Main Engine MAN B&W K 80 MC-C

Warning

S900-1

0001 S900-1

Warning! It is important that all MAN B&W Diesel A/S engines are operated within the given specifications and performance tolerances specified in the engines’ Technical Files and are maintained according to the MAN B&W Diesel A/S maintenance instructions in order to comply with given emissions regulations. In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, §94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions, including, but not limited to, the instructions to that effect included in the Technical File.

When referring to this page, please quote S900 Edition 0001 MAN B&W Diesel A/S

Page 1 (1)

K80MC-C

VOLUME II MAINTENANCE

900 - Introduction Documents in this Chapter Table of Contents, Volume II 90050 90060

0289 0002

Checking & Maintenance Schedule General - Safety Precautions

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Table of Contents

900

Volume II - Maintenance No.

Edition

Title

900 - Introduction Table of Contents 90050 0289 Checking & Maintenance Schedule 90060 0002 General - Safety Precautions 901 - Cylinder Cover 101-01 0077 Cylinder Cover, Data 901-01 0260 Cylinder Cover 90151 0208 Cylinder Cover - Panel 90164 0001 Cylinder Cover - Hydraulic Jack Spares 90165 0001 Cylinder Cover - Lifting Tools 902 - Piston with Rod & Stuffing Box 102-01 0090 Piston, Data 902-01 0290 Piston 102-02 0064 Piston Rod Stuffing Box, Data 902-02 0231 Piston Rod Stuffing Box 90251 0258 Piston and Piston Rod - Panel 90261 0102 Piston and Piston Rod - Tools 90264 0006 Piston and Piston Rod - Tilting Tools 90265 0001 Piston and Piston Rod - Support Tools 90266 0001 Piston - Lifting Tools 903 - Cylinder Liner and Cylinder Lubrication 103-01 0075 Cylinder Liner, Data 903-01 0259 Cylinder Liner 103-02 0028 Cylinder Lubricator, Data 903-02 0256 Cylinder Lubricator 90361 0083 Cylinder Liner - Tools 90362 0005 Cylinder Liner - Milling Tools 90364 0004 Test Equipment for Lubricators 90366 0003 Cylinder Liner - Lifting Tools 904 - Crosshead with Connecting Rod 104-01 0069 Crosshead Bearing, Data 904-01 0253 Crosshead Bearing 104-02 0070 Crosshead, Data 904-02 0252 Crosshead 104-03 0044 Reciprocating Parts, Data 904-03 0215 Reciprocating Parts 104-04 0062 Crankpin Bearing, Data 904-04 0233 Crankpin Bearing 104-05 0060 Connecting Rod, Data 904-05 0237 Connection Rod 90451 0155 Connecting Rod and Crosshead - Panel MAN B&W Diesel A/S

Page 1 (4)

Table of Contents

900

Volume II - Maintenance No. 90462

Edition 0018

Title Connecting Rod - Tools

905 - Crankshaft, Thrust Bearing and Turning Gear 105-02 0086 Main Bearing, Data 905-02 0261 Main Bearing 105-03 0075 Thrust Bearing, Data 905-03 0247 Thrust Bearing 105-04 0050 Journal Bearing, Data 105-05 0061 Axial Vibration Damper, Data 905-05 0230 Axial Vibration Damper 90551 0221 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel 90562 0123 Crankshaft - Tools 90564 0020 Crankshaft - Measuring Tools 90570 0003 Thrust Shaft - Tools 90571 0001 Main Bearing Shell - Tools 90572 0001 Main Bearing - Measuring Tools 906 - Control Gear 106-01 0051 Chain, Data 906-01 0246 Chain 106-02 0067 Chain Tightener, Data 906-02 0230 Chain Tightener 106-03 0043 Camshaft, Data 906-03 0218 Camshaft 106-04 0045 Camshaft Bearings, Data 906-04 0219 Camshaft Bearings 90651 0203 Chain Drive and Camshaft - Panel 90664 0001 Crankshaft - Pin Gauge 907 - Starting Air System 107-01 0019 Starting Air Distributor, Data 907-01 0219 Starting Air Distributor 107-02 0041 Start Air Valve, Data 907-02 0217 Starting Air Valve 908 - Exhaust Valve 108-01 0037 High-Pressure Pipe, Data 908-01 0226 High-Pressure Pipe 108-02 0094 Exhaust Valve, Data 908-02 0269 Exhaust Valve 108-03 0057 Exhaust Valve Actuator, Data 908-03 0227 Exhaust Valve Actuator 108-04 0041 Exhaust Valve Roller Guide, Data 908-04 0222 Exaust Valve Roller Guide 108-05 0017 Exhaust Valve Cam, Data MAN B&W Diesel A/S

Page 2 (4)

Table of Contents

900


Edition

908-05 108-07 908-07 90851 90861 90862 90863 90864

0219 0034 0228 0177 0022 0036 0015 0003

Title Exhaust Valve Cam Exhaust Valve - Special Running, Data Exhaust Valve Exhaust Valve - Panel Exhaust Valve - Tools Exhaust Valve - Hydraulic Tools Exhaust Valve - Extra Tools Exhaust Valve - Extractor Tool

909 - Fuel Oil System 109-01 0061 Fuel Pump Settings, Data 909-01 0241 Fuel Pump Settings 109-02 0005 VIT System, Data 909-02 0206 VIT System 109-03 0050 Fuel Pump Cam, Data 909-03 0234 Fuel Pump Cam 109-04 0061 Fuel Pump, Data 909-04 0224 Fuel Pump 109-05 0065 Fuel Pump Top Cover, Data 909-05 0234 Fuel Pump Top Cover 109-06 0052 Fuel Pump Barrel Assembly, Data 909-06 0220 Fuel Pump Barrel Assembly 109-07 0040 Fuel Pump Suction Valve, Data 909-07 0214 Fuel Pump Suction Valve 109-08 0054 Fuel Pump Puncture Valve, Data 909-08 0217 Fuel Pump Puncture Valve 109-09 0034 Fuel Pump Shock Absorber, Data 909-09 0216 Fuel System Shock Absorber 10910 0016 Lifting Gear Roller Guide, Data 90910 0218 Lifting Gear for Roller Guide 10911 0065 Fuel Valve, Data 90911 0249 Fuel Valve 10912 0048 Spindle Guide, Data 90912 0228 Spindle Guide 10913 0033 Non-Return Valve in Fuel Valve, Data 90913 0206 Non-Return Valve in Fuel Valve 10914 0080 Fuel Oil High-Pressure Pipes, Data 90914 0255 Fuel Oil High-Pressure Pipes 10915 0062 Fuel Pump Roller Guide, Data 90915 0236 Fuel Pump Roller Guide 90951 0446 Fuel Valve and Fuel Pump - Panel 90961 0069 Fuel Valve - Tools 90966 0008 Fuel Valve Nozzle - Tools 90967 0001 Fuel Puncture Valve - Tools 90968 0001 Fuel Valve - Inspection Tools MAN B&W Diesel A/S

Page 3 (4)

Table of Contents

900

Volume II - Maintenance No. 90974 90977 90979 90980

Edition 0001 0001 0001 0001

Title Fuel Valve Nozzle - Cleaning Tools Mounting Tools - Pump Barrel Seals Mounting Tools - Suction Valve Seals Mounting Tools - Air Piston Seals

910 - Turbocharger System 110-01 0051 Air Cooler Element, Data 910-01 0243 Air Cooler Element 110-02 0009 Non-Return Valve after Air Cooler, Data 910-02 0210 Non Return Valve after Air Cooler 110-03 0031 Auxilary Blower, Data 910-03 0218 Auxilary Blower 110-04 0005 Butterfly Valve, Data 910-04 0205 Butterfly Valves 110-05 0010 Turbocharger Turbine, Data 910-05 0213 Turbocharger Turbine 110-06 0032 Water Mist Catcher, Data 910-06 0222 Water Mist Catcher 91063 0018 Air Cooler - Tools 91063 0019 Air Cooler - Tools 91063 0020 Air Cooler - Tools 91064 0001 Travelling Trolley 91066 0002 Air Cooler - Lifting Tools 911 - Safety Equipment 111-01 0026 Safety Valve, Data 911-01 0212 Safety Valve 111-02 0013 Relief Valve, Data 911-02 0211 Relief Valve 111-03 0001 Scavenge Air Receiver Safety Valve, Data 911-03 0001 Scavenge Air Receiver Safety Valve 912 - Assembly of Large Parts 112-02 0015 Holding Down & End Chock Bolts, Data 912-02 0208 Holding Down and End Chock Bolts 112-03 0027 Stay Bolts, Data 912-03 0213 Stay Bolts 912-05 0201 Crankcase Oil Outlet 91261 0075 Hydraulic Tools for Large Parts 91265 0002 Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks) 913 - General Tools 913-01 0211 Hydraulic Tools 913-03 0007 Working Platforms 913-04 0202 Standard Tightening Torques MAN B&W Diesel A/S

Page 4 (4)

Table of Contents

900


Edition

913-05 913-06 913-07 91311 91351 91356 91357 91359 91360 91361 91362 91363 91364 91366 91368

0205 0205 0207 0204 0034 0051 0006 0003 0005 0052 0060 0040 0059 0066 0011

Title Torque Spanner Tightening Gauge Screws and Nuts Lubricating Accessories - Hydraulic Tools Lifting Tools, etc. Open-Ended Spanners Torque Spanners Pliers Combination Spanners Ring Slugging Spanners Spanners Open-Ended Spanners Instruments Working Platforms

MAN B&W Diesel A/S

Page 5 (4)

MAN B&W Diesel

Checking and Maintenance Schedule, 80-108 MC/MC-C Engines

900-1

The Checking and Maintenance Schedules indicate the intervals at which it is deemed appropriate to inspect the individual components of the engine and to carry out overhauls, if necessary, based on the engine condition or on time criteria.

Design modifications may necessitate a revision of the instructions, in which case the revised instructions and changed overhauling intervals, if any, will apply and supersede those originally issued (see e.g our Service Letters).

The stated Normal hours of service should only be used as a guide, as differences in the actual service conditions, the quality of the fuel oil or lubricating oil, the treatment of cooling water, etc. will decisively influence the actual service results, and thus the intervals between necessary overhauling.

In addition to the checking and overhauling intervals stated in this schedule, please note that the periodical survey requirements of the classification society may require additional checks and overhauls to be carried out. For further information please refer to the classification society.

The procedures are divided into three categories: Condition checking procedures

marked under the heading Normal hours of service with a C, deal with the service condition of a number of engine components, and form the basis for estimating whether further overhauling is necessary. In a number of cases the condition checking procedures refer to Volume I of the instruction book, in which more detailed descriptions and working procedures can be found.

Condition-based overhauling procedures

are those procedures which under the heading Normal hours of service are marked with an O, and opposite which, under the heading Overhaul to be based on procedure No. (column P), a procedure number is stated. This procedure number normally refers to one of the above condition checking procedures which form the basis of the overhaul. For this reason, the intervals stated are for guidance only.

Time-based overhauling procedures

also marked with an O under the headings Normal hours of service or Based on observations, are the procedures where an actual basis for estimation is lacking. It is recommended, therefore, to carry out these procedures at the overhauling intervals stated as a basis. Where a symbol O or C is indicated in Based on observations (column B), this is due to the fact that special service conditions may make checking or overhauling necessary beyond the actual standard schedules indicated.

When referring to this page, please quote Maintenance Schedule A90050 Edition 0289

Page 1 of 6

900-1

Page 2 of 6


MAN B&W Diesel


MAN B&W Diesel


V : See Volume I “Operation” A : Adjustment to be carried out C : Check the condition

M : See maker’s instructions O : Overhaul to be carried out H : Check new/overhauled parts after 500-1500 hours Regular Checks

No.

Procedure

H

902 Piston with Rod and Stuffing box -1 Piston Inspection through scavenge ports -2 Piston rod stuffing box

2

4

6

8

905 -2 -3 -3 -4 -5

Crankshaft and Thrust Bearing Main bearing Thrust bearing Guide bearing Journal bearing Axial vibration damper

12

16

24

32

B

C*

O O

C,O

O

C*

O

C

903 Cylinder Liner and Cylinder Lubrication -1 Cylinder liner Inspection through scavenge ports Measuring wear inside liner -2 Cylinder lubricators Accumulators nitrogen pressure Crosshead with connecting rod Crosshead bearing Crosshead Reciprocating parts Crankpin bearing Connecting rod

R : Parts to be replaced B : Based on observations P : Refer to

Service interval (x1000 hours of operation)

Daily Weekly Monthly

901 Cylinder Cover -1 Cylinder cover Indicator cock

904 -1 -2 -3 -4 -5

900-1

P

Remarks

* Check whenever exhaust valve is removed

V * Check clearances without dismantling segments

O C C C C

A A

V,M

C,O C,O C,O C,O O

V

C

C C C C

C C C C

C C C C

C,O C,O C,O C,O O

V

C C


Bearings should only be opened up if bearing material fragments fall out.

V

Bearings should only be opened up if bearing material fragments fall out.

V

Page 3 of 6

900-1




No.

Procedure

-7 -8

Electronic axial vibration monitor Mechanical checking Tacho pick-up Angle encoder

906 Mechanical Control Gear -1 Chains -2 Chain tightener Chain wheels, spray nozzles and guide bars -3 Camshaft -4 Camshaft bearings Camshaft coupling, fitted bolts -5 Moment compensator Governor Functional check of overspeed device Functional check of speed-setting system (engine with bridge control system) 907 Starting Air System -1 Starting air distributor -2 Starting air valve 908 -1 -2 -3 -4 -5

Exhaust Valve High-pressure pipe Exhaust valve Exhaust valve actuator Actuator safety valve Exhaust valve roller guide Exhaust valve cam

Page 4 of 6

MAN B&W Diesel

H



Service interval (x1000 hours of operation) 2

4

6

8

12

16

24

32

B

P

C,O C,O

M M

R A R C,A C,O

V

Remarks

C C

C C,A C C

C C,A C

C

C O

C C C

New or overhauled chain to be checked/retightened after 500, 1500 and 4000 hours

C,A M M M

C C

C

C C,O

A

O O O C,A C* C*

C* C*

C

O O

* only inspection through camshaft covers


MAN B&W Diesel




No.

-7

Procedure

H


Service interval (x1000 hours of operation)


2

4

6

8

12

16

24

32

Exhaust valve special running

909 Fuel Oil System Fuel oil water content -1 Fuel pump settings -2 VIT system -3 Fuel pump cam -4 Fuel pump -5 Fuel pump top cover -6 Fuel pump barrel assembly -7 Fuel pump suction valve -8 Fuel pump puncture valve -9 Fuel pump shock absorber -9 Fuel system shock absorber -10 Lifting gear for roller guide -11 Fuel valve Fuel nozzle -12 Spindle guide -13 Non-return valve -14 Fuel oil high-pressure pipes -15 Fuel pump roller guide -16 Fuel pump special running 910 -1 -2 -3 -4

900-1

Turbocharger System Air cooler Non-return valve Auxiliary blower Butterfly valves

B

P

Remarks

O

C

C

A,C A A O O R

O

C,O C,O C C C C,O R

V V

O O O

R O C*

C*

C C C


C

O O O

O O O O

* Only inspection through camshaft covers

V

Check ∆p and ∆t Check at every port inspection

Check at every port inspection

Page 5 of 6

900-1




No.

Procedure

-5

Turbocharger turbine Turbocharger air filter Protective grid before turbocharger Turbocharger lubricating oil water content Water mist catcher

-6 911 -1 -2 -3

Safety Equipment Overpressure indicator valve Relief valve Scavenge air receiver safety valve Functional test of alarm system for thrust bearing and slow down /shut down system Checking and adjustment of pressure gauge Checking and adjustment of thermometers Checking and adjustment of thermostats Checking and adjustment of pressurestats Checking and adjustment of turning gear switch

912 Assembly of Large Parts -2 Holding-down and end chock bolts -3 Stay bolts Top bracings Diaphragm in crankcase oil outlet System lubricating oil water content System lubricating oil bottom tank Cooling water quality Crankcase 913 General Tools -1 Hydraulic tools Page 6 of 6

MAN B&W Diesel

H



Service interval (x1000 hours of operation) 2

4

6

C* C

8

12

16

24

32

C C

B

P

C,O O R

V,M

C* C*

V M

C

O O O

C C C C C

A A A A A

C

C C C

C*

* Dry cleaning daily

* Only if separate oil system * Check ∆p

C,O

C C C

Remarks

M M M M M M

C C

* Initial check only

C C

R

C

M

Empty and clean tank

O C

A

V,M

C*

* Check for loose nuts and bearing material fragments

O

M


General – Safety Precautions

900-2

Before maintenance work is carried out, the engine must be stopped and blocked according to the safety precautions given on the specific Data Sheet.

SAFETY PRECAUTIONS X

Stopped engine

X

Shut off starting air supply – At starting air receiver

X

Block the main starting valve

X

Shut off starting air distributor/distributing system supply

X

Shut off safety air supply – Not ME-engines

X

Shut off control air supply

X

Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps

X

Engage turning gear

X

Shut off cooling water

X

Shut off fuel oil

X

Stop lubricating oil supply

X

Lock the turbocharger rotors

The sketch gives the approximate location of the valves concerned:

When referring to this page, please quote Safety Precaution A90060 Edition 0001 MAN B&W Diesel A/S

Page 1 (1)

901 - Cylinder Cover Documents in this Chapter 101-01 901-01 90151 90164 90165

0077 0260 0208 0001 0001

Cylinder Cover, Data Cylinder Cover Cylinder Cover - Panel Cylinder Cover - Hydraulic Jack Spares Cylinder Cover - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Cover MAN B&W Diesel

101-1

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X X X X X X X X X X X

Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description

Value

Unit

D01-01

Exhaust valve stud, screwing-in torque

550

Nm

D01-02

Starting valve stud, screwing-in torque

240

Nm

D01-03

Fuel valve stud, screwing-in torque

140

Nm

D01-05

Cylinder cover stud, check distance

196 - 197

mm

D01-06

Cylinder cover, complete

6300

kg

D01-07

Cylinder cover without valves

4600

kg

D01-08

Cooling jacket

120

kg

D01-09

Exhaust valve stud

120

kg

D01-10

Cylinder cover stud

110

kg

D13-01

Hydraulic pressure, mounting

900

bar

D13-02

Hydraulic pressure, dismantling

800 - 990

bar

When referring to this page, please quote Data D10101 Edition 0077

Page 1 (2)

Cylinder Cover

101-1

MAN B&W Diesel

Data

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. P90951 refers to chapter 909.

Plate

Item No.

Description

P90151

46

Grinding tool for exhaust valve seat

P90151

58

Milling and grinding wheel for fuel valve seat

P90151

60

Milling and grinding wheel for starting valve seat

P90151

83

Grinding handle

P90151

105

Grinding handle for starting valve

P90161

Cylinder Cover - Tools

P90165

Cylinder Cover - Lifting Tools

P91351

10

Hydraulic pump, pneumatically operated

P91351

58

Hose with unions (3000 mm), complete

Page 2 (2)



Dismantling

Shut off Oil and Water Supply 1.

901-1.2

2.

Check engine blocking. Check that the engine is stopped and blocked according to the safety precautions given on the data sheet.

2. Shut off the oil supply.

3. Shut off the water supply. Close the water outlet above the exhaust valve. Close the water outlet on the exhaust side of the cylinder cover.

M901010260D01

Close the fuel oil supply for the unit concerned.

3.

Shut off the water supply placed on the exhaust side below the exhaust gas receiver. Open the drain next to the inlet valve.

M901010260D02

Open the venting cock next to the outlet valve.

When referring to this page, please quote Procedure M90101 Edition 0260

Page 1 (14)

901-1.2

Cylinder Cover Dismantling

MAN B&W Diesel

Dismantling of Pipe Connections 4. 4. Disconnect the oil pipes. Remove the hydraulic high pressure pipe for the exhaust valve. See Procedure 9081.2 Unscrew the drain pipe for the exhaust valve.

M901010260D04

Remove the fuel oil high pressure pipes. See Procedure 90914.2.

5.

Disconnect the pipes for return fuel oil from the fuel valves. 5. Disconnect the water pipes. Unscrew and remove the water outlet pipes. 6. Exhaust gas compensator. Remove the protective jacket enclosing the insulation for the intermediate pipe or compensator. Remove the insulation.

M901010260D05

Remove the clamp ring from the flange between the intermediate pipe and the exhaust receiver.

M901010260D06

6.

Page 2 (14)


Cylinder Cover MAN B&W Diesel 7.

901-1.2

Dismantling

Disconnect the starting air pipe. 7. Unscrew and remove the control air pipe for the starting air valve. Unscrew and remove the air pipe for the starting valve.

8. Cylinder cover loosening.

Loosen and remove the cylinder cover nuts, see Data. For use of hydraulic tools, see Procedure 9131.

M901010260D07

Remove the protective caps from the cylinder cover nuts.

8.

M901010260D08

D1302


Page 3 (14)

901-1.2

Cylinder Cover Dismantling

MAN B&W Diesel

Cylinder Cover Lifting and Landing 9. 9. Cylinder cover lifting.

