seal by placing a support at 254 mm (10") forward of FR 19 and centering the shaft in the seal with feeler gauges. This method provides pre-loading without the use of a calibrated jack.

2) With the front mount locking screws still installed, position the engine together with the gearbox on the foundation and. using the mounting bracket adjusting screws (jacking screws) and the thrust bolts (stoppers). align them radially and plan parallel to the propeller shaft.

Page5 of 8

Reduction Gear See Note Propeller Shaft

T8QrooI&3S"P'..o

Fig.4

Max. Pennissible deviation from plan parallel (a) and shaft centerlines (b): *Reference dwg 55600281 01 a = 0.050 mm (.002") [referenced to a dia. of220 mm] b = 0.100 mm (.004") eccentricity [dial gauge detlection = 0.200mm (.008"TIR) concentricity]

Note: The drive unit must not be lower than the propeller shaft.

Both the above errors can occur simultaneously. Per dwg 87 WPB 243-001 the distance from the gearbox output flange to the intennediate bearing is 2889 mm (113.74").

3) Check the level of the fluids in the engine and gearbox (oil and coolant) and fill if necessary to insure that the gearbox is full of oil, and the engine is full with oil and water.

4) Remove mount blocking screws(l), nuts(2) and washers( 6)- referring to fig.2. Allow engine/gearbox plant to sit over-night, with front mounts now on the rubber. *reference to dwg 555007 1423 and M060430

5) Check the radial and plan parallel alignment. Adjust front mounts in the vertically direction with jacking screws if necessary to re-gain alignment according to above specs. Record figures for reference.

6) Using the jacking screws, raise front of engine further by 0.25 mm - 0.4 mm (.0 I - .0157") to allow for further front mount settlement which will occur during initial running.

7) Insert precision-made adequately dimensioned packing elements under the mounting brackets, and secure the drive unit to the foundation. - see Pages 3 and 4.

If fitted bolts are not used at the gearbox mounts, solid stops must be fitted to the foundation, at least in the direction of "ahead propeller thrust".

8) Final alignment (initial) check. Record figures for reference.

9) Bolt gearbox and propeller shaft flanges together.

- Tightening torque for the ZF BW 255 flange bolts: 430 Nm (317 ft-Ibf)

- Lubricant: Engine Oil

Notes / Hints:

During the alignment process, any time that the engine is to be lifted by means other that the jacking screws, the front engine mounts are to be locked in position first, that the load on the rubber is not relieved.

The engine/gearbox plant alignment should be re-checked after the first 50 - 100 operating hours, and at which time the alignment should be within the given tolerance/specifications.

Drift Limits on Mounts Due to Oegredation or Wear

Upon completion of Preliminary Acceptance Trials (PAT) record the forward engine mount drift limit datums for use in determining the maximum allowable wear on the mount elements. These datums are the clearance between the flange and the outer casing of the conical bearing. The clearance shall be taken with machinist's (i.e. long) feeler gauges at the forward and aft locations on both the inboard and outboard forward engine mounts, four (4) locations total per engine.

Ensure that the feeler contacts both sides of the flange. See Fig 5 below. The maximum gap is the datum plus 1.5 mm (.059 inches).

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Page7 of 8

ENCLOSURES

Calculation of Shaft Bearing Loads for 2 Shaft Bearing System Arr.DWG, Engine 8V 396 TE 94 wi BW 255 Gearbox* Arrangement, Engine Mounting, Free-End* Instructions for Crankshaft Transportation Locking Oevice* Instructions for Engine Mounting Locking Oevice* Propulsion Shaft Details General Infonnation on ResilientMount "Drift Limit" ZF Marine Alignment Procedure Acceptance Letter dtd 4/28/99

*MTU Reference Documentation encl. (1) 556002 81 01 encl. (2) 555 007 1423 encl. (3) M060464 encl. (4) M060430 encl. (5) 87 WPB 243-001 encl. (6) encl. (7) encl. (8)