Section 907

Starting Air System

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Description
107-1 Starting Air Distributor
907-1.1 - Checking
907-1.3 - Overhaul
107-2 Starting Air Valve
907-2.1 - Checking
907-2.2 - Dismantling
907-2.3 - Overhaul
907-2.4 - Mounting

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 Plate
PLATE 107-1
Starting Air Distributor Edition
EDITION 03
Data Data
DATA 1(1)

SAFETY PRECAUTIONS Standard Tools: See Section 913

Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data:
Ref. Description Value Unit

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 Plate
PLATE 907-1.1
Starting Air Distributor Edition
EDITION 205
Checking Page
PAGE 1(5)

1. Turn the engine to bring the piston of cylin-

der No. 1 to TDC. Check the position with 2
the pin gauge.
See Procedure 906-3.

2. Remove the small end cover of the distrib-

utor housing.

3. Check that the TDC marking scratch on the

starting cam is positioned vertically at the
valve slide of cylinder No. 1.

4. If necessary adjust the position of the start-

ing cam by loosening the centre screw and
turning the starting cam until the TDC mark-
ing scratch is positioned vertically at the
valve slide of cylinder No. 1. Then tighten
the centre screw.
3

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 Plate
PLATE 907-1.3
Starting Air Distributor Edition
EDITION 205
Overhaul Page
PAGE 2(5)

Difficulties in starting can be caused by the

2 starting air distributor valve slides “sticking”
(see Volume I, Chapter 703), so that these are
not activated and pressed against the cam dur-
ing the starting procedure.

This can be caused by too high humidity in the

main starting air system, which can result in the
formation of rust, and also by dirt, preventing
the slide valves from functioning.

In both cases it is necessary to clean the valve

slides and the liners in the distributor housing
to remove dirt, rust and foreign particles.

3 Experience will show how often this is neces-

sary to prevent starting difficulties, as differ-
ences will be found from plant to plant.

1. Blank off the main starting air and the con-

trol air. If this is not possible, lock the main
starting valve in the close position with a
padlock.

2. Remove all the pipes from the end of the

distributor.

Loosen and remove the screws from the

small and large end covers. Dismount the
end cover which gives access to the slide
valves.

3. Turn the camshaft until the slot in the start-

ing cam is opposite the pin of the valve
slide.
4
4. Remove the screws and the cap from the
particular valve slide in question.

Remove the guide screw for the valve

slide.

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 Plate
PLATE 907-1.3
Starting Air Distributor Edition
EDITION 205
Overhaul Page
PAGE 3(5)

5. Remove the complete slide valve (with

spring and the upper liner) from the distrib- 5
utor housing by means of a brass mandrel.

6. Press-in the spring and remove the two part

locking ring.

7. Remove the upper spring guide, the spring,

the lower spring guide and the upper liner
from the valve slide.

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 Plate
PLATE 907-1.3
Starting Air Distributor Edition
EDITION 205
Overhaul Page
PAGE 4(5)

8. Clean all the sliding surfaces on the valve

9 slide. Lubricate all parts with Molybdenum
Disulphide (MoS2).

Clean the liners and the distributor housing.

Test that the valve slide moves easily in
the liners.

Note !

Polishing with emery cloth or steel wool

must not take place as this will cause
scratching marks on the sliding surfaces
of the piston valve slide or distributor
housing.

9. Place the upper liner, the lower spring

10 guide, the spring and the upper spring
guide over the valve slide.

10. Press-in the spring and mount the two-part

locking ring.

11. Mount the complete slide valve in the dis-

tributor housing by means of a brass man-
drel. (Check that the slot of the starting cam
is opposite the pin of the valve slide, when
mounting).

Lubricate the groove in the starting cam

with Molybdenum Disulphide (MoS2).

11

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 Plate
PLATE 907-1.3
Starting Air Distributor Edition
EDITION 205
Overhaul Page
PAGE 5(5)

12. Mount the guide screw for the valve slide.

Mount the cap and the screws on top of the 12
slide valve.

13. Finally, mount the two end covers and con-

nect the main starting air and the control
air.