D0106

Hook on the engine room crane to the lifting attachment on top of the exhaust valve. Check that all cylinder cover connections have been loosened and removed. Lift away the cylinder cover complete. 10. Cylinder cover landing.

M901010260D09

Land the cylinder cover on a couple of wooden planks.

M901010260D10

10.

Page 4 (14)



901-1.2

Dismantling

11. Remove sealing ring. 11.

M901010260M12

Remove and discard the sealing ring between the cylinder cover and cylinder liner.


Page 5 (14)

901-1.3

Cylinder Cover Overhaul

MAN B&W Diesel

Overhaul Preparations 1. 1.

D0109

Dismantle valves and pipes. Dismantle all valves and pipes from the cylinder cover. See Procedure 9072.2, 9082.2 and 90911.2. Remove all studs on top of the cylinder cover.

M901010260O01

Cooling Water Jacket 2. Remove the cooling water jacket. Mount four eyebolts and the lifting chains as shown in the sketch. Remove the four screws which secure the cooling jacket to the cylinder cover.

2.

Lift the cylinder cover free of the cooling jacket and land it on a couple of planks.

D0107

Remove and discard the Orings from the cover, and carefully clean the cooling jacket and the cylinder cover.

M901010260O02

3. Mount the cooling water jacket.

3.

D0108

Provide the cylinder cover with new Orings, well lubricated with vaseline. Lift the cylinder cover and guide the jacket/ cover into position, using the guide pin as a reference (manoeuvre side). Fit and tighten the screws for the cooling jacket.

M901010260O03

Silicone

Page 6 (14)



901-1.3

Overhaul

Reconditioning of Bores 4. 4. Seat reconditioning tools. The tools for reconditioning of the valve seats are found on tool panel 901. 5. Fuel valve bore.

Clean the fuel valve bores using the carbon cutter. If required, recondition the fuel valve seating with the appropriate cutter. Grind the seating with the grinding mandrel and a grinding compound (e.g. Carborundum No. 200).

M901010246O04

The tool consists of a common spindle with a handle, a guide, a carbon cutter, a seating face cutter and a grinding mandrel.

5.

After the milling/grinding, clean the bore and seating carefully, and check that the seating is not damaged.

2

3

M901010260O05

1


Page 7 (14)

901-1.3

Cylinder Cover Overhaul

MAN B&W Diesel

6. Exhaust valve bore. 6. The tool consists of a spindle with a handle and a grinding disc. After cleaning the valve bore and seating, grind the seating with the grinding disc and a grinding compound (e.g. Carborundum No. 200).

M901010240O07

After the grinding, clean the bore and seating carefully, and check that the seating is not damaged.

7.

7.

Starting valve bore. The tool consists of a guide, a cutter, and a grinding disc. Recondition the starting valve bore and seating in the same way as described for the fuel valve bore.

M901010243O07

When replacing the valves on a cylinder cover while it is mounted on the engine, recondition the valve bores/seating as described here, however, without removing the studs.

Page 8 (14)



901-1.3

Overhaul

8. Indicator safety valve bore. 8. Clean the bores for safety valve/indicator cock. Preparations before Mounting 9. Fitting of studs.

Tighten up the studs in accordance with the screwingin torque stated on the data sheet. Fill up the grooves between the valve studs and the bores for the valve studs with permatex to prevent water or oil from entering the bores during operation of the engine.

M901010260O08

Lubricate the threads with ‘Never Seize’ or molybdenum disulphide (MoS2) and fit the valve studs.

D0101

9.

10. Mounting of valves.

D0103

Install the valves on the cylinder cover, see Procedures 9072.4, 9082.4 and 90911.4.

M901010260O09

D0102


Page 9 (14)

901-1.4

Cylinder Cover Mounting

MAN B&W Diesel

Landing Preparation 1. 1.

Sealing ring. Check that the liner sealing surface is clean. Place a new sealing ring on top of the cylinder liner.

M901010260M01

2. Water connections. Check that the water connections are clean and provided with new Orings. Lubricate the Orings with Vaseline and fit them on the cylinder liner.

M901010260M02

2.

Page 10 (14)



901-1.4

Mounting

Cylinder Cover Mounting 3. 3. Cylinder cover landing.

D0106 Carefully wipe the cylinder cover contact surface facing the cylinder liner, while the cover is resting on the support. Lift the cylinder cover by means of the crane and lower it carefully into position. During the landing, carefully check that the cooling water connecting pipes engage correctly with the holes in the cooling jacket. 4. Cylinder cover stud check distance.

If necessary, adjust to the distance D0105 by turning the stud.

M901010260M03

If the cylinder cover studs have been removed and reinstalled, check the distance the stud is protruding from the cylinder cover.

4.

M901010254M04

D0105


Page 11 (14)

Cylinder Cover

901-1.4

Mounting

MAN B&W Diesel

5. Cylinder cover tightening. 5. Fit and tighten the cylinder cover nuts.

D1301

For operation of hydraulic jacks, see Procedure 9131. Fit the protective caps on the cylinder cover studs. Fitting Pipe Connections

M901010260M05

6. Mount the exhaust gas compensator.

6.

When mounting the clamp connecting the compensator and the intermediate pipe/exhaust valve it may, in some cases, become necessary to use the engine room crane. Clean the flanges and the clamp ring carefully and lubricate all contact faces with Molycote.

M901010246M05

Fit the insulating jacket around the intermediate pipe.

Page 12 (14)


Cylinder Cover MAN B&W Diesel 7.

901-1.4

Mounting

Connect the starting air pipe. 7. Connect and tighten the air pipe for the starting valve. Connect and tighten the control air pipe for the starting air valve.

8. Connect the water pipes. Mount and tighten the water outlet pipes.

Mount the hydraulic high pressure pipe for the exhaust valve. See Procedure 9081.4. Connect the drain pipe for the exhaust valve.

M901010260M07

9. Connect the oil pipes.

8. Connect the fuel oil high pressure pipes. See Procedure 90914.4.

M901010260M08

Connect the pipes for return fuel oil from the fuel valves.

M901010260M09

9.


Page 13 (14)

901-1.4

Cylinder Cover Mounting

MAN B&W Diesel

Open Oil and Water Supply 10. 10. Close the drain and open the water supply. Close the venting cock next to the outlet valve. Close the drain next to the inlet valve. Slowly open the water supply valve, placed below the exhaust gas receiver. Vent the unit by releasing air through the venting cock next to the outlet valve. When the venting is finished, close the venting cock. Open the two water outlet valves on the exhaust side of the cylinder cover.

M901010260M10

11. Open the oil supply. Open the fuel oil supply for the unit concerned.

M901010260M11

11.

Page 14 (14)


Cylinder Cover Panel

When referring to this page, please quote Plate P90151 Edition 0208 MAN B&W Diesel A/S

Plate P90151-0208

Page 1 (2)

Plate P90151-0208 Item No. 010 022 046 058 060 071 083 095 105 117 129

Page 2 (2)

Cylinder Cover Panel

Item Description

Item No.

Item Description

Panel for tools Name plate Grinding tool, exhaust valve seat Milling and grinding tool, fuel valve seat Milling and grinding wheel, fuel valve seat Dismantling tool, fuel valve Handle, sundry types Grinding ring, starting valve Pin spanner, starting valve Test equipment, combined safety valve Extension studs, lifting cylinder cover


Cylinder Cover - Hydraulic Jack Spares MAN B&W Diesel

When referring to this page, please quote Plate P90164 Edition 0001

Plate P90164-0001

Page 1 (2)

Plate P90164-0001 Item No. 011 023 035 047 059 060 072 084 096 118

Page 2 (2)

Cylinder Cover - Hydraulic Jack Spares MAN B&W Diesel

Item Description

Item No.

Item Description

Wooden box Tommy bar Spanner Venting screw Quick coupling male Disc O-ring with back-up ring O-ring with back-up ring Stud setter Disc


Cylinder Cover - Lifting T ools Tools MAN B&W Diesel


Plate P90165-0001

Page 1 (2)

Plate P90165-0001 Item No. 017

Page 2 (2)

Cylinder Cover - Lifting T ools Tools MAN B&W Diesel

Item Description

Item No.

Item Description

Lifting chains for cylinder cover


902 - Piston with Rod & Stuffing Box Documents in this Chapter 102-01 902-01 102-02 902-02 90251 90261 90264 90265 90266

0090 0290 0064 0231 0258 0102 0006 0001 0001

Piston, Data Piston Piston Rod Stuffing Box, Data Piston Rod Stuffing Box Piston and Piston Rod - Panel Piston and Piston Rod - Tools Piston and Piston Rod - Tilting Tools Piston and Piston Rod - Support Tools Piston - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

102-1

Piston Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X

Shut off safety air supply – Not ME engines

X


X

Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps

X

Engage turning gear

X

Shut off cooling water

X

Shut off fuel oil

X

Stop lubricating oil supply

X


Data Ref. D01-05 D02-01 D02-04 D02-05 D02-06 D02-08 D02-09 D02-10 D02-11 D02-13 D02-14 D02-46 D02-15 D02-16 D02-17 D02-18 D02-19 D02-20 D02-21 D02-22 D02-23 D02-24 D02-25 D02-47 D02-48 D02-49 D13-01 D13-02

Description Cylinder cover stud, check distance Test pressure Piston rod/crown stud, screwing-in torque Piston skirt, tightening torque Cooling oil pipe, tightening torque Piston ring new, radial width Piston ring worn, min. radial width Groove No.1, max. vertical height Groove Nos. 2, 3 and 4, max. vertical height Piston ring new, height of ring No. 1 Piston rings new, height of ring Nos. 2, 3 and 4 CPR ring CL groove, min. depth Minimum free ring gap ( before dismantling ) Minimum ring gap, ring No. 1 ( new ring in new liner ) Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) Vertical clearance, new parts Vertical clearance, worn parts, max. Piston complete Piston crown Piston rod Piston skirt Piston cooling pipe Lifting tool, tightening torque Piston top centre, max. permissible burn-away Piston top centre diameter Piston top outer ring area, max. permissible burn-away Hydraulic pressure, mounting Hydraulic pressure, dismantling

When referring to this page, please quote Data D10201 Edition 0090 MAN B&W Diesel A/S

Value 196 - 197 7 300 380 190 25.2 21.2 18.8 14.8 17.9 13.9 1.8 44 5.6 4.0 0.48 0.97 3300 870 2000 210 55 200 9 375 6 900 800 - 990

Unit mm bar Nm Nm Nm mm mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg kg Nm mm mm mm bar bar Page 1 (2)

102-1

Piston Data

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. P90951 refers to chapter 909. Plate

Item No.

Description

P90251

40

Lifting tool for piston rod foot

P90251

75

Template for piston top

P90251

87

Distance piece for stuffing box

P90251

99

Cover for stuffing box hole

P90251

110

Pressure test tool for piston

P90251

134

Piston ring expander

P90251

158

Guide screw for piston crown

P90251

171

Dismantling screw piston skirt

P90261

Guide ring for piston

P90262

Hydraulic jack for piston rod

P90264

Tools for tilted lift

P90265

Support for piston

P90266

Piston - Lifting Tools

P90366

Cylinder Liner - Lifting Tools

P90451

120

P91351

10


P91351

34


P91351

60


P91351

117

Page 2 (2)

Rubber cover for crosshead

5-way distributor block, complete


Piston MAN B&W Diesel

902-1.1

Checking

Scavenge Port Inspection

1.

To detect possible leakages from the piston or cylinder cover, keep the cooling water and cooling oil circulating during the scavenge port inspection. The scavenge port inspection is carried out from the scavenge air receiver. An additional view of the rings is possible through the cleaning cover on the manoeuvring side. Turn the engine at least ½ a revolution, and begin with a unit arriving downwards, just above the scavenge air ports. Inspect the piston rod and the lower part of the cylinder wall. While the piston is passing downwards, inspect the piston skirt, all the piston rings, the ring lands and the piston top.

M902010280C01

1.

2.

2. Ring inspection: Inspect the rings, one at a time, and note down the results. See Volume I, Operation, Chapter 707.

M902010280C02

3. Ring tension: Check the tension of the piston rings, by pressing against them with a wooden stick.

M902010280C03

3.


Page 1 (23)

Piston

902-1.1

Checking

4.

MAN B&W Diesel

4. Ring grooves: Measure the total clearance between the piston ring and the ring groove. The total clearance must not exceed the value stated in Data.

D0218

D0219

Measure the clearance at the top (E) and bottom (F) of the piston ring groove. Total clearance = E + F.

E

M902010280C04

F

Max. 2mm

5. Uppermost piston ring: If possible, measure the depth of the pressure relief grooves with a calliper. The piston rings must be replaced if the radial depth of the grooves has worn down to less than stated in Data D0246. Checking, in connection with piston overhaul

5.

D0246

Note! It is recommended to replace all the piston rings whenever a piston is removed from the engine.

M902010280C05

6. Piston support: Remove the piston from the cylinder and place it on the piston support. See Procedure 9021.2. For evaluation of the rings, see Volume I, Chapter 707.

M902010280C06

6.

Page 2 (23)


Piston MAN B&W Diesel 7.

902-1.1

Checking

Free ring gap: Before dismantling the piston rings, measure the free ring gap of all the piston rings.

7.

D0215

For dismantling the piston rings, see Procedure 9021.3.

9. Ring grooves: Clean the ring grooves and check them for burn marks or other deformation. Measure the ring grooves with a calliper gauge, see Data D0210 and D0211.

M902010280C07

8. Radial ring width: Measure the radial width of the rings. Note down the results See Volume I, Operation, Chapter 707.

8. Clearance in piston ring grooves: The maximum vertical height in a worn ring groove must not exceed the value stated in Data. The groove is also worn out if there is no chromium layer.

D0208

New

M902010280C08

If the ring grooves are worn out, the piston crown must be reconditioned, contact MAN B&W Diesel A/S for advice.

D0209

Worn

9.

D02-10 D02-11

M902010280C09

Max 2mm


Page 3 (23)

Piston

902-1.1

Checking

MAN B&W Diesel

10. Piston top template: Check that the piston top template is permanently marked with the piston top centre diameter D0248.

10.

Check that the centre area C has been marked off, and write the maximum permissible burnaway rate on the template. See data D0247.

C R

M902010280C10

D0248

Mark the outer part of the template R for ring area, and write the maximum permissible burnaway rate for the ring shaped area. See data D0249. 11. Piston crown top: Clean the piston crown and check the burnaway by means of the template.

11.

D0247 D0249

For maximum permissible burn away on the piston top centre area, see Data D0247. For the ring shaped area, see Data D0249. Check the burnaway on the whole circumference of the piston crown top. If the burnaway exceeds the values given in Data, contact MAN B&W for advice.

M902010280C11

Note down the results for later reference.

Page 4 (23)



Dismantling

Preparations in the crankcase 1.

902-1.2

1.

Access: Open the crankcase door to the cylinder concerned.

M90201280D01

Turn the crosshead down far enough to give access to the piston rod stuffing box and the piston rod/crosshead connection.


Page 5 (23)

902-1.2

Piston Dismantling

2.

MAN B&W Diesel

2. Telescopic pipe: Loosen and remove the screws which tighten the telescopic pipe to the bend. Remove one screw from the telescopic stuffing box housing and mount the special tool for suspending the telescopic pipe or use the thread in the telescopic pipe stuffing box housing. Turn the crosshead to TDC. Suspend the telescopic pipe by means of the tool. Turn the crosshead downward and remove the distance pipe from the bend. Note!

M902010280D02

When a piston is dismantled, never turn the engine without first dismantling the telescopic pipe from the crosshead.

Page 6 (23)



902-1.2

Dismantling

3. Stuffing box: Release the stuffing box by removing the innermost screws from the stuffing box flange.

3.

On engine models where the drain pipe is connected directly to the stuffing box: Disconnect the stuffing box drain pipe.

Do NOT remove the outermost screws from the flange.

4.

D1302

M902010280D04

4. Loosen the piston rodcrosshead connection: Loosen and remove the hydraulic nuts, see Data. See Procedure 9131.

M902010280D03

Note!


Page 7 (23)

902-1.2

Piston Dismantling

5.

MAN B&W Diesel

5. Stuffing box distance pieces: Mount the two distance pieces on the piston rod foot to protect the lower scraper ring and to guide the stuffing box. Preparations on the cylinder top 6. Cylinder cover: Remove the cylinder cover. See Procedure 9011.2. Make a scratch mark in liner and piston cleaning ring to ensure correct remounting. Remove the piston cleaning ring.

M902010280D05

Carefully remove any wear ridges at the top of the cylinder liner. See Procedure 9031.3.

M902010280D06

6.

Page 8 (23)


Piston MAN B&W Diesel 7.

902-1.2

Dismantling

Piston lifting tool: Turn the piston to TDC. The top of the piston is now free of the cylinder liner.

7.

D0225

Clean the lifting groove of the piston crown and mount the lifting tool. Note!

Limited lifting high: If the engine is not equipped with long distance pieces, remove one or two cylinder cover studs, using a stud setter.

M902010280D07

Make sure to mount the lifting tool correctly, so that the claws of the lifting tool enter the lifting grooves of the piston crown.


Page 9 (23)

Piston

902-1.2

Dismantling

MAN B&W Diesel

Piston lift

8.

8. Lift the piston out of the cylinder liner and guide the piston rod foot through the stuffing box flange. If the engine is equipped with long distance pieces for the stuffing box, the piston rod foot can pass between two cylinder cover studs. Place the two halves of the support around one of the openings in the platform. Lower the piston rod foot and stuffing box through the opening in the platform. Secure the two support halves with screws and lower the piston on the support. Check the piston is resting on the piston rod flange.

M902010280D08

D0220

Page 10 (23)



902-1.2

Dismantling

9. Protect the crosshead bearing: Place a cover over the opening for the piston rod stuffing box at the bottom of the cylinder unit.

9.

Turn the crosshead down far enough to permit mounting of the protective rubber cover on the crosshead bearing cap. The protective rubber cover is found on tool panel 904. The covers must remain in place to protect the crosshead bearing journal from impurities until the piston is remounted.

M902010280D09

Clean, measure and recondition the cylinder liner. See Procedure 9031.


Page 11 (23)

Piston

902-1.3

Overhaul 1.

1.

D0220

MAN B&W Diesel Piston support: Place the piston in the support and remove the piston lifting tool. See Procedure 9021.2. Clean the piston top and the piston rings. Check the free ring gap and the burnoff on the piston top. See Procedure 9021.1. Remove the stuffing box. See Procedure 9022.3.

M902010280O01

2. Piston ring dismantling: Take off the piston rings by means of the ring expanders. If the engine is equipped with two ring expanders, the short ring expander is for the uppermost ring.

2.

First remove the uppermost ring, then ring No. two, three and four. Clean and inspect the rings and the ring grooves. See Procedure 9021.1. 3. Piston crown dismantling: Loosen and remove the hydraulic nuts between the rod and the piston crown. See Data.

M902010280O02

For operation of hydraulic tools, see Procedure 9131.

M902010280O03

3.

Page 12 (23)

Lift the piston crown and skirt clear of the piston rod.

D0221 + D0223

D1302 When referring to this page, please quote Procedure M90201 Edition 0290


902-1.3

Overhaul

4. Piston rod and cooling pipe: Remove the screws from the cooling oil pipe flange.

4.

D0224

Mount the eye bolts and lift out the cooling oil pipe.

D0206

Clean and inspect the cooling oil pipe and the piston rod, then remount the cooling oil pipe, see Data. Check that the surfaces of the Oring groove is clean and smooth.

5. Piston crown turning: Unhook the crane from the piston lifting tool, and connect the lifting tool and the crane hook by means of a wire rope. Lift up the piston crown.

M902010280O04

Mount a new Oring on the piston rod flange.

D0222

5.

Install a tackle in a suitable place with sufficient space below for the piston crown. Attach the tackle to the wire rope on the piston skirt and carefully turn the piston crown upside down. Use both cranes if the engine room is equipped with two cranes.

M902010290O05

Fit two eyebolts in the piston skirt and a wire rope between the bolts as shown in the sketch.

Land the piston lifting tool and the piston crown on a sufficient support of wood pieces. Loosen the piston lifting tool and lift the piston crown clear of the tool.


Page 13 (23)

Piston

902-1.3

Overhaul

MAN B&W Diesel

6. Piston crown dismantling and cleaning: Place the piston crown with skirt on a wooden support as shown.

6.

D0223

Remove the locking wire and the screws in the skirt. If necessary, use two dismantling screws to pull the skirt off the piston crown. Mount two eye bolts in the skirt. Lift the skirt and land it on a couple of planks. Discard the sealing ring on the piston skirt.

M902010280O05

Thoroughly clean and inspect all parts of the crown and skirt. If coke deposits are found in the cooling spaces of the piston crown, the coke deposits should be washed out with Carbon Remover or a similar cleaning fluid. When all coke deposits have been dissolved, clean and inspect the piston crown again.

7.

Note! Coke deposits reduce the heat transfer from the piston crown to the cooling oil. The deposits must be removed as a routine procedure when a piston is overhauled.

M902010280O06

D0205

If the piston crown is renewed, remove the piston crown studs using a stud setter.

D0204 7.

Piston crown assembly: Mount the piston crown studs in a new or overhauled piston crown, lubricate the threads on the studs with molybdenum disulphide (MoS2). Tighten the studs to the specified torque using a stud setter, see Data D0204. Mount a new Oring on the piston skirt, check that the surfaces of the Oring groove is clean and smooth, coat the ring with lubricating oil before mounting. Mount the piston skirt on the piston crown. Tighten the screws to the specified torque, see Data D0205. Lock the screws with locking wire. See Procedure 9137.

Page 14 (23)



902-1.3

Overhaul

8. Piston crown and skirt mounting: Lubricate the Oring on the piston rod flange with lubricating oil.

8. 4

6 5

Land the overhauled piston crown and skirt on the piston rod.

2

4

1 3

6

Mount and tighten the hydraulic nuts on the piston crown studs.

2

5 4

3 1

1 3

5 2 2

6

3 1

4 5

6

When tightening the hydraulic nuts follow the tightening sequence. All the nuts must be tightened twice to full tightening pressure, see Data. Sealing ring and pressure test

9. Sealing ring test: Mount the pressuretesting tool on the piston rod foot. Connect compressed air to the testing tool and fill the piston to 45 bar. Close the valve on the testing tool and remove the air connection. The piston must now hold the pressure for minimum 30 minutes.

D1301

M902010280O07

According to current class rules, the piston must be pressure tested hydraulically. It is possible to carry out a test of the sealing rings with compressed air before filling the piston with oil. The sealing ring test can also be carried out when the piston is resting in the support tool.

9.

Spray a little soap water on to the surface joints between piston rod/crown/skirt and around the hydraulic nuts to detect leaks.

M902010277O16

Dry off all soap water.


Page 15 (23)

Piston

902-1.3

Overhaul

10. Pressure test: For this test, the piston must be turned upside down (see next step to turn a complete piston).

10.

D0201

M902010277O17

oil

Page 16 (23)

MAN B&W Diesel

Fill the piston and piston rod with lubricating oil. Mount the pressuretesting tool on the piston rod foot. Pressuretest the piston at the pressure stated on the Data Sheet. Check the contact surfaces of the piston and the sealing rings for tightness. Check that there are no cracks in the piston crown. Turn the piston upside up and drain out the piston oil.



902-1.3

Overhaul

11. Piston turning: Lift the piston with the normal lifting tool. Lower the piston rod foot until it is close to the platform. Land the foot on a wooden block.

11.

Lower the piston crown to the platform and land it on a wooden block in such a way that it is possible to remove the lifting tool. Mount an eyebolt in the side of the lifting tool, hook on the crane and remove the lifting tool from the piston crown. Attach the lifting bracket to the bottom of the piston rod foot. Hook the crane on to the lifting bracket. Lift the piston rod foot clear of the wooden block. Keep lifting until the piston rod is in a vertical position. Note!

M902010280O10

During the lift, follow with the crane to keep the crane positioned vertically above the lifting point. The stuffing box must be removed.


Page 17 (23)

Piston

902-1.3

Overhaul

12. Piston completion: Fit the new piston rings (alternately righthand and lefthand cuts, with the ring gaps staggered 180° and with the TOP mark upwards), using the ring expander.

12. A

TOP

B A

C

B

MAN B&W Diesel

When mounting the piston rings, use the ring expanders to prevent unintended deformation of the rings.

C

Do not expand the rings more than necessary. The uppermost ring (CPRring) must be mounted with the short ring expander.

D

Mount the piston rod stuffing box. See Procedure 9022.3.

M902010280O11

D

Page 18 (23)



Mounting

Preparation of piston 1.

902-1.4

1.

Check the piston rings and piston crown in accordance with Procedure 9021.1, if not already done. Mount the lifting tool on the piston crown. See Data D0225.

2. Stuffing box position: Ensure that the stuffing box is correctly positioned over the distance pieces mounted on the piston rod foot. Both the holes for the flange and the drain hole for the drain pipe must be positioned correctly.

M902010280M01

D0225

M902010277M02

2.


Page 19 (23)

Piston

902-1.4

Mounting

MAN B&W Diesel

Preparation of cylinder liner

3.

3. Mount the guide ring: Mount the guide ring in the top of the cylinder liner. The cut outs for the lifting tool must be turned to foreaft position. 4. Stuffing box cover: Remove the cover from the piston rod stuffing box opening in the bottom of the cylinder unit.

M902010280M03

Clean the stuffing box flange. 5. Crosshead position: Turn the crosshead to a position 45° from TDC (crank web pointing towards exhaust side).

M902010277M05

4.

M902010277M06

5.

Page 20 (23)

45°



902-1.4

Mounting

Mounting of piston 6.

D0220

6. Coat the Orings of the stuffing box and the piston rod with oil. Coat the piston rings and cylinder liner with cylinder lubricating oil.

7.

Protective cover: Remove the protective rubber cover from the crosshead.

8. Crosshead alignment: Turn the crosshead almost to TDC. If necessary, mount the hydraulic nuts on the studs and screw down until the nuts are flush with the top of the studs.

M902010280M06

Lower the piston into the cylinder liner – while guiding the piston rod foot through the cutout in the stuffing box flange – until the piston rings are inside the liner.

7.

Lower the crosshead just enough to enable removal of the nuts. Turn the crosshead upwards until the piston rod lands on the crosshead. When mounting the piston on the crosshead, make sure that the piston rod foot does not damage the threads of the studs. Ensure that the guide ring in the crosshead fits correctly in the centre hole of the piston rod.

M902010277D10

Turn the crosshead upwards until the piston rod foot lands on the nuts, thereby turning the crosshead until the face is parallel to the piston rod foot.

8.

M902010280M08

Unscrew the lifting tool and remove the lifting tool and the guide ring for piston rings.


Page 21 (23)

902-1.4

Piston Mounting

MAN B&W Diesel

9. Stuffing box: Turn down and land the stuffing box on the stuffing box flange. Check that the holes in the stuffing box and stuffing box flange are correctly centered.

9.

Tighten the piston rod stuffing box by means of the screws through the inner holes in the stuffing box flange. For Data, see Procedure 9022.

M902010280M09

On engine models where the drain pipe is connected directly to the stuffing box:

10.

• Mount the stuffing box drain pipe. Remove the distance pieces from the piston rod foot.

D1301

10. Tightening of the piston rodcrosshead connection: Mount and tighten the piston rod nuts with the hydraulic jacks. See Data. See Procedure 9131. 11. Telescopic pipe: Place the distance pipe on the bend for the telescopic pipe.

M902010280M10

Turn up towards TDC until the telescopic pipe is landed on the distance pipe. Remove the suspending tool and mount the screws and tighten the telescopic pipe to the bend. For Data, see Procedure 9042.

M902010280M11

11.

Page 22 (23)



902-1.4

Mounting

12. Piston cleaning ring: Mount the piston cleaning ring in accordance with the scratch mark. If the PCring is damaged (broken or cracked), it must be replaced by another ring. See Procedure 9031.

12.

Mount the cylinder cover studs with the stud setter. Screw the stud down to contact and half a revolution back. 14. Cylinder cover: Land the cylinder cover on the liner and check the distance that the stud is protruding from the cylinder cover. If necessary, adjust the distance D0105 by turning the stud.

M902010277M14

13. Cylinder cover studs: If the cylinder cover studs have been removed, remount them. Carefully clean the surfaces around the base of the studs and check the Orings on the studs.

13.

15. Runningin: Smear the piston rod with molybdenum disulphide, and turn the crankshaft a couple of revolutions. At the first opportunity, start the engine and keep it running for about 15 minutes at a speed corresponding to “Dead Slow” Ahead.

M902010277M15

Tighten the cylinder cover nuts and mount the necessary pipes. See Procedure 9011.4.

14. Then stop the engine and inspect the piston rod and stuffing box.

M902010280M14

D0105


Page 23 (23)

Piston Rod Stuffing Box MAN B&W Diesel

102-2

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 Stopped engine

X X X X X X X X X X X

Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description

Value

Unit

D02-26

Stuffing box flange, outer screws tightening torque

180

Nm

D02-27

Stuffing box flange, inner screws tightening torque

200

Nm

D02-28

Stuffing box halves, tightening torque

80

Nm

D02-29

Uppermost rings, ring-end clearance

4x6

mm

D02-30

Lowermost rings, ring-end clearance

3x3

mm

D02-34

Sealing ring springs new, free length

831

mm

D02-38

Scraper ring springs new, free length

782

mm

D02-44

Stuffing box complete

190

kg

D02-45

Stuffing box half

65

kg

D02-50

Stuffing box halves fitted bolts, tightening torque

80

Nm


Page 1 (2)

Piston Rod Stuffing Box

102-2

MAN B&W Diesel

Data


Item No.

Description

P90251

109

Mounting tool for stuffing box spring

P90251

122

Worktable for stuffing box

P90451

120


Page 2 (2)



902-2.1

Checking

1. After the piston rod stuffing box has been dismantled, check the following clearances: See Procedure 902-2.2.

1.

A

Uppermost scraper ring and sealing rings Clearance at ring ends (scraper ring). Total clearance (scraper ring). (D02-29)

D0229 B

Clearance at ring ends (sealing rings). Total clearance (sealing rings). (D02-29) Lowermost scraper rings Clearance at ring ends. Total clearance. (D02-30)

D0230 A

As a general guide, it is recommended – depending on the overhauling intervals and one’s own experience – to replace sealing rings and scraper rings when the specified clearance values D02-29 and D02-30 have been halved. 2. Garter springs:

M902020230C01

The ring clearances stated in Data apply to new rings.

B

D0229

2.

D0230

D0234

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.

M902020227C02

D0238


Page 1 (10)

902-2.2

Piston Rod Stuffing Box Dismantling

1.

MAN B&W Diesel

In connection with dismantling of the piston, only the innermost screws in the stuffing box flange and the screws for the drain oil pipe should be removed. If, in the period between piston overhauls, it becomes necessary to inspect the piston rod stuffing box, proceed as follows:

M902020231D01

1. Turn the crosshead to about 90° from TDC.

2.

Mount the rubber cover around the piston rod to protect the crosshead bearing from impurities. 2. Remove the drain oil pipe and all innermost screws and all outer screws except for two screws placed diametrically opposite in the stuffing box flange, longitudinally to the engine.

M902020231D02

3. Mount the worktable around the piston rod so that the two remaining screws in the stuffing box flange can be loosened through the holes.

M902020230D03

3.

Page 2 (10)



902-2.2

Dismantling

4. Remove the two long dismantling screws from the worktable.

4.

Mount them in the stuffing box through the holes in the worktable. Remove the remaining two screws from the stuffing box.

6. Remove the two long dismantling screws from the stuffing box and mount them in the worktable.

5.

M902020229D05

By means of the four short screws in the worktable, press the stuffing box out of the flange. For overhauling the stuffing box, see Procedure 902-2.3.

M902020230D04

5. Turn the piston to BDC, thereby withdrawing the stuffing box from the cylinder frame bottom.

M902020230D05

6.


Page 3 (10)

902-2.3

Piston Rod Stuffing Box Overhaul

MAN B&W Diesel

Normally, overhaul of the piston rod stuffing box is carried out by routine methods in connection with the dismantling (pulling) of the pistons. During such overhauls, the piston rests on a support placed over one of the cut-outs in the top platform. Work on the stuffing box is then carried out from the platform below.

M902020230O04

Overhaul inside the engine is carried out in the same way as outside the engine. 1. Mount two eye bolts in the stuffing box flange, and hook on two tackles. Lift the stuffing box a little up the piston rod, and mount the worktable round the piston rod at a suitable working height.

1.

Land the stuffing box on the worktable, and remove the tackles and eye bolts.

M902020230O01

D0244

2. Remove the O-ring of the stuffing box. If the O-ring is intact and is to be used again, move it up the piston rod and secure it in this position, for example with tape. Remove the nuts from the stuffing box assembling bolts.

M902020230O02

2.

Page 4 (10)



902-2.3

Overhaul

3. Take out the six bolts, and pull away one stuffing box half.

3.

Mount two eye bolts on the stuffing box half and remove it from the worktable.

D0245

4. Using a feeler gauge, measure the vertical clearance of the rings. See Procedure 902-2.1.

6. Measure the clearance between the ring segments to determine whether replacement is necessary. See Procedure 902-2.1. Dismantle and stack the rings in the same order as when fitted in the stuffing box.

M902020230O03

5. Remove the remaining stuffing box half and press all sealing rings and scraper rings down against the worktable.

7.

D0234

Carefully clean all the ring segments. Inspect and assess the surface quality of the sealing rings. If their sliding surfaces have scratches or marks, replace the rings.

D0238

8. Inspect the surface of the piston rod. If small longitudinal scratches have occurred (caused by poorly adapted stuffing box rings), smooth the piston rod surface carefully with a fine grained carborundum stone. In the case of coarse scratches, it may prove necessary to machine-grind the surface in a workshop.

M902020227C02

7. Check the lengths of the springs. See Procedure 902-2.1.

8.

M902020230O08

9. Clean the halves of the stuffing box housing.


Page 5 (10)


902-2.3

Overhaul

10.

A B C

MAN B&W Diesel

10. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be positioned) with molybdenum disulphide (MoS2). For correct mounting of the sealing and scraper rings see the sketch. The scraper ring in groove no. 4 must be without relief grooves on the underside.

Scraper ring

A Scraper ring

B Sealing ring

C

M902020230O10

No relief groove

Page 6 (10)

Relief groove



902-2.3

Overhaul

11. Assemble all the stuffing box ring units round the piston rod, on the worktable, in the following way:

11.

• Place the lowermost scraper ring segments on the worktable. • Place the spring round the segments, and hook the spring ends together.

On top of the scraper rings, assemble the two sealing ring units (each consisting of a 4-part and an 8-part ring). Assemble the 8-part sealing ring so that the two guide pins face upwards, place the spring round the segments and, hook the spring ends together.

M902020229O11

Repeat this procedure for the remaining scraper rings.

12.

Assemble the 4-part sealing ring above the 8-part sealing ring. Push the two rings together in such a manner that the guide pins in the lower sealing ring engage with the two holes in the upper sealing ring.

12. Use the stuffing box half on the worktable to adjust the height of all the assembled ring units on the piston rod until the ring units are opposite the corresponding grooves in the stuffing box housing. Subsequently, push the stuffing box half into contact with the piston rod, round the ring units.

M902020230O12

Finally, assemble the uppermost ring unit (consisting of a 4-part scraper ring and an 8-part sealing ring).

Note! If the stuffing box is assembled inside the engine, place two pieces of plywood of the same thickness as the flange on the worktable, to ease the assembling.


Page 7 (10)

902-2.3

Piston Rod Stuffing Box Overhaul

MAN B&W Diesel

13. Check the ring clearance again.

13.

Then place the other half of the stuffing box housing on the worktable, pushing it into place round the rings.

D0228

In the middle holes mount and tighten up the fitted bolts to the torque specified on the Data Sheet, See Data D02-50

D0250

14. Mount eye bolts and wire ropes, and lift the stuffing box a little.

M902020230O13

14.

Mount the O-ring in the stuffing box groove.

Remove the worktable and lower the stuffing box until it rests against the distance pieces on the piston rod foot.

D0244

Remove wire ropes and screws.

M902020230O14

Mount and tighten the standard bolts to specified torque, See Data D02-28

Page 8 (10)



902-2.4

Mounting

1. In connection with mounting of the piston, only the innermost flange screws are to be mounted and tightened, see data.

1.

After overhauling the stuffing box inside the engine, assemble the stuffing box halves on top of the four screws.

Turn down the short screws so that the stuffing box lands on the flange. 2. Turn the piston upwards until the stuffing box is in place in the cylinder frame.

M902020230M01

Mount the two long screws from the worktable in the stuffing box.

Note! Make sure that the two guide pins in the flange enter the guide holes in the bottom of the cylinder frame.

2.

M902020230M02

3. Mount two screws in the flange through the holes in the worktable.

M902020230M03

3.


Page 9 (10)

902-2.4

Piston Rod Stuffing Box Mountingl

MAN B&W Diesel

4. Remove the long screws from the stuffing box and mount them in the worktable.

4.

Remove the worktable from the piston rod. 5. Mount the drain oil pipe. Mount and tighten all the inner and outer screws for the stuffing box. See Data.

M902020230M04

6. Remove the protecting rubber cover from the piston rod/crosshead. Smear the piston rod with molybdenum disulphide. Then turn the crankshaft a couple of revolutions.

5.

If possible: Start up the engine and keep it running for about fifteen minutes at a number of revolutions corresponding to very slow or idle speed.

M902020231O05

Then stop the engine and inspect the piston rod and stuffing box.

D0226 D0227

M902020231O06

6.

Page 10 (10)


Piston and Piston Rod Panel


Plate P90251-0258

Page 1 (2)

Plate P90251-0258 Item No. 014 026 040 063 075 087 099 109 110 122 134 160

Page 2 (2)

Piston and Piston Rod Panel

Item Description

Item No.

Item Description

Panel for tools Name plate Lifting tool for piston rod Lifting tool for cylinder liner Template for piston top Distance piece for stuffing box Cover for stuffing box hole Hook for mounting of spring Pressure tester Worktable Piston ring expander Dismantling screw


Piston and Piston Rod - T ools Tools MAN B&W Diesel


Plate P90261-0102

Page 1 (2)


Page 2 (2)

Piston and Piston Rod - T ools Tools MAN B&W Diesel

Item Description

Item No.

Item Description

Guide ring for piston


Piston and Piston Rod - Extra Tools

Plate P90264-0006

Piston and Piston Rod - Extra Tools 0006 P90264


Page 1 (2)

Plate P90264-0006 Item No. 015 027 039

Piston and Piston Rod - Extra Tools

Item Description

Item No.

Item Description

Collar ring for piston Support for tilting tool Support for tilting tool

Page 2 (2)


Piston and Piston Rod - Support Tools


Plate P90265-0001

Page 1 (2)


Page 2 (2)

Piston and Piston Rod - Support Tools

Item Description

Item No.

Item Description

Support iron for piston



Plate P90266-0001

Piston - Lifting Tools 0001 P90266


Page 1 (2)



Item Description

Item No.

Item Description

Lifting tool for piston

Page 2 (2)


903 - Cylinder Liner and Cylinder Lubrication Documents in this Chapter 103-01 903-01 103-02 903-02 90361 90362 90364 90366

0075 0259 0028 0256 0083 0005 0004 0003

Cylinder Liner, Data Cylinder Liner Cylinder Lubricator, Data Cylinder Lubricator Cylinder Liner - Tools Cylinder Liner - Milling Tools Test Equipment for Lubricators Cylinder Liner - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Liner MAN B&W Diesel

103-1

Data


X X X X X X X X X X X


Data Ref.

Description

Value

Unit

D03-02

Lifting tool bolts, screwing-in torque

200

Nm

D03-03

Cylinder diameter, new

800

mm

D03-04

Piston cleaning ring diameter, new

798.3

mm

D03-16

Piston cleaning ring radial width, new

15.8

mm

D03-17

PC-ring/Liner max. wear deviation

0.8

mm

D03-05

Cylinder liner, complete

D03-06

Cooling jacket

D03-18

PC-rings replacement criteria:

4700

kg

130

kg

Liner diameter: 800 mm Liner wear:

Install:

0

Standard PC-ring (new or max. diameter wear of 0.80 mm

– 0.80 mm

0.80 –

1.6 mm

Oversize PC-ring

>

1.6 mm

No PC-ring


Page 1 (2)

Cylinder Liner

103-1

MAN B&W Diesel

Data

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. P90951 refers to chapter 909. Plate P90251

Item No. 051

Description Lifting tool for cylinder liner

P90361

Measuring tool for cylinder liner

P90366


Page 2 (2)



903-1.1

Checking

1. Dismount the cylinder cover, the piston cleaning ring and the piston. See Procedures 901-1.2 and 902-1.2.

1.

Clean the cylinder liner and scavenge air ports. 2. Position the cylinder liner measuring tool. Measure the cylinder liner with an inside micrometer at the positions indicated on the measuring tool.

D0303

Take measurements in the fore-and-aft and athwartship directions.

3. Carefully scratch over any scores or marks and grind away the wear ridges. See Procedure 903-1.3. 4. Check the lubricating points of the cylinder by pumping cylinder oil to each lubricating point with the cylinder lubricator. Clean any blocked lubricating duct.

M903010259C02

Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707.

2.

M903010259C04

Mount the piston and cylinder cover. See Procedures 902-1.4 and 901-1.4.


Page 1 (11)

Cylinder Liner

903-1.1

Checking

MAN B&W Diesel

5. Piston cleaning (PC) ring:

5.

The PC-ring is to be regarded as an integrated part of the liner and it is intended to follow the service life of the liner.

M903010259C06

During inspection of the piston and the liner, the PC-ring must also be inspected.