13

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 Plate
PLATE 107-2
Starting Air Valve Edition
EDITION 05
Data Data
DATA 1(2)

SAFETY PRECAUTIONS Standard Tools: See Section 913

Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Weight of starting air valve 36 kg

D-2 Valve tightening angle 60

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 Plate
PLATE 107-2
Starting Air Valve Edition
EDITION 05
Data Data
DATA 2(2)

083 046

117
901

105

058

060

095

071

060

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 Plate
PLATE 907-2.1
Starting Air Valve Edition
EDITION 204
Checking Page
PAGE 1(6)

1. When the starting air valve has been over-

hauled, see Procedure 907-2.3, connect a 1
supply of working air to the control air inlet
at the top of the valve.

Check that the valve opens approx. 15-20

mm.

2. Close off the air supply

Check that the valve closes fully.

3. Repeat steps 1 and 2 a couple of times.

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 Plate
PLATE 907-2.2
Starting Air Valve Edition
EDITION 204
Dismantling Page
PAGE 2(6)

1. Shut off the starting air and control air inlet.

1
Dismount the control air pipes

Mount two eye bolts in the top cover of the

valve.

Hook a lifting wire on to the eye bolts.

Unscrew the fixing nuts of the starting

valve flange.

2. Lift away the starting valve.

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 Plate
PLATE 907-2.3
Starting Air Valve Edition
EDITION 204
Overhaul Page
PAGE 3(6)

1. Place the starting air valve horizontally in a

bench vice provided with “soft” jaws. 1

Remove and discard the O-ring from the

valve housing.

2. Loosen and remove the screws from the

top cover.

Dismount the top cover.

3. Use the face wrench for the spindle as a

back-stop when loosening the two screws
which tighten the piston to the spindle.

Remove the screws.

When unscrewing, the piston will partially

be pressed out of the valve housing due to 2
the spring force.

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 Plate
PLATE 907-2.3
Starting Air Valve Edition
EDITION 204
Overhaul Page
PAGE 4(6)

4. Remove the piston from the top end of the

4 valve housing.

Take out the spindle from the bottom end of

the valve housing.

Remove the spring from the top end of the

housing.

5. Apply grinding paste, e.g. carborundum No.

200. Grind the valve housing seating with
the grinding ring.

6. When lapping the seating of the spindle

and valve housing to match, use the face
wrench to rotate the spindle.

As grinding paste, use e.g. carborundum

No. 500.

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 Plate
PLATE 907-2.3
Starting Air Valve Edition
EDITION 204
Overhaul Page
PAGE 5(6)

7. Thoroughly clean the valve housing and all

the parts in diesel oil or kerosene. 7

Lubricate all internal parts and sliding sur-

faces with, e.g., Molybdenum Disulphide,
MoS2.

Insert the spindle in the valve housing.

Then mount the spring in the housing
around the spindle and, finally, place the
piston on top of the spindle.

8. Fit the washer and the two screws.

When tightening the screws, the piston will

compress the spring.

Tighten the screws continuously until the

piston faces tightly against the spindle. Use
the face wrench as a back-stop.

Lock the screws.

9. Mount and tighten the top cover.

Fit a new O-ring on the valve housing.

10. Check the starting air valve. 9

See Procedure 907-2. 1.

If the valve is not to be mounted in the en-

gine immediately, cover all openings with
plastic to prevent dirt from entering the
valve during storage.

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 Plate
PLATE 907-2.4
Starting Air Valve Edition
EDITION 204
Mounting Page
PAGE 6(6)

1. Carefully clean the starting valve bore in

1 the cylinder cover and, if necessary, recon-
dition the seat for the starting valve in the
bore, see Procedure 901-1.2.

Fit a new O-ring on the overhauled valve

and lubricate with Neverseize or Molybde-
num Disulphide, MoS2.
For overhaul, see Procedure 907-2.2.

2. Mount the valve in the cylinder cover.

3. Mount the nuts and tighten-up alternately,

in at least three steps, to an angle of 40 .

Loosen the nuts again and repeat the pro-

cedure to reach the full tightening angle D-
2.
2
Mount the control air pipes and turn on
starting air and control air.

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