B

6. Measure the PC-ring radial width B, and find the most worn place. Compare with Data D03-16 and calculate the wear of the PC-ring, multiply the wear by 2 to get the PC-ring diameter wear. Measure the liner in the fore-aft and athwart-ship directions at piston skirt TDC position, corresponding to measuring point No. 5 on the liner-measuring tool. Compare the measurements with the diameter of a new liner as stated in Data. Calculate the wear of the liner. 7. Compare the PC-ring diameter wear with the wear of the liner. If wear of the two components does not deviate more than D03-17 then reinstall the PC-ring. If deviation between PC-ring wear and liner wear is more than D03-17 or if the PC-ring is broken or cracked, replace the ring with a new PC-ring, an oversize ring or no ring according to Table D03-18 on the Data sheet. If it is necessary to install an oversize PCring, contact MAN B&W Diesel for advice. When a new liner is installed, also a new PC-ring must be installed. When a new liner is ordered, also a new PC-ring must be ordered.

Page 2 (11)



903-1.2

Dismantling

1. Dismount the cylinder cover. See Procedure 901-1.2.

1.

Discard the sealing ring from the top of the cylinder liner. Turn the piston down far enough to make it possible to remove the wear ridges at the top of the liner. See Procedure 903-1.3. Dismount the piston cleaning ring and the piston. See Procedure 902-1.2.

3. Disconnect the oil pipes leading from the cylinder lubricator to the cylinder liner.

M903010259D02

2. Screw the two lifting tools on to the cylinder liner. Check with a feeler gauge that there is no clearance between lifting tool and cylinder liner. For tightening torque, see Data.

M903010259D03

3.


Page 3 (11)

903-1.2

Cylinder Liner Dismantling

MAN B&W Diesel

4. Dismount the four cooling water pipes – between the cooling jacket and cylinder cover and discard the O-rings from the pipes – and clean them carefully.

4.

Attach the crane to the lifting crossbar.

D0305

Hook the lifting tools on to the crossbar on both sides of the cylinder liner. Lift the liner with the cooling jacket out of the cylinder frame. Note!

M903010259D04

Low lifting height in the engine room may require the removal of one or more cylinder cover studs before dismantling the cylinder liner.

6.

Land the cylinder liner vertically on, for instance, a couple of planks. Remove the cooling water pipes and discard the O-rings. 5. Clean the cylinder frame internally, taking special care with the contact surfaces for the cylinder liner at the top of the cylinder frame.

M903010259D06

6. The lifting tools are also used for transporting the cylinder liner.

Page 4 (11)



903-1.3

Overhaul

1. Unscrew the non-return valves from the cylinder liner.

1.

Clean and inspect the non-return valves. 2. Attach two tackles to the crossbar, as shown. Mount two lifting eye bolts in the cooling jacket.

Loosen the screws on the clamps which fix the cooling jacket to the cylinder liner. Turn the clamps away from the liner.

M903010259O01

Hook the tackles on to the lifting eye bolts on the cooling jacket and haul tight.

M903010259O02

2.

D0306


Page 5 (11)

903-1.3

Cylinder Liner Overhaul

3.

MAN B&W Diesel

3. Lower the cooling jacket by means of the tackles and the crane, and land it on the wooden planks. Check that the cooling jacket does not tilt when it is lowered. 4. Mount the lifting tools in the cylinder liner. Lift the cylinder liner away from the cooling jacket.

M903010259O03

Clean the cooling jacket internally.

M903010259O04

4.

Page 6 (11)


Cylinder Liner

903-1.3

Overhaul

MAN B&W Diesel

5. Check and assess the condition of the cylinder liner according to the description given in Volume I, Chapter 707.

5.

Carefully scratch over any scores or marks on the cylinder liner running surface, by means of a rough grindstone held in the hand.

6. It is recommended to use a wear ridge milling machine to create the groove. For use of the milling machine, see supplier’s instruction.

C M903010259O05

Check in the top of the liner for a wear ridge (where the piston rings reverse direction). If there is any sign of a wear ridge, it is necessary to create a groove by grinding.The groove serves to prevent the build-up of a new wear ridge.

A B

6.

7. Alternatively, place an old piston ring on the top of the piston and turn to a position that enables the grinding disc to rest on the old piston ring while removing the wear ridge. Use a grinding disc with a round edge.

The maximum depth of the groove is calculated as Smax = D x 0.0045. Note! It is of the utmost importance that the groove is made with a regular rounding as shown in the sketch.

M903010259O06

Check the distance C before grinding to ascertain that the wear ridge was caused by the top ring at TDC.

7.

S

C

R=45 mm

M903010259O07

C

D


Page 7 (11)

903-1.3

Cylinder Liner Overhaul

MAN B&W Diesel

8. If necessary, mount a new cylinder liner. 8. Note! If a new cylinder liner is mounted, a new piston cleaning ring must also be mounted after mounting the piston. Apply a thin layer of grease on the contact surface for the cooling jacket on the liner. Mount the lifting tools on the liner. Lift the liner a little and mount new O-rings for the cooling jacket. Then place the liner in the cooling jacket. Remove the lifting tools.

M903010259O08

9. Lift the cooling jacket into position – marking scratches jacket/cylinder liner must coincide (camshaft side).

M903010259O09

9.

Page 8 (11)



903-1.3

Overhaul

10. Turn the clamps until they fit in the groove of the liner, and tighten the screws.

10.

Remove the tackles and the eye bolts from the cooling jacket.

M903010259O10

11. Mount the non-return valves for cylinder lubrication.

M903010259O11

11.


Page 9 (11)

Cylinder Liner

903-1.4

Mounting

MAN B&W Diesel

1. Loosen the water connections on the cooling jacket.

1.

Mount the lifting tools on the cylinder liner and tighten to specified torque. See Data.

D0302 D0305

Hook the chains from the lifting crossbar on to the lifting tools, and lift the jacket/ liner assembly.

M903010259M01

Mount the lowermost O-rings and apply a little lubricating oil on the rings. 2. Check that the joint surfaces on the cylinder frame and cylinder liner are completely clean. Coat the joint surfaces with permatex or a similar liquid sealing compound.

2. Mount the cylinder liner in the cylinder frame. Replace the O-rings on the water connections and mount the water connections on the cooling jacket.

M903010259M02

Remove the cylinder liner lifting tools. 3. If one or more cylinder cover studs have been removed during the dismantling of the cylinder liner, discard the old O-rings and mount new ones on the cylinder cover studs. Mount the studs in the cylinder frame, using the stud setter.

M903010259M03

3.

Page 10 (11)


Cylinder Liner

903-1.4

Mounting

MAN B&W Diesel

4. Screw the pipes from the lubricator on to the non-return valves, but do not tighten.

4.

When this is in order, tighten the pipes firmly on the non-return valves and again pump manually until it is certain that each individual lubricating point functions correctly. 5. Lubricate the inside of the cylinder liner with cylinder lubricating oil and mount the piston. See Procedure 902-1.4. 6. Mount the piston cleaning ring, the sealing ring and land the cylinder cover on the liner. See Procedure 901-1.4.

M903010259M04

Vent the cylinder lubricating system by manually pumping each individual pipe through until oil, without air bubbles, comes out from the union pipe/non-return valve.

6.

Note! Make sure to mount the piston cleaning ring correctly, so that the scratch marks are aligned.

M903010259M06

Tighten the upper water connections on the cooling jacket as soon as the cylinder cover is correctly positioned.


Page 11 (11)

103-2

Cylinder Lubricators Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X


X

Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description

Value

Unit

D03-10

Inlet accumulator, nitrogen pressure,

30

bar

D03-11

Outlet accumulator, nitrogen pressure,

1.5

bar

D03-13

Plug screw, tightening torque,

30

Nm


Page 1 (2)

103-2

Cylinder Lubricators Data


Page 2 (2)

Item No.

Description Test Equipment for Lubricators


Cylinder Lubricators MAN B&W Diesel

903-2.1

Checking

Check of Oil Injection:

1.

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 lubricator. 2. If the cylinder cover or the exhaust valve is removed, check inside the liner that all lubricating points are working properly.

Turn the piston to BDC and check inside the liner with a mirror and a powerful light source that all lubrication points are working properly. With running engine: 3. Check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator.

M903020245C01

Otherwise, remove the covers for scavenge port inspection.

3. The LEDs give signal when oil is injected. Check the pressure shocks from the injection of the lubricators on each lubricator pipe by feeling with a hand.

M903020245C02

If in doubt, disconnect the pipe at the cylinder liner to observe the oil flow.


Page 1 (13)

903-2.1

Cylinder Lubricators Checking

MAN B&W Diesel

Check of Accumulators: 4.

D0311

4. Check of Inlet Accumulator Checking the inlet accumulator can be done with running engine. Close the valve that connects the accumulator to the distributor block. Mount the special hose on the minimess coupling and drain all oil out of the accumulator.

M903020256C04

Check the nitrogen pressure. For use of pressure setting tool, see Step 6. For correct pressure, see Data. 5. Check of Outlet Accumulator The outlet accumulators are to be dismounted while the nitrogen pressure is checked.

5.

Dismount the outlet accumulator. See Procedure 903-2.2.

M903020256C05

Check the nitrogen pressure, using the pressure setting tool.

D0311

M903020245C05

6.

6. Use of Pressure Setting Tool Assemble the pressure setting tool as shown in the Figure, and mount the reducing valve on the nitrogen cylinder. If necessary, use a threaded adaptor. Mount a 0-60 bar pressure gauge on the filling valve when the inlet accumulator (0.7 litre) is checked, and a 0-10 bar pressure gauge when the outlet accumulators (0.16 litre) are checked.

Page 2 (13)



903-2.1

Checking

7. Before mounting the filling valve on the accumulator, check that the accumulator top is clean. Mount the filling valve on the relevant accumulator with the union nut. Check that valves C and F are closed.

7.

C

A

E

D0313

F

Loosen the plug screw in the accumulator using a ½” square drive handle in socket E.

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 Data.

B M903020247C07

It is now possible to read the actual nitrogen pressure in the accumulator on the dial gauge on the filling valve.

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 the filling valve from the accumulator. Retighten the plug screw to the torque stated in Data. Remount the accumulator.


Page 3 (13)

Cylinder Lubricators

903-2.2

Dismantling

MAN B&W Diesel

Dismantling of lubricators: 1.

A

B

Both lubricators can be dismounted with running engine, one at a time. If the engine is running when a lubricator is dismounted, it is important to check that the other lubricator is doubling injection frequency.

M903020256D01

1. Close the supply valve for the lubricator concerned, using the special tool. The lowermost valve is for lubricator marked A and the uppermost valve is for lubricator marked B.

2.

Let the lubricator inject oil until the feedback LED stops flashing. Disconnect the electrical plug on the topside of the lubricator. 2. Unscrew the screws in the pipe flange of the lubricator and disconnect the cover with pertaining pipes.

M903020256D02

3. Unscrew the four screws from the top that secure the lubricator to the hydraulic block, and remove the lubricator.

Page 4 (13)



903-2.2

Dismantling

Dismantling of accumulators: 4. 4. Inlet Accumulator Close the valve that connects the accumulator to the distributor block. Mount the special hose on the minimess coupling and drain the oil out of the accumulator. Unscrew the accumulator. If the engine is running, a new or checked accumulator should be mounted at once.

Close the supply valve for the accumulator concerned, using the special tool. The outer valve is for accumulator marked A and the inner valve is for accumulator marked B.

M903020256D04

5. Outlet Accumulator

5. Let the lubricator inject oil until the feedback LED stops flashing.

A

B

M903020256D05

If space conditions permit, unscrew the accumulator; otherwise the lubricator must be dismounted, see Step 1.


Page 5 (13)

903-2.3

Cylinder Lubricators Overhaul

1.

MAN B&W Diesel

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. 2. Remove the screws from the cylinder block.

M903020247O01

3. Pull up the cylinder block. Remove the spring and actuator piston with plungers. Remove and discard the O-ring from the cylinder block.

2.

M903020247O02

Remove the cover for the non-return valves. Take out springs and balls. Remove and discard the O-rings.

M903020247O03

3.

Page 6 (13)



903-2.3

Overhaul

4. Screw out the non-return valves and remove and discard the O-rings.

4.

Clean the valves and check them with compressed air. 5. Inspect the plungers, actuator piston and cylinder block for wear, using a magnifying glass.

Mount the non-return valves in the cylinder block.

M903020247O04

6. Fit the non-return valve with new O-rings.

M903020247O05

5.

M903020247O06

6.


Page 7 (13)

903-2.3

Cylinder Lubricators Overhaul

7.

MAN B&W Diesel

7. Pre-assemble the cylinder blockwith the actuator piston and plungers to ensure the correct guidance of the plungers, before finally assembling the cylinder block unit. Mount the spring and press down the actuator piston with plungers. Mount an M6 x 60 screw with a washer to keep the spring compressed. Fit the cylinder block with a new O-ring. 8. Remove the cover from the terminal box and disconnect the wires for the feedback (pick-up) sensor. Remove the terminal box and the plug for the solenoid valve.

M903020247O07

Carefully unscrew the feedback sensor and remove and discard the O-ring. Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth.

M903020247O08

8.

Page 8 (13)


Cylinder Lubricators MAN B&W Diesel 9

903-2.3

Overhaul

Turn the lubricator upside down in the vice.

9.

Unscrew the solenoid valve. Discard the O-rings. 10. Solenoid valve: Disassemble and clean the valve.

Lubricate the slide with oil and check that the slide can move lightly with a good fit in the housing.

M903020247O09

Check the slide for wear. If the slide is scratched or scuffed, the valve must be replaced by a new one.

Assemble the valve. 10. See also manufacturer’s instructions. 11. Before mounting the feedback sensor, check that the sensor is flush with the sensor housing.

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.

M903020244O12

Mount the feedback sensor or a new one, if necessary, with a new O-ring.

M903020245O10

11.

1 2 3 BN (brown) BK (black) 4 BU (blue) 5


1 2 Solenoid valve

Feedback sensor

Page 9 (13)


903-2.3

Overhaul

MAN B&W Diesel

12. Connect the wires and mount the cover on the terminal box.

12. LED

2

13. Mount the solenoid valve fitted with new O-rings. Coat the O-rings with a little grease to keep the rings in place during mounting. 14. Mount the cylinder block assembly in the cylinder housing.

Brown+15 Blue OV

M903020242O08

Black FBsignal

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.

M903020247O13

13.

M903020247O14

14.

Page 10 (13)



903-2.3

Overhaul

15. Mount the adjusting screw fitted with a new O-ring and the distance bushing.

15.

Mount the oil accumulator. 16. 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.

M903020247O01

Cover all surfaces with a thin layer of oil.

16.


Page 11 (13)


903-2.4

Mounting

MAN B&W Diesel

Mounting of Lubricators 1. 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 between the lubricator and the pipe connection. 2. Open the supply valve and mount the electrical plug. Check the injection of the cylinder oil on the led on the terminal box for the specific lubricator.

M903020256D02

For checking injection timing, see Procedure 905-8.1.

2.

B

M903020256M02

A

Page 12 (13)



903-2.4

Mounting

Mounting of Accumulator 3. 3. Mount the accumulator. Remove the drain hose from the minimess coupling. Open the valve that connects the accumulator to the distributor block.

M903020256M03

Check the oil injection. See Procedure 903-2.1.


Page 13 (13)

Cylinder Liner - T ools Tools MAN B&W Diesel


Plate P90361-0083

Page 1 (2)

Plate P90361-0083 Item No. 012 024 048

Page 2 (2)

Cylinder Liner - T ools Tools MAN B&W Diesel

Item Description

Item No.

Item Description

Measuring rod for cylinder liner, long Measuring rod for cylinder liner, short Measuring tool for cylinder liner


Cylinder Liner - Milling Tools


Plate P90362-0005

Page 1 (2)

Plate P90362-0005

Cylinder Liner - Milling Tools

Item No.

Item Description

018

Wear ridge milling machine

Page 2 (2)

Item No.

Item Description


Test Equipment for Lubricator

Plate P90364-0004


Page 1 (2)

Test Equipment for Lubricator 0004 P90364

MAN B&W Diesel A/S

Test Equipment for Lubricator

Plate P90364-0004 Item No. 019 020 032 044 056 068 081 103 115 139 152 164 176 211 223

Item Description

Item No.

Item Description

Tool box Nameplate Adaptor Pressure gauge Spanner Pressure gauge Adaptor Hose with 2 union Quick coupling, minimess Reducing valve Adaptor Adaptor Adaptor Adaptor Filling and testing valve

Page 2 (2)




Plate P90366-0003

Page 1 (2)


Page 2 (2)


Item Description

Item No.

Item Description

Cross bar for cylinder liner


904 - Crosshead with Connecting Rod Documents in this Chapter 104-01 904-01 104-02 904-02 104-03 904-03 104-04 904-04 104-05 904-05 90451 90462

0069 0253 0070 0252 0044 0215 0062 0233 0060 0237 0155 0018

Crosshead Bearing, Data Crosshead Bearing Crosshead, Data Crosshead Reciprocating Parts, Data Reciprocating Parts Crankpin Bearing, Data Crankpin Bearing Connecting Rod, Data Connection Rod Connecting Rod and Crosshead - Panel Connecting Rod - Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Crosshead Bearing MAN B&W Diesel

104-1

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X X X X X X X

X


Data Ref.

Description

Value

Unit

D04-01

Crosshead bearing, top clearance max.

0,7

mm

D04-02

Crosshead bearing, top clearance min.

0,35

mm

D04-03

Oil wedge length, L

15

mm

D04-04

Crosshead bearing cap

D04-05

900

kg

Crosshead bearing shell, upper

94

kg

D04-06

Crosshead bearing shell, lower

120

kg

D04-07

Crosshead bearing cap with bearing shell

1000

kg

D04-16

Thrust piece, tightening torque

550

Nm

D04-58

Stuffing box, telescopic pipe, tightening torque

340

Nm

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Crosshead Bearing

104-1

MAN B&W Diesel

Data


Plate

Item No.

P90451

47

Wire guide

P90451

59

Lifting attachment - connecting rod

P90451

60

Lifting tools - crosshead

P90451

72

Chain for suspending piston

P90451

84

Retaining tool telescope pipe

P90451

96

Bracket for support, Crosshead

P90451

106


P90451

118


P91351

010


P91351

046


P91351

058


P91351

117


P91366

058

Feeler gauge

Page 2 (2)

Description



904-1.1

Checking

White metal bearings 1. The top clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing components. For the top clearance of a new bearing, see the Data D-1.

2. Turn the crosshead concerned to BDC. 3. Measure the clearance in the crosshead bearing by inserting a feeler gauge at the top of the upper bearing shell. 4. The difference between the actual clearance measurements and the measurements noted in the Adjustment Sheet at the shop test/sea trial (or the clearance noted for a new bearing installed later) must not exceed 0.1 mm. If the clearance is too large, the crosshead must be disassambled for inspection. See Procedure 904-2.2. 5. The wear limit for a crosshead bearing shell is confined to a 50% reduction of the oil wedge length L. This can only be checked after the crosshead has been disassembled.

2.

D0401 D0402

M904010253C03

1. Open the crankcase door at the relevant cylinder.

M904010253C02

For the top clearance of a specific bearing, see the measurement in the Adjustment Sheet in Volume I, OPERATION.

3.

If the wear limit exceeds the 50% reduction, the bearing shell must be replaced by a new one.

(Oil Wedge) L 1/2 M904010253C05

6. For further external inspection of the crosshead bearing, see Chapter 708, ‘Bearings’ in the instruction book, Volume I, OPERATION.

D0403 L


Page 1 (8)

904-1.2

Crosshead Bearing Dismantling

MAN B&W Diesel

This procedure applies to the following two dismantling situations:

1.

• with piston mounted (steps 1-11) • with piston removed (steps 3-11) With piston mounted:

M904010253D01

1. Turn the crosshead down far enough to give access to the nuts on the piston rod, the crosshead bearing cap, and the screws on the telescopic pipe. 2. Mount the two chains for suspending the piston in the inner screw holes at the top of the crankcase, in the athwartship direction. 3. Mount two eyebolts in the two outer screw holes in the top of the frame box in the athwartship direction.

2.

Remove the thrust pieces for axial guidance of the connecting rod. Mount the spacer rings and the hydraulic jacks for loosening the crosshead bearing cap nuts and the piston rod nuts. Loosen the nuts. M904010253D02

For operation of the hydraulic tools, see Procedure 913. Remove the hydraulic jacks, and unscrew the nuts. Caution!

3.

M904010253D03

Never suspend or remove the piston without suspending the telescopic pipe.

Page 2 (8)

D1302



904-1.2

Dismantling

4. Mount a lifting eye bolt on each side of the piston rod foot.

4.

Mount a lifting eye bolt with an extension screw on each side of the bearing cap. 5. Loosen and remove the screws which secure the telescopic pipe to the bend.

6. Turn the crosshead to TDC. Hook the ends of the chains to the lifting eye bolts on the piston rod. Suspend the telescopic pipe, using the tool stud.

M904010253D04

Remove one screw from the telescopic stuffing box housing, and mount the special tool for suspending the telescopic pipe.

5.

Turn the crosshead downward, and the piston rod will remain suspended from the two chains.

M904010253D05

When turning downwards, remove the distance tube from the bend.

M904010253D06

6.


Page 3 (8)

Crosshead Bearing

904-1.2

Dismantling

7.

MAN B&W Diesel

7. Turn down to BDC.

D0404 D0407

Suspend two tackles from the eyebolts, in the athwarthship direction. Hook the tackles on to the eye bolts in the crosshead bearing cap and raise the cap. Check the upper bearing shell and the upper part of the journal.

M904010253D07

Mount the wire guide in the top of the door opening.

8.

If desired, mount a third tackle outside the engine and lift the bearing cap out of the engine.

D0405

8. Place the bearing cap on one side on a couple of wooden planks. Check the bearing shell, see Procedure 904-1.1. 9. Mount lifting attachments on the head of the connecting rod.

M904010253D08

Fasten pull lifts to the fixed lifting brackets on the frame box wall and fix the connecting rod in the vertical position.

M904010253D09

9.

Page 4 (8)


Crosshead Bearing

904-1.2

Dismantling

MAN B&W Diesel

10. Mount the four supports for guide shoes on the crosshead guides.

10.

Carefully turn the crank down towards the exhaust side, until the guide shoes rest on the supports. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports.

11. Turn the crankthrow carefully towards BDC while ‘following’ with the tackles, thus continuously supporting the connecting rod.

M904010253D10

Haul the tackles tight.

Caution! Take care not to scratch the crosshead bearing journal or damage the threads of the crosshead bearing studs.

11.

Regarding checking of journal and bearing shells, see Volume I, OPERATION, Chapter 708, ‘Bearings’. 12. In cases where it is necessary to remove the lower bearing shell, tilt the connecting rod towards the doorway in the camshaft side, using the tackles.

M904010253D11

With the crosshead resting on the supports, check the lower part of the crosshead journal and the bearing shell.

12. Dismount the locking screws, and turn the bearing shell so far up that an eye bolt can be mounted.

D0406

M904010253D12

Lift the bearing shell out of the engine.


Page 5 (8)

Crosshead Bearing

904-1.4

Mounting

MAN B&W Diesel

With piston mounted/With piston removed: 1. 1. Mount and secure the bearing shell in the bearing housing. The excess height X is to ensure the correct tightening-down of the bearing shell and must not be eliminated.

D0405

M904010253M01

Raise the connecting rod to an upright position.

2.

Lubricate the bearing shell and the journal with plenty of lubricating oil.

x

x 2. Turn to TDC while ‘following’ with the tackles, for assembling the crosshead and the connecting rod. Note! Take care that the bearing studs do not damage the crosshead.

3. Remove the supports from the crosshead guides.

M904010253M02

Remove the tackles and the lifting attachments from the head of the connecting rod. Turn the crankthrow to BDC.

M904010253M03

3.

Page 6 (8)


Crosshead Bearing

904-1.4

Mounting

MAN B&W Diesel

3. Lift the bearing cap back into the engine.

3.

Lubricate the crosshead bearing journal with plenty of lubricating oil. Lower the bearing cap onto the crosshead, and remove the tackles.

Note! It must be ensured that a clearance between the thrust piece and the crosshead exists fore and aft before any tightening of the thrust piece.

M904010253M04

4. Mount the thrust pieces for axial guidance of the connecting rod. For tightening torque, see Data.

4. With the piston mounted: 5. Use a rubber cover to cover the oil inlets/ outlets on top of the crosshead.

D0416

Turn the crosshead upwards until the piston rod foot lands on the nuts, thereby turning the crosshead until the face is parallel with the piston rod foot. Lower the crosshead just enough to enable removal of the nuts and the rubber cover. If any shims have been removed from the crosshead, mount them again.

M904010253M05

Mount all hydraulic nuts on the studs, screw down until the nuts are flush wich the top of the studs.

5.

Turn the crosshead upwards until the piston rod lands on the crosshead. When mounting the piston on the crosshead, make sure that the piston rod foot does not damage the threads of the studs.

M904010253M06

Ensure that the guide ring in the crosshead fits correctly in the centre hole of the piston rod.


Page 7 (8)

Crosshead Bearing

904-1.4

Mounting

MAN B&W Diesel

6. Mount the distance pipe on the telescopic pipe bend.

6.

Turn up the crosshead until the telescopic pipe lands on the distance pipe. Remove the chains and eye bolts from the top of the frame box, from the piston rod foot and from the crosshead bearing cap in the athwartship direction.

M904010253M07

Remove the wire guide from the engine. Remove the suspending tool stud and mount the screws in the telescopic stuffing box housing.

D0416 D0458

Mount the screws and tighten the telescopic pipe, see Data.

7. 7. Turn down to BDC and mount the hydraulic nuts on the studs. For operation of the hydraulic jacks, see Procedure 913.

D1301

Tighten the nuts on the piston rod foot and on the crosshead as stated in Data. With the piston removed:

M904010253M08

8. Mount the piston. See Procedure 902-1.4.

Page 8 (8)

9. Turn down to BDC and tighten all four crosshead bearing cap nuts simultaneously. See Data. For operation of the hydraulic jacks, see Procedure 913.


Crosshead MAN B&W Diesel

104-2

Data


X


Data Ref.

Description

Value

Unit

D04-07


1000

D04-09

Inlet pipe, tightening torque

D04-10

Inlet pipe stud, screwing-in torque

450

Nm

D04-11

Guide strip nuts, tightening torque

400

Nm

D04-14

Crosshead/piston rod stud, screwing-in torque

150

Nm

D04-15

Telescopic pipe, tightening torque

340

Nm

D04-16


550

Nm

D04-17

Cooling oil outlet pipe, tightening angle

D04-18

Inlet pipe, tightening angle

D04-20

Clearance between thrust piece and crosshead

D04-21

Crosshead complete

D04-22

Guide shoe

D04-23

Cooling oil outlet pipe

D04-49

Connecting rod studs , screwing-in torque

D04-51

Connecting rod complete

D04-58

Stuffing box, telescopic pipe, tightening torque

D04-59

100/50

100/20 50 0.35-0.60

kg Nm/°

Nm/° ° mm

5000

kg

413

kg

30

kg

480

Nm

5650

kg

340

Nm

Telescopic pipe

57

kg

D04-59

Telescopic pipe

57

kg

D04-60

Inlet pipe

57

kg

D04-62

Crosshead without guide shoes

4200

kg

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Crosshead

104-2

MAN B&W Diesel

Data


Plate

Item No.

P90451

47

Wire guide

P90451

59


P90451

60

Lifting tools - crosshead

P90451

72


P90451

84

Retaining tool telescope pipe

P90451

96


P90451

106


P90451

118


P90451

131

Drawing tool - bell shaped

P90451

202

Extension (X-Head Cap / Piston Rod)

P91351

010


P91351

046


P91351

058


P91351

117


P91359 P91366

Page 2 (2)

Description

Torque Spanners 058

Feeler gauge



904-2.2

Dismantling

1. Dismount the main bearing lubricating oil pipes.

2.

2. Turn the crosshead to BDC to give access to the nuts on the crosshead bearing cap.

D1302

Mount the retaining tool for the telescopic pipe on the stuffing box housing for the telescopic pipe.

Mount the spacer rings and the hydraulic jacks for loosening the crosshead bearing cap nuts. For operation of the hydraulic tools, see Procedure 913-1.

M904020252D02

Mount two eye bolts in the athwartship direction, and suspend two tackles.

4. Loosen the nuts, remove the hydraulic jacks and unscrew the nuts. 3. Turn the crosshead to TDC.

4. Turn to BDC and mount connecting rod lifting tools. Use two tackles to retain the connecting rod in an upright position. Mount two eye bolts and extension screws in the crosshead bearing cap and hook on the tackles from the top of the crankcase.

M904020252D04

Suspend the telescopic pipe by means of the tool. Suspend the piston. To suspend the piston, see Procedure 904-1.

D0407

Lift the bearing cap out of the engine. Remove the piston rod guide ring and the shim from the crosshead. Remove both thrust pieces on the crosshead bearing cap.


Page 1 (9)

Crosshead

904-2.2

Dismantling

MAN B&W Diesel

5. Dismount the four bearing cap studs, using the stud setter.

5.

D0423 D0460

Dismount the guide pin for the oil inlet bend using the special extractor. Mount the eye bolt in one of the threaded holes in the bend, hook on a tackle and haul tight.

M904020252D05

Remove the outlet pipe, dismount the bend for the telescopic pipe and remove the studs from the crosshead.

6.

Mount the special lifting tool on the crosshead. 6. Attach tackle chains from the two tackles in the athwartship direction to the wire ropes on the lifting tool.

M904020252D06

Lift the crosshead free of the connecting rod.

Page 2 (9)


Crosshead

904-2.2

Dismantling

MAN B&W Diesel

7. Use the tackles to tilt the connecting rod to-wards the exhaust side, while turning the crankthrow towards the camshaft side.

7.

D0451

Transfer the tackles from one lifting attachment to another, as necessary.

By alternate use of the tackles, tilt the connecting rod until it is out of the way. 8. Remove the oil pipes from the two adjacent main bearing caps. 9. Remove the guide strips and the stop screws from the bottom of the guide shoes.

M904020250D07

Stop turning when the crankthrow is in a position where there is room in the adjacent cylinder units to pull the guide shoes through the openings in the side walls just above the main bearings.

9.

Mount lifting eye bolts in both guide shoes.There has to be space in the adjacent cylinder units to pull the guide shoes through the openings in the side walls just above the main bearings.

It is recommended to tag the guide strips and shims to avoid mixing them.

10. Lower the crosshead so that the guide shoes are just below the cutout in the side walls of the frame box.

M904020250D09

Note!

10.

Note!

M904020250D10

Make sure that the crosshead journal does not touch the crank.


Page 3 (9)

904-2.2

Crosshead Dismantling

11.

MAN B&W Diesel

11. Hook the tackles on to the eye bolts in the guide shoes. 12. Mount two eye bolts in the holes for stop screws in the guide shoes in the adjacent cylinder units, and suspend two tackles from the eye bolts.

M904020252D11

13. Haul the tackles for the guide shoes tight and, at the same time, pull the guide shoes sideways until they are free of the crosshead. Take the guide shoes through the openings in the side walls by means of the tackles in the two adjacent cylinders. Lift the guide shoes to provide space for turning the crosshead.

M904020250D12

12.

M904020252D13

13.

Page 4 (9)


Crosshead

904-2.2

Dismantling

MAN B&W Diesel 14. Turn the crosshead 90°.

14.

15. Mount a tackle outside the engine and, by means of wire rope and tackle, remove the crosshead from the engine. Land and protect the crosshead outside the engine.

Note! Take care that the crosshead does not bump into anything as this will damage the sliding surfaces of the crosshead.

M904020252D14

Remove the guide shoes from the engine and tag them.

M904020252D15

15.


D0462

Page 5 (9)

Crosshead

904-2.4

Mounting

MAN B&W Diesel

1. Clean the crosshead and mount the lifting tool with shackle and wire ropes.

1.

Mount the wire guide tool in the framebox door opening.

M904020252M01

Suspend two tackles from the top of the framebox between the guides. Suspend two tackles from the top lifting brackets in the framebox and use them in conjunction with a tackle mounted outside the engine to carefully lift the crosshead and ease it into the crankcase.

D0422 D0462

2. Turn the crosshead 90° to enable mounting of the guide shoes. Check that the oil inlet and outlet holes are pointing towards the exhaust side.

2. 3. Attach two tackles to the eye bolts at the bottom of the guide shoes in the adjacent cylinders. Using these tackles and a tackle outside the engine, carefully lift the guide shoes into the engine. Note!

M904020252M02

When handling the crosshead, take great care that its surfaces are not scratched or damaged. If necessary, protect the crosshead with a cloth.

M904020252M03

3.

Page 6 (9)

D0422 When referring to this page, please quote Procedure M90402 Edition 0252


904-2.4

Mounting

4. Lubricate the sliding surfaces of the guide shoes and the crosshead with plenty of clean lubricating oil, and push the guide shoes into position through the openings in the side walls.

4.

5. Use the tackles in the top of the framebox to lift the crosshead into a working position and mount the guide strips and shims on the side of the guide shoes.

Remove the tackles and the eye bolts from the guide shoes. 6. Lift the crosshead to a position above the connecting rod in the upright position.

M904020252D13

Mount the stop screws in the bottom of the guide shoes.

5. Raise the connecting rod to the upright position. Lubricate the crosshead bearing liberally with clean lubricating oil and carefully lower the crosshead into place.

7. Dismount the tackles and connecting rod lifting tools from the connecting rod.

M904020252M05

Unhook the wire ropes from the crosshead lifting tool.

D0411 D0421

M904020252M06

6.


Page 7 (9)

904-2.4

Crosshead Mounting

8.

D0408 D0409 D0410 D0449 D0418

MAN B&W Diesel

8. Turn the connecting rod and crosshead to BDC. Remove the lifting tool from the crosshead. Mount the studs for the cooling oil inlet bend. Mount the bend and outlet pipe. See Data.

M904020252M08

Mount the cylindrical dowel with threaded hole in the bend, and mount the bearing cap studs. Mount the piston rod guide ring and the shim on the crosshead. 9. Lift the crosshead bearing cap into the engine.

9.

D0407 D0416 D0420

Lubricate the crosshead journal with plenty of clean lubricating oil. Carefully land the bearing cap on the crosshead. Mount the hydraulic nuts. Mount the thrust pieces on the bearing cap. Note! It must be ensured that a clearance between the thrust piece and the crosshead exists fore and aft before any tightening of the thrust piece.

M904020252M09

Tighten the screws to the torque stated in Data.

Page 8 (9)

For correct tightening, see also Procedure 913-5.


Crosshead

904-2.4

Mounting

MAN B&W Diesel 10. Tighten the hydraulic nuts.

10.

For operation of hydraulic tools, see Procedure 913-1. Remove the hydraulic tools and the eye bolts from the engine. Check the clearances between the guide strips, guide shoes and crosshead guides. See Procedure 904-3. Mount the main bearing lubricating oil pipes. Mount the piston and the telescopic pipe. See Procedure 904-1.

At this point it is recommended to check the crosshead bearing clearance. See Procedure 904-1.

11. Remove all tools from the engine. Note!

M904020252M10

Note!

D0458 D0459

D1301

11.

M904020250M10

Search the crankcase to ensure that there are no tools, shackles or rags left behind.


Page 9 (9)

Reciprocating Parts MAN B&W Diesel

104-3

Data


X X X X X X

Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps

X

Engage turning gear Shut off cooling water Shut off fuel oil

X

Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description

Value

Unit

Acceptance criteria with piston in centre (F-A direction) D04-25

PF+PA, N max.

0.85

mm

D04-26

PF+PA, O max.

1.35

mm

D04-28

E+G, H+F, N max.

0.60

mm

D04-29

E+G, H+F, N min.

0.20

mm

D04-30

E+G, H+F, O max.

0.90

mm

D04-34

J+X, L+Y, K+X, M+Y, N max.

1.20

mm

D04-35

J+X, L+Y, K+X, M+Y, N min.

0.60

mm

D04-36

J+X, L+Y, K+X, M+Y, O max.

1.40

mm

D04-39

QF/QA, O max.

0.80

mm

D04-41

ZF/ZA O min.

5.0

mm

D04-42

TF + TA

0.80

mm


Page 1 (2)

Reciprocating Parts

104-3

MAN B&W Diesel

Data


Page 2 (2)

Item No.

Description Feeler gauge


Reciprocating Parts

904-3.1

Checking Reciprocating Parts S90MC-C 0215 Checking 904-3.1

1.

In order to achieve uniform measuring conditions on board, the ship’s trim must be as close as possible to 0°.

Bend each end approx. 250 mm up along the framebox side. See T. Fill the tube with water (possibly coloured) until the water level is approx. 100 mm from the end of the tube.

MA904-5.0 72 01

1. Mount a transparent plastic tube along the length of the bedplate.

2. Trim the ship until the difference between the water level S fore and aft is less than 1.5 mm per 1000 mm.

Fore

Measurements are to be taken with a ruler.

Aft

2. Turn the crankshaft in ASTERN direction to 45° after BDC (the guide shoe must rest against the crosshead guide).

Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction.

PA PF HN904-3.1 212 02

Check the centering of the piston in the cylinder liner by measuring the clearance (by applying a long feeler gauge from the scavenge air space) between the piston skirt and the cylinder liner in the Fore and Aft positions (PF-PA).

45°

Ast

ern

3. 50

3. Turn in astern direction until the bottom of the guide shoe is 50 mm in the vertical direction above the top of the cut out in the web plate.

EXH

G 1-2 10

E 1-2

CAM

F 1-2

HN904-3.1 212 03

H 1-2

When referring to this page, please quote Procedure M90403 Edition 0215 0$1% :'LHVHO$6

Page 1 (3)

Reciprocating Parts

904-3.1

Checking 4.

4. Measure the clearance between the crankthrow and the connecting rod. 5. Measure the clearance between the thrust piece and the crosshead (TF and TA or QF and QA. Measure the clearance between the crosshead guides and the guide shoes (E, F, G and H). Measure the clearance between the guide strips and crosshead guides (J, K, L and M). The clearance, calculated as J+X, K+Y, L+Y and M+Y, is adjusted by the insertion of shims so that it is symmetrical in relation to the clearance between the piston skirt and the cylinder liner.

MN904-3.1 215 04

Parallelism between the guide strip and guide is to be kept within a tolerance of 0.2 mm per 1000 mm. BF and BA correspond to the thickness of the shims and are only to be measured if an adjustment is carried out.

5. Exhaust Side

MN904-3.1 215 05

Camshaft Side

Page 2 (3)


Reciprocating Parts

904-3.1

Checking 6.

6. It is recommended that the measured results are noted down so that possible later changes can be ascertained.

Cyl. Piston/Liner

1

2

3

4

PF PA

Shim Thickness Frame Box

BF BA E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4 J+X L+Y K+X

MN904-3.1 215 06

M+Y Crosshead Connecting Rod Crankthrow Connecting Rod


QF/TF QA/TA ZF ZA

Page 3 (3)

Crankpin Bearing MAN B&W Diesel

104-4

Data


X


Data Ref.

Description

Value

Unit

D04-43

Crankpin bearing clearance, max.

0.8

mm

D04-44

Crankpin bearing clearance, min.

0.4

mm

D04-45

Crankpin bearing cap complete

566

kg

D04-46

Crankpin bearing, upper shell

67

kg

D04-47

Crankpin bearing, lower shell

34

kg

D04-48

Crankpin bearing cap + shell + bearing studs

600

kg

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Crankpin Bearing

104-4

MAN B&W Diesel

Data


Plate

Item No.

Description

P90451

047

Wire guide

P90451

059


P90451

096


P90451

106


P90461

Connecting Rod - Hydraulic Tools

P90462

Lifting tool for crankshaft shell

P91351

10

Hydraulic pump, pneumatic operated

P91351

46


P91351

60


P91351

105

P91356

3-way distributor block, complete Lifting Tools, Etc.

P91366

58

Feeler gauge

P91366

61

Slide caliper

Page 2 (2)



904-4.1

Checking

The bottom clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing assembly components.

2.

For the bottom clearance of a specific bearing, see the measurement in the Adjustment Sheet in Volume I, OPERATION. 1. Open the crankcase door at the relevant cylinder.

3. Measure the clearance in the crankpin bearing by inserting a feeler gauge at the bottom of the bearing shell in both sides. See Data for bottom clearance. 4. The difference between the actual clearance measurement and the measurement recorded in the Adjustment Sheet (or the clearance noted for a new bearing installed later) must not exceed 0.1 mm. If so, the crankpin bearing must be disassembled for inspection. See Procedure 904-4.2.

M904040233C02

2. Turn the crank concerned to BDC.

3.

D0443 D0444

An average wear rate of 0.01 mm per 10,000 hours is regarded as normal. 6. For further external inspection of the crankpin bearing, see Chapter 708 ‘Bearings' in the instruction book, Volume I, OPERATION.

M904040233C03

5. The wear limit for the crankpin bearing shells is based on an evaluation of the bearing condition at the time of inspection.

5.

M904040233C04

D0446


Page 1 (8)

904-4.2

Crankpin Bearing Dismantling

MAN B&W Diesel

1. Suspend two tackles from the lifting brackets, in the athwartship direction.

1.

Mount the wire guide in the top of the crankcase door opening. 2. Turn the crank to TDC. Mount eye bolts in each side of the crankpin bearing cap and, using shackles and wire ropes, hook on the tackles and haul tight. M904040233D01

Loosen the crankpin bearing stud nuts, using the hydraulic jacks. For operation of the hydraulic jacks, see Procedure 913-1. 2.

Remove the hydraulic jacks and the nuts. 3. Lower the bearing cap while seeing carefully that the studs do not damage the crankpin journal. Land the bearing cap on a couple of planks placed in the oil pan. Inspect the bearing shell.

M904040233D02

D1302

3.

M904040233D03

D0448

Page 2 (8)



904-4.2

Dismantling

4. If the bearing shell needs to be replaced, remove the whole bearing cap from the crankcase.

4.

D0448

Suspend a tackle outside the engine above the crankcase door opening.

Using the tackle from the frame box inside wall, together with the tackle suspended outside the engine, lift the bearing cap out of the crankcase. 5. Place the bearing cap on one side on a couple of planks. Dismount the bearing shell lock screws and replace the bearing shell by a new one.

M904040233D04

Turn the crankthrow to the exhaust side to give space for lifting out the crankpin bearing cap.

5.

The bearing shells must be replaced in pairs. 6. Turn to TDC.

Carefully turn the crank to the camshaft side and down until the guide shoes rest on the supports. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports.

M904040233D05

Mount the four supports for guide shoes on the crosshead guides.

M904040233D06

6.


Page 3 (8)

904-4.2

Crankpin Bearing Dismantling

7.

MAN B&W Diesel

7. Mount a lifting attachment for securing the connecting rod at the lower end, on the camshaft side. Hook the tackle on to the lifting attachment.

M904040233D07

8. Carefully turn the crankshaft downwards, while ‘following’ with the tackle, making sure that the upper part of the bearing comes completely clear of the recess in the crankshaft when the parts begin to ‘separate’. If necessary suspend a second tackle from the bracket below the doorway. Continue turning the crankshaft until the bearing surface can be freely inspected.

8. Inspect the bearing shell surface and the crankpin journal. 9. If it is necessary to replace the bearing shell, proceed as follows: Turn the crankshaft approx. 80° to a horizontal position.

M904040233D08

Release the tackle so that the connecting rod is hanging freely.

M904040233D09

9.

Page 4 (8)



904-4.2

Dismantling

10. Mount an eye bolt in the bottom of each guide shoe.

10.

Suspend two tackles from the eye bolts. 11. Place the lifting tool for the crankpin upper shell on the crank webs and hook the tackles on to the lifting tool.

12. Dismount the bearing shell lock screws. Lower the lifting tool with the bearing shell, using the tackles.

M904040233D10

Mount the tool on the bearing shell in the connecting rod, using the tackles, and haul tight.

M904040233D11

11.

M904040233D12

12.

D0446


Page 5 (8)

Crankpin Bearing

904-4.4

Mounting

MAN B&W Diesel

1. If necessary, replace the bearing shells with new ones. The bearing shells must be replaced in pairs.

1.

Bearing shells of three mm undersize are available as spares in case of journal rectification. Coat the bearing shell surfaces and the journal with clean oil.

M904040231M01

The excess height X is to ensure the correct tightening-down of the bearing shell, and must not be eliminated. 2. Lift the upper bearing shell for the crankpin concerned into the crankcase. Carefully lift the bearing shell into position in the connecting rod, and mount the lock screws.

2.

3. Remove the lifting tool, the tackles and the eye bolts from the guide shoes.

M904040233M02

D0446

M904040233M03

3.

Page 6 (8)



904-4.4

Mounting

4. Hook the tackle on to a beam under the gallery platform and on to the lifting attachment on the connecting rod, and haul tight.

4.

Carefully turn the crankshaft upwards, while following up with the tackle, making sure that the upper part of the bearing enters the recess in the crankshaft when the parts turn together.

5. Turn the crosshead to TDC. Remove the four guide shoe support brackets from the crosshead guides.

M904040233M04

Remove the tackle and the lifting attachment from the connecting rod.

M904040233D06

5.


Page 7 (8)

904-4.4

Crankpin Bearing Mounting

MAN B&W Diesel

6. Suspend the tackles from the lifting brackets in the side of the frame box.

6.

Lift the bearing cap assembly into the crankcase and land it on a couple of planks placed in the oil pan.

D0448 Remove the wire guide tool from the engine.

M904040233M06

7. Hook the tackles on to the wire ropes and lift the bearing cap into position against the connecting rod. Caution! During mounting, take care that the studs do not damage the crankpin journal, and check that the guide pins mounted in the bearing cap enter the holes in the connecting rod.

7.

Mount the nuts and, by means of spacer rings and hydraulic jacks, tighten the crankpin bearing cap. See Data. For operation of hydraulic jacks, see Procedure 913-1.

M904040233M07

Remove the tackles from the side of the frame box.

Page 8 (8)

D1301


Connecting Rod MAN B&W Diesel

104-5

Data


X


Data Ref.

Description

D04-07


D04-16

Value

Unit

1000

kg


550

Nm

D04-48

Crankpin bearing cap + shell + bearing studs

600

kg

D04-49

Connecting rod studs , screwing-in torque

480

Nm

D04-50

Connecting rod, without bearing caps

5000

kg

D04-52

Connecting rod stud

18

kg

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Connectin Rod

104-5

MAN B&W Diesel

Data


Plate

Item No.

Description

P90451

47

Wire guide

P90451

59


P90451

72


P90451

96


P90451

106


P90461

Connecting Rod - Hydraulic Tools

P90464

Crosshead - Hydraulic Tools

P91351

10


P91351

46


P91351

58


P91351

117

P91356 P91366 P91368

Page 2 (2)

5-way distributor block, complete Lifting Tools, Etc.

58

Feeler gauge Working Platforms



904-5.2

Dismantling

1. Suspend the piston rod and dismount the crosshead bearing cap. See Procedure 904-1.2.

1.

2. Suspend two tackles from the two lifting brackets at the sides of the frame box. Mount the wire guide in the top of the crankcase doorway.

Dismantle the crankpin bearing cap, and remove it from the engine. See Procedure 904-4.2. Mount the four support brackets for guide shoes on the crosshead guides.

M904050237D01

3. Turn the crank to TDC.

D1302 D0407

M904050237D02

2.

M904050237D03

3.


Page 1 (6)

Connecting Rod

904-5.2

Dismantling

MAN B&W Diesel

4. Mount the lifting attachments for fixing the connecting rod on the head of the connecting rod.

4.

Use the tackles fastened to lifting brackets A and B on the frame box wall, and attach the tackle hooks to the mentioned lifting attachments on the connecting rod.

B

A

Haul the tackles tight.

M904050237D04

Also mount a lifting attachment in the crankpin end of the connecting rod, on the exhaust side. Carefully turn the crank down towards the exhaust side, until the crosshead shoes rest on the supports.

5.

A

B

D0450 D0452

Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. 5. Turn the crankthrow towards BDC while “following” with the tackles, thus continuously supporting the connecting rod. 6. Turn the crankthrow to 90° before BDC.

M904050237D05

Remove the four studs from the connecting rod.

Page 2 (6)

Shift the hook of the tackle attached to lifting bracket B from the lifting attachment on the lowermost side of the connecting rod to the lifting attachment on the uppermost side.



904-5.2

Dismantling

7. By means of the tackle from lifting bracket A, tilt the connecting rod towards the camshaft side until the connecting rod is leaning out of the doorway.

7.

A

Attach a tackle to lifting bracket C on the frame box wall and connect the tackle hook to the lifting attachment at the lower end of the connecting rod.

8. Attach a tackle to the gallery-mounted lifting bracket E, and hook on to the lifting attachment on the connecting rod. Shift the tackles from one lifting bracket/attachment to the other, as required.

C

M904050237D07

Turn the crank carefully upwards while “following” with the tackles, guiding the head of the connecting rod out of the doorway.

8.

E A

Remove the floor chequer plate for the pertaining cylinder. 9. Place a plated wire rope round the connecting rod, hook on the engine room crane and haul tight.

Lift the connecting rod out of the engine using the engine room crane and the tackles.

B

C

M904050237D08

Continue turning upwards till about 30° after TDC, while “following” with the tackles and the engine room crane.

B

9.

E A

B

M904050237D09

D0450


Page 3 (6)

Connecting Rod

904-5.4

Mounting

MAN B&W Diesel

1. Equip the connecting rod with the same lifting attachments as mentioned under dismantling.

1.

A

Turn the crank to a position about 30° past TDC on the camshaft side.

B

Apply clean lubricating oil to the crankpin bearing shell and journal.

M904050237M02

D0450

2. Lift the connecting rod carefully into the crankcase by alternate use of the engine room crane and the tackles attached to lifting brackets A and B. Attach a tackle to bracket E and the upper end of the connecting rod.

2.

E A

3. When the end of the connecting rod rests on the crankpin journal, attach a tackle to bracket C and the lower end of the connec-ting rod.

B 4. Turn the crankthrow towards BDC, past TDC, while ‘following’ with the tackles. Lower the engine room crane and remove the strap around the connecting rod.

C

M904050237M03

Shift tackle B from the lower end to the upper end of the connecting rod.

3.

E A

B

M904050237D08

C

Page 4 (6)


Connecting Rod

904-5.4

Mounting

MAN B&W Diesel

5. Turn the crankthrow to 90° before BDC, and use the tackles to raise the connecting rod to an upright position.

5.

Shift tackle A from the lower end to the top of the connecting rod.

A

B

A

B

Remove the tackle at E.

C

Remove the tackle at C. Remove the lifting attachment at the lower end of the connecting rod. 6. Screw the studs into the connecting rod. Using the stud setter and a torque wrench, tighten the studs to the torque stated in Data.

M904050237M05

Shift tackle B from the lifting attachment on one side to the other side of the connecting rod.

6.

Lubricate the crosshead bearing shell and journal. 7. Turn the crankthrow towards TDC while ‘following’ with the tackles, carefully land the crosshead on the connecting rod.

D0449 D0452

Take care that the studs do not damage the crosshead bearing journal.

M904050237M06

Note!

M904050237M07

7.


Page 5 (6)

904-5.4

Connecting Rod Mounting

MAN B&W Diesel

8. When the crank is in TDC, mount the crankpin bearing cap. See Procedure 904-4.4.

8.

Turn to BDC and mount the crosshead bearing cap and the piston. See Procedure 904-1.4. 9. Remove the tackles and lifting attachments.

M904050237M08

10. Turn the crosshead to BDC. Tighten all four crosshead bearing cap nuts simultaneously. See Data. For use of hydraulic jacks, see Procedure 913-1.

D0448

Mount the thrust pieces for axial guidance of the connecting rod, and tighten to the specified torque. See Data.

M904050237M09

9.

M904050237M10

10.

Page 6 (6)

D1301 D0416


Connecting Rod and Crosshead - Panel MAN B&W


Plate P90451-0155

Page 1 (2)

Plate P90451-0155 Item No. 011 023 047 059 060 072 084 096 106 118 120 131 143 155 167 180 202 275 287

Page 2 (2)

Connecting Rod and Crosshead - Panel MAN B&W Item No.

Item Description

Item Description

Panel for tools Name plate Wire guide Lifting attachment, connecting rod Lifting tool, crosshead Chain for suspending piston Retaining tool, telescope pipe Bracket, support of crosshead Bracket, support of crosshead Rubber cover, crosshead Rubber cover with hole, crosshead Drawing tool Template Crowfoot spanner Crowfoot spanner Template Screw Protective screw Protective screw


Connecting Rod - Tools

Plate P90462-0018

Connecting Rod - Tools 0018 P90462


Page 1 (2)


Connecting Rod - Tools

Item Description

Item No.

Item Description

Lifting tool for crankpin shell

Page 2 (2)


905 - Crankshaft, Thrust Bearing and Turning Gear Documents in this Chapter 105-02 905-02 105-03 905-03 105-04 105-05 905-05 90551 90562 90564 90570 90571 90572

0086 0261 0075 0247 0050 0061 0230 0221 0123 0020 0003 0001 0001

Main Bearing, Data Main Bearing Thrust Bearing, Data Thrust Bearing Journal Bearing, Data Axial Vibration Damper, Data Axial Vibration Damper Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel Crankshaft - Tools Crankshaft - Measuring Tools Thrust Shaft - Tools Main Bearing Shell - Tools Main Bearing - Measuring Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Main Bearing MAN B&W Diesel

105-2

Data


X


Data Ref.

Description

Value

Unit

D05-01

Main bearing, top clearance max.

0.85

mm

D05-02

Main bearing, top clearance min.

0.60

mm

D05-03

Main bearing cap

1100

kg

D05-04

Main bearing shell, upper

70

kg

D05-05

Main bearing shell, lower

70

kg

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Main Bearing

105-2

MAN B&W Diesel

Data


Plate

Item No.

Description

P90551

40

Pulley for wire for main bearing

P90551

64


P90551

76

Lifting tool - main bearing cap

P90551

88

Dismantling tool, main bearing shell

P90551

90

Mounting tool for bearing shell

P90551

123

Retaining tool for main bearing shell

P90551

159

Eye bolt

P90551

160

Wire

P90551

172

Mounting tool, thin bearing shell

P90551

218

Wire guide

P90562

Lifting tool for crankshaft

P90571

Main Bearing Shell - Tools

P90572

Main Bearing - Measuring Tools

P91351

010


P91351

022

Hydraulic pump, hand operated

P91351

034


P91351

058


P91351

117


P91356

Lifting Tools, Etc.

P91366

058

Feeler gauge

P91366

061

Slide caliper

P91366

073

Dial gauge and stand tool

Page 2 (2)



905-2.1

Checking

General

1.

The condition of the main bearings can be checked by: • Deflection readings • Visual checking • Edge checking and

Crankshaft deflection readings Crankshaft deflection readings should be taken while the ship is afloat (i.e. not while in dry dock). As the alignment is influenced by the engine temperature as well as the loading conditions, deflection measurements should, for comparison purposes, always be made under nearly the same temperature and load conditions.

2. “Positive” (+)

Place a dial gauge axially in the crank throw opposite the crankpin, as illustrated on the sketch. The correct mounting position is marked with punch marks on the crank throw. See also Chapter 708 in Volume I.

2. “Closing” of the crank throw (compression of the gauge) is regarded as negative (–) and “opening” as positive (+). 3. Set the dial gauge to zero at the B1 side near BDC. Whilst turning clockwise, take the readings when the throw passes the positions: B1

(near bottom)

C

(camshaft side)

T

(top)

E

(exhaust side)

B2

(near bottom)

“Negative” () M905010208C02

1.

M905020046C01

• Measuring of top clearance.

3.

T

C

Looking forward M905010204C03

1/2 (B2+B1) = B

E

B1


B

B2

B1 C T E B2 ½ (B1+B2)=B

Page 1 (19)

905-2.1

Main Bearing Checking

4.

MAN B&W Diesel

4. When taking deflection readings for the three aftmost cylinders, the turning gear should, at each stoppage, be turned a little backwards to ease off the tangential pressure on the turning wheel teeth. Otherwise, this pressure may falsify the readings. For evaluation of the crankshaft deflection readings, see Volume I, OPERATION, Chapter 708.

M905020046C01

If the crankshaft deflection (alignment indicator) is approaching the tolerance limits (see Vol. I, OPERATION), the two adjacent main bearings must be checked for wear. See next page for checking of main bearing.

5.

If the bearings are found to be in good order, please contact MAN B&W Diesel or the engine manufacturer for checking of the bedplate alignment. As reference, use the “after seatrial” deflection table.

M905010208C05

The condition of the bearing can be checked as follows: 5. Visually look for bearing metal fragments in the oil pan, and check the filters for metal fragments. Such fragments can be from crosshead, guide shoe or crankpin bearings. If fragments are found, the damaged bearing can be found by edge checking with a feeler. General Bearing damage usually propagates rather quickly towards the edge of the bearing where, eventually, it causes chips to be broken off, which means that loose pieces of white metal can fall down into the crankcase beneath the bearing support. Large, thick pieces will normally be found during a crankcase inspection, and small, thin pieces can enter the filter. A check of the bearing edges together with inspection of the crankcase and the filter normally provides a good indication of the bearing condition.

Page 2 (19)



905-2.1

Checking

Checking the bearing edges

6.

6. Bearing edges can be checked with a “feeler” that is able to follow the bearing edge against the journal the whole way round on each side. If white metal is missing at the edge, the tip of the “feeler” will enter the hole, thus locating the damage. In most cases this hole can be seen by the naked eye as a dark spot when using a strong flashlight.

7.

Wire-feeler It is rather easy to make a feeler (see sketch). The “feeler” should be made from a piece of steel wire (e.g. a welding rod) approx. 0.6 - 1 m long depending on the engine type, and 2 to 3 mm thick. Approx. 7 to 10 mm of the wire should be bent to an angle of approx. 65° to form a “feeler tip”. Grind the tip smooth to obtain the shape and dimension shown on the sketch. Note that the thickness of the white metal is approx. 1.5 mm, which is why the tip should be less than 1.2 mm thick, and bigger than the max. top clearance. At the other end of the tip, a “handle” should be made by bending a hook or similar in the same direction as the tip.

<1.2 mm >0.7 mm 7-10 mm

1

60-70 2-3 mm

500-1000

7.

Hole in the edge

M905010208C06

The No. 1 and the two aftmost main bearings are more difficult to access on the whole circumference on each side, but it is often possible to bend the “feeler” to suit the situation and thus reach as far round as possible.

Wire feeler

The above dimensions of the “wire-feeler” are guideline values and may depend on the engine type as well as individual, personal designs.

M905020252C06

Note!


Page 3 (19)

Main Bearing

905-2.1

Checking

MAN B&W Diesel

8. If there is too large a difference in the crankshaft deflection readings (autolog) check the clearance in the individual bearings.

8.

M905010208C08

Bearing clearance checks should also be carried out during time-based overhauls and surveys. If there is a suspicion of a damaged bearing, it is recommended to edge check the bearing, without opening up.

9. 9. Before measuring, check that the feeler blades are in good condition. The feeler is inserted along the crank throw. When the feeler hits the journal, it is horizontally pushed against the clearance. Now the feeler blade is pushed max. 20 mm into the gap.

M905010208C09

10 The clearance is measured at both the fore and the aft part of the bearing. Note! The bearing clearances for a new bearing stated in Data (see Data 105-2) are for guidance purposes only.

20

10.

M905020258C10

D0501 D0502

Page 4 (19)



905-2.1

Checking

11. The difference between the actual clearance measurement and the measurement recorded in the adjustment sheet (or the clearance noted for a new bearing installed later) must not exceed 0.10 mm. If it does, see Volume I, Operation, Chapter 708. For evaluation of the bearing, see Volume I, Operation, Chapter 708.

M905020227C03

If the bearing needs to be disassembled for inspection, see procedure 905-2.2.


Page 5 (19)

Main Bearing

905-2.2

Dismantling 1.

Aftmost main bearing (= Journal bearing)

MAN B&W Diesel

Positioning the crankshaft 1.

Dismantling of main bearing. The bearings are divided into two categories: • The main bearings

M905020238D01

• The aftmost main bearing often referred to as “Journal bearing” (See Procedure 905-4). 2. Before any dismantling, check and write down the main bearing top clearances and crankshaft deflection readings for the cylinder unit concerned.

Main bearings Thrust bearing

3. Turn the crank throw to the position shown on the sketch and in such a way that the top of the studs is flush with the crank throw.

2.

Note!

M905020238D02

Be sure that the crosshead for the neighbouring cylinder is in a higher position than for the cylinder you are working on, otherwise it will be impossible to lift the cap.

3.

MANSIDE

M905020238D03

EXHSIDE

Page 6 (19)



905-2.2

Dismantling

Oil pipes

4.

4. Disconnect the lubricating oil pipe from the main pipe. Note!

Note! Some engines have temperature sensors fitted to the main, crosshead, and crankpin bearings. These sensors must be carefully handled to avoid damaging the equipment.

M905020238D04

On some engines, the oil pipes for the Axial Vibration Damper (AVD) have to be removed together with the oil pipe on main bearing No. 1.

5.

Mounting of tools and tackles Mount pulley E, pulley F and the special eye bolt D, as shown on the sketch.

Check with a 0.05 mm feeler gauge that there is no clearance between the pulley and the stop screw (guide shoe).

M905020236D05

Pulley F has to be tightened to full surface contact, i.e. using a spanner. On some engines the stop screw in the guide shoe has to be removed. Some are provided with a threaded hole.

F

D

E

Note! Do not use pulley F if it is not tightened to full contact.


Page 7 (19)

Main Bearing

905-2.2

Dismantling 6.

6. Mount the wire guide as shown. The wire guide must be finally positioned when tightening the tackles. Mount the wire guide on the crosshead guide.

A

B

MAN B&W Diesel

Mount tackles in the following positions: A: a 3 ton chain tackle, in a wire strap around the beam. B: a 3 ton chain tackle. (On some engines a special bracket has to be mounted, before mounting the shackle.)

M90502-0261D06

D

C: a 3 ton pull lift D: a 1 ton tackle C

Loosening the nuts 7.

7.

Before mounting, check the jacks as shown in Procedure 913-1.

8. Place the spacer rings over the nuts on the bearing cap. Screw down the extension studs on the main bearing studs.

M905020253D09

Place three hydraulic jacks on each spacer ring. Screw down the four upper nuts on the extension studs. Tighten them firmly.

8.

D13-02

Then turn the upper nuts 3/4 turn backwards to obtain a clearance of about 4.5 mm. Note! Be sure to mount the spacer rings and the hydraulic jacks with the TOP mark upwards.

D13-02 TOP

9. Connect the hydraulic jacks to the highpressure pump by means of the distributor block and high-pressure hoses.

TOP

M90502-0261D08

TOP

Page 8 (19)

Bleed the entire hydraulic system and raise the pressure as indicated in Data. Then loosen the nuts. Remove the upper nuts, the hydraulic jacks, the spacer rings and the extension studs. Unscrew the main bearing nuts from the studs. For operation of the hydraulic jacks, see Chapter 913.



905-2.2

Dismantling

Removal of main bearing cap

P

10.

A

10. Mount the main bearing lifting tool on the main bearing cap.

D05-03

Place one wire rope around pulley E, as shown, and attach it in tackle A, from outside the engine.

P

E

Note! When tightening up the tackle, be sure that the wire guides are positioned correctly to protect crosshead guides and doorframe.

M90502-0261D10

Tighten up tackle A and carefully lift the main bearing cap clear of the studs.

11. 11. When clear of the studs, pull the other wire rope around wire guide F, as shown, and attach it to tackle C, below the door.

F C

Tighten tackle C and release tackle A, until the main bearing cap is suspended vertically below pulley F.

A

Mount the short wire rope across the lifting tool. Mount the hook from tackle B (upper in the crankcase), in the short wire, and tighten it up.

M905020238D17

12. Remove the wire rope from tackle A and let it hang freely.

12. If necessary, pull the main bearing cap free of the crosshead guides, using tackle D, from the opposite web plate.

B

F C

D

M905020252D12

E


Page 9 (19)

Main Bearing

905-2.2

Dismantling 13.

MAN B&W Diesel

13. Release tackle C and at the same time, tighten tackle B until the bearing cap is hanging freely below tackle B.

B

Release and unhook tackles C and D. 14. Attach the hook of tackle A, from outside the engine, to the short wire rope across the lifting tool. By tightening tackle A and releasing tackle B, lift the bearing cap out of the engine, and place it on a couple of wooden planks.

M905020254D13

D

Removal of upper bearing shell C

14. B

A

15. Mount the bearing shell lifting tool on the upper main bearing shell, pull the wire around pulley F, as shown, and attach it to tackle A outside the engine. Carefully lift the bearing shell, until it is hanging freely below the guideshoe.

D0503

Lift the bearing shell out of the engine in the same way as the bearing cap.

M905020261D14

D

C

15.

M90502-0261D15

D05-04

Page 10 (19)



905-2.2

Dismantling

Removal of upper bearing shell

16.

16. If the crankshaft is turned with the bearing cap dismounted, use the two stops to prevent the lower shell from being rolled out. 17. Place the crosspiece in the bedplate with the ends resting on the cross girders, and position the hydraulic jacks beneath the crank webs as shown.

Connect the hydraulic jacks to the high pressure pump, and raise the pressure until the crankshaft has been lifted 0.2-0.5 mm, but max. the clearance in the two adjacent bearings.

M905020238D24

Tighten the screws against the crank webs and compress the jacks.

17.

Note down the pressure for later reference. 18. Check that there is min. 0.1 mm clearance between journal and bearing shell, or between bearing shell and main bearing support, on both sides of the journal.

The feeler blade must be inserted minimum 60 mm into the gap to pass the bore relief in the bearing shell. If the clearance is less than 0.1 mm, move the crosspiece sideways until clearance is obtained. Normally, adjustment needs to be 50-150 mm to the exhaust side (the side where the clearance is missing).

M905020238D27

Note!

18.

min 0.1 mm

Note!

EXH

CAM

M905020238D28

Min. 60 mm

The lower shell must be lifted out to the side with the most clearance, which is normally the manoeuvre side.


Page 11 (19)

905-2.2

Main Bearing Dismantling

19.

MAN B&W Diesel

19. If re-positioning of the crosspiece does not ensure a vertical lift, place a 5-tonne jack between the side wall and the crank throw, to correct the journal position in this way. If it is available, note down the pressure applied to the jack. This data is used to ensure that the crankshaft is in the same position when the new bearing is installed.

M905020238D25

Note! It is recommended that the crankshaft lifting tool is only removed if it is urgently necessary and then only after the main bearing shell has been reinstalled.

20. Dismount the locking screws. 20.

M905020238D26

Place the dismantling tool on top of the lower bearing shell. Make sure that the flap on the dismantling tool enters the oil groove in the bearing shell.

Page 12 (19)



905-2.2

Dismantling

21. Pull the lower shell around and up until it lies over the main bearing journal. Never use a tackle larger than 0.5 tonne.

21.

Note!

22. Take the lower shell out of the engine in the same way as the upper shell, i.e. using the lifting tool.

M905020236D27

While pulling out the shell, it is recommended to hold a foot or hand on the wire rope, to tighten it up and to observe whether the shell is sticking.

22.

M90502-0261D22

D05-05


Page 13 (19)

905-2.3

Main Bearing Overhaul

1 + 2.

1.

MAN B&W Diesel Clean and inspect the bearing shells. It is recommended that the main bearing shells be replaced in pairs.

M905020252O01

If it is nevertheless desired to replace only one shell, this requires a careful evaluation of the condition of the shell that is to be reinstalled. See Instruction book, Volume I, Chapter 708. For advice on replacing individual bearing shells, it is recommended to contact MAN B&W Diesel A/S or the engine builder. 2. Before remounting: • Check the bearing support for damage and burrs. If damage is found, contact MAN B&W Diesel for advice. • Make sure that all parts are clean, use non-fluffy cloth to clean between journal and main bearing support. • Lubricate the bearing journal, the main bearing support and the back of the shell, with main engine lubricating oil.

Page 14 (19)



Mounting

Mounting of bearing shells 1.

905-2.4

1.

Using the bearing shell lifting tool, the pulleys and tackles, lift the lower bearing shell into the crankcase and land it on the crankshaft journal.

Lubricate the journal, the lower bearing shell and the bearing support with clean oil. Place the lower bearing shell on the journal and push it down by hand. To ensure that the shell is correctly mounted, check that the distance from the main bearing support to the shell is equal in both sides.

M90502-0261M01

2. Position the guide tool for the lower bearing shell on the main bearing support. Remove the lifting tool from the bearing shell.

D05-05

2.

3. Remove the guide tool when the lower bearing shell has been mounted.

Lower the crankshaft and remove the hydraulic jacks and the crosspiece from below the crankshaft. Wipe the contact surfaces between the upper and the lower bearing shells clean with a non-fluffy piece of cloth.

M90502-0261M02

Mount the locking screws in the bearing support.

M905020252M03

3.


Page 15 (19)

Main Bearing

905-2.4

Mounting

MAN B&W Diesel

4. Land the upper bearing shell on the main journal in the same way as the lower bearing shell.

4.

D0504

Make sure that none of the edges of the upper bearing shell are resting on the edge of the bearing support. If necessary, place the special tool between the studs and press the shell into place.

M905020252M04

Clean the contact surfaces between the bearing support and the bearing cap. Make sure that no oil is left on the contact surfaces.

5. B

A

5. Mount the lifting tool on the bearing cap. Using the tackles and wire ropes on the main bearing cap lifting tool, lift the bearing cap into the crankcase in reverse order to dismantling. See Procedure 905-2.2, steps 22-21.

D0503

M905020261D14

D

Page 16 (19)

C



Mounting

6. Using the pulleys mounted inside the crank case, move the bearing cap into position vertically above the crankshaft bearing journal in the reverse order to dismantling. See Procedure 905-2.2, steps 20-17. 7.

905-2.4

6 a. B

Carefully lower the main bearing cap on to the upper bearing shell. Keep a hand on the wire rope while lowering, so that sticking of the bearing cap is immediately felt.

M905020254D13

D

C

6 b.

F C

M905020252M07

A

7.

A

M905020238M08

E


Page 17 (19)

Main Bearing

905-2.4

Mounting

MAN B&W Diesel

8.

8.

Note! Be sure that the cap lands correctly and that the spring pin in the assembly surface enters the hole in the bearing cap.

9. Remove the bearing cap lifting tool.

M905020238M09

Screw the nuts on to the main bearing studs. Using a tommy bar, tighten the nuts on both sides of the bearing cap. Tightening of hydraulic nuts 10. Mount the nuts, the spacer rings, the hydraulic jacks, and tighten the nuts. See Data and Procedure 905-2.2, step 5 and 6.

9.

After tightening the bearing cap, check the clearance once more.

M905020238M15

For operation of the hydraulic tools, see Procedure 913-1.

10.

D13-01 TOP TOP

M90502-0261M10

TOP

Page 18 (19)



905-2.4

Mounting

11.

11. Note! Before removing the hydraulic jacks, check the top clearance between the upper bearing shell and the journal.

D0501 D0502

12. Remove all tools from the engine.

Search the crankcase to ensure that there are no tools, shackles or rags left behind. 13. Mount the lubricating oil pipe on the main bearing cap,

M905020252M11

Note!

20

M905020238M14

12.

C

M905020252M13

13.


Page 19 (19)

Thrust Bearing MAN B&W Diesel

105-3

Data


X


Data Ref.

Description

D05-06

Thrust bearing segment

D05-07

Value

Unit 90

kg

Segment stopper

440

kg

D05-16

End cover

550

kg

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Thrust Bearing

105-3

MAN B&W Diesel

Data


Plate P90551

Item No. 100

P90662

Description Tool for turning out segments Camshaft - Hydraulic Tools

P91351

010


P91351

046


P91351

058


P91351

105


P91356 P91366

Page 2 (2)

Lifting Tools, Etc. 058

Feeler gauge



905-3.1

Checking

The clearance in the thrust bearing was measured during testbed trials of the engine and noted down in the ‘Adjustment Sheet’ which is inserted at the front of Volume I, OPERATION.

1.

In service it is only necessary to measure the wear of the thrust bearing pads, and to inspect for white metal particles below the thrust bearing. 1.

A wear groove of 1 mm is positioned in the uppermost thrust segment. (The segment with thermometers) For measuring the wear, it is necessary to dismantle the foremost segment stopper. See Procedure 9053.2.

M905030241C01

For a new engine the clearance is 0.51.0 mm, and for an engine in service it must not exceed 2.0 mm.

2.

If a feeler gauge of 0.1 mm is not able to enter the groove (the wear is more than 0.9 mm), the thrust bearing must be overhauled. 3. Note down the wear for later reference.

M905030245C02

2. To measure the wear, the thrust segment has to be pressed against the thrust cam, to eliminate any gap, i.e. by using a suitable crowbar on the back of the segment.

M905030245C03

3.


Page 1 (5)

905-3.2

Thrust Bearing Dismantling 1.

1.

D0516

MAN B&W Diesel

Remove the end cover of the engine. Remove the lub. oil pipe from the aftmost main bearing shell. Remove the lub. oil pipe above the thrust segments. Remove the protecting shields from the thrust collar.

M905030246D01

2. Loosen and remove the nuts from the segment stoppers by using hydraulic tools. Dismount the stud, if necessary. 3. Mount the special lifting attachment in the chain drive and suspend a tackle over the stopper which has to be removed.

2.

M905030247D02

Remove the stoppers above the thrust segment (AHEAD or ASTERN) that are to be taken out, and lift the stoppers out of the chain casing.

D1302

3.

M905030247D03

D0507

Page 2 (5)



905-3.2

Dismantling

4. Suspend a tackle from the chain tightener bracket above the segments which are to be removed.

4.

For turningup the thrust segments, mount the segment tool on the thrust cam, in the holes for the protective shields.

Note! Never remove more than one segment at a time.

M905030247D04

5. Turn up the segments, one at a time, by turning the engine, and remove the segment from the chain casing. Inspect the segment and remount it before turning up the next segment. See Procedure 9053.4.

5.

M905030246D05

D0506


Page 3 (5)

905-3.4

Thrust Bearing Mounting 1.

1.

D0506

MAN B&W Diesel Suspend a tackle from the crossbar above the segments which are to be mounted. Mount the segment tool on the chain wheel. Land the segment on the journal and remove the eye bolt from the segment. Carefully slide the segment on to the segment tool. Turn the engine to dismantle the next segment. See Procedure 9053.2.

M905030247M01

2. After the last segment has been mounted, turn the segment tool up and dismount it.

M905030247M02

2.

Page 4 (5)



905-3.4

Mounting

3. Mount the segment stoppers.

3.

Mount the hydraulic jacks and tighten the nuts on the stoppers. See Data.

D0507

Mount the protective shield. 4. Mount the lub. oil pipe for the thrust segments.

5. Mount the end cover.

M905030247M03

Mount the lub. oil pipe for the aftmost main bearing.

D1301

M905030246M04

4.


Page 5 (5)

Journal Bearing MAN B&W Diesel

105-4

Data


X


Data Ref.

Description

Value

Unit

D05-11

Min. bearing clearance

0.60

mm

D05-12

Max. bearing clearance

0.85

mm

D05-13

Journal bearing cap

1100

kg

D05-14

Upper bearing shell

70

kg

D05-15

Lower bearing shell

70

kg

D05-16

End cover

550

kg

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Journal Bearing

105-4

MAN B&W Diesel

Data


Plate

Item No.

Description

P90551

40


P90551

76

Lifting tool - main bearing cap

P90551

88

Dismantling tool, main bearing shell

P90551

90

Mounting tool for bearing shell

P90551

172

Mounting tool, thin bearing shell

P90561

Main Bearing - Hydraulic Tools

P90570

Thrust Shaft - Tools

P90571

Main Bearing Shell - Tools

P91351

010


P91351

034


P91351

058


P91351

117


P91356

Lifting Tools, Etc.

P91366

058

Feeler gauge

P91366

061

Slide caliper

P91366

073


Page 2 (2)


Axial Vibration Damper MAN B&W Diesel

105-5

Data


X


Data Ref.

Description

Value

Unit

D05-18

Inner studs, screwing-in torque

270±20

Nm

D05-22

Outer studs, screwing-in torque

800±20

Nm

D05-23

Horizontal screws, tightening torque

2150±20

Nm

D05-24

Horizontal screws, tightening torque/angle

D05-25

Damper housing, upper part

2025

kg

D13-01


900

bar

D13-02


800 - 990

bar


100/53

Nm/°

Page 1 (2)

Axial Vibration Damper

105-5

MAN B&W Diesel

Data


Plate

Item No.

P90262

Description Hydraulic jack for piston rod

P90551

111

Lifting attachment

P90551

196

Tightening template A.V.D.

P90564

Crankshaft - Measuring Tools

P91351

046


P91351

058


P91351

105


P91351

117


P91356

Lifting Tools, Etc.

P90662

Camshaft - Hydraulic Tools

Page 2 (2)



905-5.1

Checking For checking the effectiveness of the axial vibration damper, it is necessary to measure the longitudinal movements of the fore end of the crankshaft during running.

1.

The measurement (or reading) should be taken at the same r/min as during the sea trials. (Preferably 90% and 100% of MCR.) As different equipment can have been mounted on the specific engines, the checking procedure describes three different systems: A: Electronic, with Axial Vibration Monitor B. Mechanical, with angle encoder fore.

A proximeter probe is built on to the lower part of the damper housing. The probe is connected to a control unit which displays peakto-peak movements and sends signals to the engine control system.

M905050229C01

A: Electronic, with Axial Vibration Monitor

1. Concerning overhaul and setting of the electronic device, refer to makers instructions and Volume I, Operation, Chapter 701. The peak-to-peak values displayed in mm are to be compared with the original values obtained during sea trial and the limits given in Volume I, Operation, Chapter 701. If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see Procedure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0230 MAN B&W Diesel A/S

Page 1 (6)

905-5.1

Axial Vibration Damper Checking B: Mechanical, with angle encoder fore

1. 1. Stop the engine. Unscrew the two plugs from the cover at the front of the engine.

M905050230C02

2. Mount the shaft piece in the end of the crankshaft. Screw the measuring arm into the small threaded hole beside the centre hole, so that the arm is perpendicular to the shaft piece. Tighten the lock nut. Attach a pencil to the arm. Note! To obtain a correct measurement, the tip of the pencil should protrude 10 mm from the end of the arm.

M905050230C03

2.

Page 2 (6)


905-5.1

Axial Vibration Damper Checking Start the engine, and let the speed rise to the number of revolutions at which the measurement is to be taken. (Preferably 90% and 100% of MCR.)

3.

S2

When measuring, press the measuring arm against the shaft piece with the one hand. With the other hand, move a sheet/block of paper, clipped on to a solid backing plate, lightly downwards against the tip of the pencil.

The axial movements (S2) recorded on the paper must be measured with a slide calliper as shown in the sketch. Before comparing the measured value (S2) with the Normal Service Value (S1), stated in Volume I, Operation, Chapter 701, it is necessary to compensate for the ratio in the tool.

M905050229C04

To ensure a certain inertia, the backing plate should have a mass of approx. 1-2 kg.

4.

S1

For a standard measuring tool (L1 = 38 mm and L2 = 200 mm), the ratio is 5.3. Therefore, S1 can be calculated as follows:

L2

If a non-standard tool is used, S1 can be calculated as follows:

S2

M905050229C10

L1

If the peak-to-peak value exceeds the Normal Service Value, it is necessary to overhaul the axial vibration damper, see Procedure 905-5.2.


Page 3 (6)

905-5.2

Axial Vibration Damper Dismantling 1. Dismantling of the axial vibration damper is carried out from cyl. No. 1.

1.

Disconnect and remove the oil pipes from the foremost bearing cap and the axial vibration damper housing. Loosen and remove the No. 1 main bearing cap. See Procedure 905-2.2.

D1302

Note!

M905050230D01

Before working on top of the main bearing shell, be sure that the open bearing is well protected, i.e. by use of clean rags.

Loosen and remove the nuts and screws from the damper housing upper part.

2.

2. Only the upper part of the housing needs to be removed, while the lower half remains mounted on the bedplate. Mount the lifting tool on the upper part of the damper.

M905050230D02

Engines with chainbox fore: Mount a tackle in the bracket above the axial vibration damper inside the chain box.

3.

Engines without chainbox fore: Mount a tackle below the fore end platform, and dismount the cover on the lifting hole above the axial vibration damper.

D0525

3. By means of a tackle and wire rope, separate and raise the upper part of the damper housing. Note!

M905050230D03

Before working below the suspended upper part, secure the upper part e.g. by mounting two of the vertical screws in the upper threaded holes.

Page 4 (6)



905-5.3

Overhaul 1. Dismantle and remove the springs from the oil sealing rings.

1.

Remove the oil sealing rings. Note!

When mounting the new oil sealing rings, first insert the lower half of the rings in the lower housing. Then press the tension springs into the groove between the oil sealing ring half and the housing. 2. Mount all the upper halves of the oil sealing rings in such a way that the clearance at both the joints on each oil sealing ring is the same.

M905050230O01

It is recommended to discard both the springs and the oil sealing rings.

2.

Now hook the new tension springs into place, ensuring that they are centralised in the grooves of the oil sealing rings.

The lower half of the oil sealing rings will protrude above the centreline.

M905050229O02

Note!


Page 5 (6)

905-5.4

Axial Vibration Damper Mounting 1. Remove the screws securing the upper part of the damper housing.

1.

Release and carefully lower the upper part of the damper housing. When reaching the oil sealing rings, take care that the rings enter the sealing ring grooves correctly.

M905050230M01

Before landing the upper part on the lower part, be sure that the guide pins have entered the guide pin holes. 2. If the studs have been removed, re-mount them at this stage. For screwing-in torque, see Data. Remove the lifting tools. 2.

D0518 D0522

Mount the horizontal screws, without tightening. Mount the nuts on the vertical studs, and tighten them two by two, using the hydraulic jacks. For operation of the hydraulic tools, see Procedure 913-1. Tighten the horizontal screws, see Data.

M905050230M02

D0524

D1301

Mount and tighten the main bearing cap. See Procedure 905-2.4. Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind.

Mount the lubricating oil pipes for damper and main bearing. Engines without chainbox fore: Mount the cover for the lifting hole above the axial vibration damper. Note! After overhaul of the axial vibration damper, it is recommended to check the axial vibrations. See Procedure 905-3.1.

Page 6 (6)


Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel


Plate P90551-0221

Page 1 (2)

Plate P90551-0221 Item No. 015 027 040 064 076 088 090 100 111 123 159 160 172 196 218

Page 2 (2)

Crankshaft, Thrust Shaft, Main Bearing, Etc. - Panel

Item Description

Item No.

Item Description

Panel for tools Name plate Pulley for wire for main bearing Pulley for wire for main bearing Lifting tool for main bearing cap Dismantling tool for main bearing shell Mounting tool for thin bearing shell Tool for turning out segments Lifting tool for main bearing cap Retaining tool for relief valve Eye bolt Wire Mounting tool for thin bearing shell Tightening template A.V.D. Wire guide for main bearing


Crankshaft - Tools

Plate P90562-0123

Crankshaft - Tools 0123 P90562


Page 1 (2)


Crankshaft - Tools

Item Description

Item No.

Item Description

Lifting tool for crankshaft

Page 2 (2)



Plate P90564-0020

Crankshaft - Measuring Tools 0020 P90564

Flange on end of crankshaft

Flange on end cover fore

Z When ordering item 016 or 028, please always state measurement “Z”


Page 1 (2)

Plate P90564-0020 Item No. 016 028 041 053


Item Description

Item No.

Item Description

Measuring instruments, axial vibration damper Shaft, measuring instruments axial vibration Measuring instruments, axial vibration damper Handle - sundry types

Page 2 (2)



Plate P90570-0003

Thrust Shaft - Tools 0003 P90570


Page 1 (2)



Item Description

Item No.

Item Description

Lifting tool, thrust shaft

Page 2 (2)


Main Bearing Shell - T ools Tools MAN B&W Diesel


Plate P90571-0001

Page 1 (2)


Page 2 (2)

Main Bearing Shell - T ools Tools MAN B&W Diesel

Item Description

Item No.

Item Description

Lifting tool for main bearing shell


Main Bearing - Measuring T ools Tools MAN B&W Diesel


Plate P90572-0001

Page 1 (2)

Main Bearing - Measuring T ools Tools

Plate P90572-0001 Item No. 021 033 045 069 070 082 094 104 116 128 141 153 165 177 189 190 200 212 224 236 248 261 273 285 332 344 356 368 381 393 403 415 427 439 440 452 464 476 488 511 523 535 547 559 560

Page 2 (2)

MAN B&W Diesel

Item Description Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Feeler Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare

gauge set gauge set gauge set gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler tip for feeler

Item No.

Item Description

gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge gauge


906 - Control Gear Documents in this Chapter 106-01 906-01 106-02 906-02 106-03 906-03 106-04 906-04 90651 90664

0051 0246 0067 0230 0043 0218 0045 0219 0203 0001

Chain, Data Chain Chain Tightener, Data Chain Tightener Camshaft, Data Camshaft Camshaft Bearings, Data Camshaft Bearings Chain Drive and Camshaft - Panel Crankshaft - Pin Gauge

MAN B&W Diesel A/S

MAN B&W Diesel A/S

106-1

Chains Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X


X


X


Data Ref.

Description

D06-18

Teeth on chain wheel, max. wear

D06-19

Original length (chain pitch x 10 links)

D06-20

10 links measurements + 1% of a tensioned chain = scrapping of chain


Value

Unit

4

mm

1143

mm

1154.4

mm

Page 1 (2)

106-1

Chains Data


Item No.

Description

P90651

70

Chain assembling tool

P90651

81

Chain disassembling tool

Page 2 (2)


Chains MAN B&W Diesel 1.

906-1.1

Checking

The engine is equipped with a set of chains:

1.

• the drive chains for the camshaft The set of chains is to be checked and, if necessary, dismantled and mounted in the same way. 2. The chains can be accessed from within the chainwheel frame. 3. Carry out the inspection as follows: • Make a general inspection for loose bolts and screws.

• Examine the rubber track of the guideways for cracks or other damage. • Replace the guideway if bits have started to be “plucked out” of the rubber track. 4. Check the teeth of the chain wheels. If abnormal wear is found, take a measurement (See Data).

M90601-0246C01

• Inspect lube oil pipes for damage, and check jet nozzles for possible stoppages or deformations.

4.

Measurements are best taken by placing a short straightedge over the straight part of the chain wheel and then measuring the distance D0618.

M906010245C02

D0618


Page 1 (6)

Chains

906-1.1

Checking

MAN B&W Diesel

5. If abnormal wear is observed at the bottom of the teeth, make a drawing in scale 1:1 of the teeth and wear profile.

5.

Draw two rulers on the drawing. For assessing the wear profile, contact MAN B&W Diesel.

M906010244C05

0

Scale 1:1

10 0

10

In most cases, scratches caused by the side plates of the chain will be found on the sides of the teeth. Such scratches can generally be considered normal. 6. The chains for the camshaft drive are matched together to ensure an even load distribution. To keep such matching chains in their pairs, the side plates of the outer link nearest to the assembled link have been marked with year, month, day and chain number. Example: No. 1 order, 840520 1A 840520 1B (840520 2C, possible 3rd chain) No. 2 order, 840520 2A 840520 2B (840520 2C, possible 3rd chain) On the same links there is an arrow (–>) which indicates the mounting direction. Check the chains for cracks on possibly defective rollers and side plates. Check that the chain rollers can run freely and that the chain links can freely move on the pin and bushing (that they are not “seized” between the pin and the bushing). It is normal, however, that the rollers get light, circumferential scratches during the runningin period. These fine scratches are of no importance and need not be considered. It is recommended that each single link is checked.

Page 2 (6)


Chains MAN B&W Diesel 7.

906-1.1

Checking

Check chain wear by measuring the length of 10 chain links. Use two master squares and a steel measuring tape as shown on the sketch. Compare the result with the value given in Data.

7.

If necessary, adjust the chain tightener. See Procedure 9062.3.

Ma

D0619 D0620

M906010245C07

20 06

x.D When referring to this page, please quote Procedure M90601 Edition 0246

Page 3 (6)

906-1.2

Chains Dismantling

MAN B&W Diesel

It may become necessary to disassemble the chain if, for instance, cracked rollers or seizures between pin and bushing have been discovered during the inspection. See Procedure 9061.1.

1.

Note! Every time a chain link is disassembled, a new link must always be fitted as the link pin pressfit is destroyed when breaking the chain. When a new link is fitted in one chain, the corresponding link in the other chain must also be renewed.

M90601-0246C01

1.

2.

Remove the tension on the chain by loosening the chain tightener. (See Procedure 9062.3). Turn the engine until the slack part of the chain, with the chain link that is to be disassembled, is in a favourable position for the work.

2. Mount a wire round the link rollers a short distance from the disassembly point, and tighten the wire lightly with a tackle. Protect the link rollers over which the wire is wrapped. Note!

M906010238D02

If the chain is to be completely removed, contact MAN B&W Diesel for further information.

Page 4 (6)

The riveting of the pins that are to be pressed out is to be chiselled or ground away.


Chains MAN B&W Diesel

906-1.2

Dismantling

3.

M906010238D03

3. Place the chain bursting tool over the outer chain link, and dismantle the link by alternately tightening the screws on the tool.


Page 5 (6)

906-1.4

Chains Mounting

MAN B&W Diesel Before assembling the inner and outer links, clean the pins and bushings.

1. 1.

Combine the inner chain link with the outer chain link and mount the compression tool. Force the loose side plate of the outer link into place by alternately tightening the screws on the compression tool.

M906010238M01

2. When the link has been assembled, remove the compression tool and lock the pin ends by riveting.

Page 6 (6)

Repeat this procedure until the chain has been assembled. Remove the tackle and wire and adjust the chain tension. (See Data and Procedure 9062.3).


Chain Tightener MAN B&W Diesel

106-2

Data


X


Data Ref.

Description

Value

Unit

D06-21

Tightening angle = 5 hexagons

300

°

D06-25

Mechanical or blocked chain tightener, clearance

0.1

mm


Page 1 (2)

Chain Tightener

106-2

MAN B&W Diesel

Data


Plate

Item No.

Description

P90651

070

Chain assembling tool

P90651

081

Chain disassembling tool

Page 2 (2)


Chain Tightener

906-2.3

Adjustment Chain Tightener S60MC-C 0230 Adjustment 906-2.3

1.

1. To retighten the chains, loosen nuts A, B, C and D to free the chain tightener bolt.

A B

2. Turn the engine at least one revolution with the chain slackened on the same side as the chain tightener wheel. If the engine is equipped with flyweights, continue turning until the flyweights are hanging vertically downwards.

Then tighten nut B as stated in D06-21 (see Data).

C D

HG906-2.3 218 01

3. Tighten nut B on the chain tightener bolt until there is a clearance between the shaft and the nut as stated in D06-25.

2.

HM906-2.2 95 01

For chain wear, see Procedure 906-1.1.

3.

B

D06-25

HG906-2.3 218 03

D06-21


Page 1 (2)

906-2.3

Chain Tightener Adjustment

4.

4. Tighten nut C hard against the contact face of the shaft. Tighten nut D. Lock nuts C and D with the tab washer. 5. Tighten nut A. Lock nuts A and B with the tab washer.

C

HG906-2.3 218 05

D

The number of times that retightening can be carried out depends on when the limit for scrapping the chain has been reached. See Data page 106-1.

5.

HG906-2.3 218 05

A

Page 2 (2)


Camshaft MAN B&W Diesel

106-3

Data


X


Data Ref.

Description

D06-27

Max. permissible change in lead angle

D06-28

corresponding to


Value

Unit 2 5.6

° mm

Page 1 (2)

Camshaft

106-3

MAN B&W Diesel

Data


Plate

Item No.

Description

P90664

Crankshaft - Pin Gauge

P90668

Camshaft - Pin Gauge

Page 2 (2)


Camshaft MAN B&W Diesel 1.

906-3.1

Checking

Turn the crankthrow for cylinder 1 to TDC.

1.

Turn in the ahead direction to ensure that the tension of the chain on the chain drive is correct. If necessary, adjust the chain tension. See Procedure 906-2.3.

2. Use the check measurement value stamped on the pin gauges to check the pin gauges for deformation. On some engines the pin gauges can be checked against punch marks made on the front cylinder frame.

M906030218C01

Check the TDC of cylinder 1 against the mark on the turning wheel.

2.

Check

M906030218C02

Che ck


Page 1 (4)

Camshaft

906-3.1

Checking

MAN B&W Diesel

3. Check the TDC position with the pin gauge on the crankthrow.

3.

Position the camshaft pin gauge in the centre punch mark, and measure the deviation, if any, in lead angle. For max. permissible change, see D06-27 and D06-28.

M906030218C03

4. Check and, if necessary, adjust the cylinder lubricator. See Procedure 903-2.1. Check the setting of the starting air distributor. See Procedure 907-1.1. 5. When checking the camshaft position, also check the running surface of the cams.

4.

As the inspection must include the entire surface of the cam, the cam should be turned one complete revolution during the inspection.

M906030218C04

The running surface of the cam must be completely smooth and bright.

2

O

D0627 D0628

M906030218C05

5.

Page 2 (4)


Camshaft MAN B&W Diesel

906-3.1

Checking

6. If light scratches are ascertained, remove them by carefully polishing the cam in the direction of rotation with a fine carborundum stone. Such light scratches can appear if the roller guide and the cam are not correctly aligned.

6.

M906030218C06

In the event of heavier scratches or direct flaking of the material on the running path, MAN B&W Diesel should be contacted for further instructions.


Page 3 (4)

Camshaft

906-3.3

Adjustmentl 1.

M906030218O01

1.

Page 4 (4)

2

MAN B&W Diesel

If the chains prove to be so heavily worn that the deviation between the measuring points and the pin gauge has reached the maximum value D06-27 and D06-28 stated in Data, MAN B&W Diesel should be contacted for further instructions.

O

D0627 D0628


Camshaft Bearings MAN B&W Diesel

106-4

Data


X


Data Ref.

Description

Value

Unit

D06-34

Bearing shell, max. wear

0,1

mm

D06-36

Oil pan

130

kg

D06-37

Camshaft bearing cap

150

kg

D06-65

Bearing shell, minimum thickness

6,35

mm

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Camshaft Bearings

106-4

MAN B&W Diesel

Data


Plate

Item No.

P90662

Description Camshaft - Hydraulic Tools

P91351

010


P91351

034


P91351

058


P91351

105


Page 2 (2)


Camshaft Bearing

906-4.1

Checking Camshaft Bearing S60MC 0219 Checking 906-4.1

1.

1. As the upper shell of the camshaft bearing assembly has been dispensed with on this engine, it is no longer necessary to measure the top clearance of the camshaft bearing. However, with normal inspection through the inspection hole in the roller guide housing, we recommend a visual inspection of the condition of the shell in the bearing cap from each side.

In the event of any signs of anomalies, the bearing shell must be dismantled for closer investigation and, if necessary, the bearing shell must be replaced

HC906-5.0 57 01

Check for wiped-out metal at the bearing ends, and for fragments of metal in the camshaft housing.

If no anomalies are found during the visual inspection, dismantling need not be carried out. When checking the camshaft bearings, it is recommended also to check the condition of the fuel and exhaust cams. See Procedures 908-5 and 909-3.


Page 1 (5)

906-4.2

Camshaft Bearing Dismantling Dismantling 906-4.2

1. Caution! Before dismantling any camshaft bearings, the main chain must be relieved of tension by loosening the chain tightener to avoid damaging engine parts.

See Procedure 906-2.3.

HC906-5.0 57 02

1. Dismount the oil outlet pipe from the oil tray. Mount an eye bolt in the cylinder frame behind the oil tray. Release the sealing flanges on the roller guide housing, loosening the screws mounted in the roller guide housing. Remove only the screws in the lower half of the sealing flange.

2.

2. Attach a wire rope to the eye bolt. Place the wire rope in the lifting fitting of the oil tray, hook on a tackle and haul tight.

D06-36

Remove the screws securing the oil tray to the roller guide housing. Ease off the oil tray, landing it on the platform.

HC906-5.0 57 03

3. Mount lifting fittings on both sides of the bearing half. Mount grooved pulleys on the roller guide housing, and hook wire ropes/ tackles on to the lifting fittings/grooved pulleys. Tighten up the tackles.

HG906-4.3 201 03

3.

Page 2 (5)


Camshaft Bearing

906-4.2

Dismantling 4.

4. Mount the hydraulic jacks and loosen the bearing nuts. For use of hydraulic jacks, see Procedure 913-1. Remove the hydraulic jacks and dismount the nuts.

HG906-4.3 201 04

5. Lower the bearing cap and place it on the platform.

D13-02

5.

HC906-5.0 57 06

D06-37


Page 3 (5)

906-4.3

Camshaft Bearing Overhaul Overhaul 906-4.3

1.

1. For assessment of the bearing condition, see Volume I OPERATION, Chapter 708 ‘Bearings’. Inspect the entire surface of the bearing journal for seizures. If seizures are found on the bearing journal surface (on account of bearing breakdown), polish the surface with a fine carborundum stone to re-establish a bright and smooth surface.

HC906-5.0 57 07

2. By closely examining the sliding surface of the bearing shell visually, an impression can be formed of whether the lubrication of the bearing surface has been insufficient or entirely missing. Normally, camshaft bearing damage only occurs due to faulty lubrication.

2.

MA906-4.3 209 02

Measure the thickness of the bearing shell with a micrometer to check the amount of wear.

Page 4 (5)

D06-34 D06-65


Camshaft Bearing

906-4.4

Mounting Mounting 906-4.4

1.

1. Clean the bearing journal, the bearing support and the bearing shell. Mount the bearing shell in the bearing cap, after coating the shell with oil. Then pull the bearing cap into place by means of tackles/ wire rope fitted through the grooved pulleys to the lifting fittings. Check that the guide pins enter correctly.

Remove the lifting fittings and grooved pulleys from the roller guide housing.

HC906-5.0 57 06

2. Mount and tighten up the nuts by means of the hydraulic tools. See Data.

3. Hoist the oil tray into place, positioning it by means of the guide pins.

D06-37 2.

Then fasten it to the roller guide housing by tightening up uniformly all round the circumference. Remove the shackle and eye bolt. Mount the screws that fasten the sealing flanges to the roller guide housing. Mount the oil pipe on the oil tray.

HG906-4.3 201 04

D13-01

3.

HC906-5.0 57 03

D06-36


Page 5 (5)

Chain Drive and Camshaft Panel


Plate P90651-0203

Page 1 (2)

Plate P90651-0203 Item No. 019 020 044 056 068 070 081 127 139

Page 2 (2)

Chain Drive and Camshaft Panel

Item Description

Item No.

Item Description

Panel for tools Name plate Pin spanner for fuel cam Chain assembling tool Chain disassembling tool Chain assembling tool Chain disassembling tool Pulley for wire Lifting attachment




Plate P90664-0001

Page 1 (2)


Page 2 (2)


Item Description

Item No.

Item Description

Pin gauge for crankshaft


907 - Starting Air System Documents in this Chapter 107-01 907-01 107-02 907-02

0019 0219 0041 0217

Starting Air Distributor, Data Starting Air Distributor Start Air Valve, Data Starting Air Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

107-1

Starting Air Distributor Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X


X

Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description


Value

Unit

Page 1 (2)

107-1

Starting Air Distributor Data


Page 2 (2)

Item No.

Description


Starting Air Distributor

907-1.1

Checking Starting Air Distributor K98MC-C 0219 Checking 907-1.1

2.

1. Turn the engine in AHEAD direction to bring the piston of cylinder No. 1 to TDC. Check the position with the pin gauge. See Procedure 906-3.1.

3. Check that the guide pin holes in the starting cam coincide or that the guide pins are mounted and the TDC marking scratch on the starting cam is positioned vertically in line with the marking scratch at the valve slide of cylinder No. 1. If the scratch marks are out of alignment, the starting cam must be dismantled.

HN907-1.1 205 02

2. Remove the small end cover of the distributor housing.

3.

4. Remove all the slide valves, see Procedure 907-1.3. Unlock the centre screw and remove the screw. Pull off the starting cam by means of two dismantling screws.

If the guide pins are bent or broken, remove the pins and mount new pins. Remount the starting cam, and the centre screw.

M90701-0219C03

Check the guide pins.

Note! The starting cam must always be provided with guide pins. Mount the slide valve for cylinder No. 1 and check the alignment once more. If the scratch marks are out of alignment, contact MAN B&W Diesel for advice.


Page 1 (5)

907-1.3

Starting Air Distributor Overhaul Overhaul 907-1.3

2.

Difficulties in starting can be caused by the starting air distributor valve slides “sticking” (see Volume I, Chapter 703), so that these are not activated and pressed against the cam during the starting procedure.

HN907-1.3 205 02

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 necessary to prevent starting difficulties, as differences will be found from plant to plant. 1. Blank off the main starting air and the control air. If this is not possible, lock the main starting valve in the closed position with a padlock. 2. Remove all the pipes from the end of the distributor.

HN907-1.3 205 03

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 pin of the valve slide (cam follower) can be pushed clear of the starting cam. 4.

4. Remove the screws and the cap from the particular valve slide in question.

HN907-1.3 205 04

Remove the guide screw for the valve slide.

Page 2 (5)



907-1.3

Overhaul 5.

5. Remove the complete slide valve (with spring and the upper liner) from the distributor housing by means of a brass mandrel. 6. Press-in the spring and remove the two part locking ring.

907-1.3 217 05

7. Remove the upper spring guide, the spring, the lower spring guide and the upper liner from the valve slide.

M90701-0219O06

6.

M90701-0219O07

7.


Page 3 (5)

907-1.3

Starting Air Distributor Overhaul

8.

8. Clean all the sliding surfaces on the valve slide. Check the sliding surfaces for wear and seizures, also check the cam follower for wear. Clean the liners and the distributor housing. Test that the valve slide moves easily in the liners. Note!

M90701-0219O08

Polishing of the liners with emery cloth must not take place as small particles of the grinding material can stick in the surface of the liner.

10.

Lubricate all parts with Molybdenum Disulphide (MoS2), also the cam follower must be well lubricated. 9. Place the upper liner, the lower spring guide, the spring and the upper spring guide over the valve slide. 10. Press-in the spring and mount the two-part locking ring.

M90701-0219O10

11. Mount the complete slide valve in the distributor housing. (Check that the pin of the valve slide goes clear of the starting cam when mounting). Lubricate the groove in the starting cam with Molybdenum Disulphide (MoS2).

M90701-0219O11

11.

Page 4 (5)



907-1.3

Overhaul 12.

12. Mount the guide screw for the valve slide. Mount the cap and the screws on top of the slide valve. 13. Check that the piston valve slides can be pushed up and down by hand just overcoming the force of the spring.

M90701-0219O12

14. Finally, mount the two end covers and connect the main starting air and the control air.

HN907-1.3 205 02

14.


Page 5 (5)

107-2

Starting Air Valve Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X

Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description

Value

Unit

D07-09

Piston tightening torque

D07-11

Valve tightening angle

60

°

D07-12

Starting air valve

75

kg


140

Nm

Page 1 (2)

107-2

Starting Air Valve Data


Item No.

P90151

95

P90151

105

Page 2 (2)

Description Grinding ring for starting valve Grinding handle for starting valve


Starting Air Valve

907-2.1

Checking Starting Air Valve K98MC 0217 Checking 907-2.1

1.

1. When the starting air valve has been overhauled, see Procedure 907-2.3, connect a 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. Shut off the air supply Check that the valve closes fully.

HM907-2.1 202 01A

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

HM907-2.1 202 01B

2.


Page 1 (6)

907-2.2

Starting Air Valve Dismantling Dismantling 907-2.2

1.

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

HG901-2.2 59 02

2. Lift away the starting valve.

2.

HG907-2.3 201 02

D07-12

Page 2 (6)


Starting Air Valve

907-2.3

Overhaul Overhaul 907-2.3

1.

1. Place the starting air valve horizontally in a bench vice provided with “soft” jaws. Remove and discard the O-ring from the valve housing. 2. Loosen and remove the screws from 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 and discard the locking device.

HM907-4.0 39 01

Dismount the top cover.

When unscrewing, the piston will partially be pressed out of the valve housing due to the spring force.

HM907-4.0 39 02

2.

HM907-4.0 39 03

3.


Page 3 (6)

907-2.3

Starting Air Valve Overhaul

4.

4. Remove the piston from the top end of the 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 seatings of the spindle and valve housing to match, use the face wrench to rotate the spindle.

HM907-4.0 39 04

As grinding paste, use e.g. carborundum No. 500.

HM907-4.0 39 05A

5.

MG907-4.0 51 05B

6.

Page 4 (6)


Starting Air Valve

907-2.3

Overhaul 7.

7. Thoroughly clean the valve housing and all the parts in diesel oil or kerosene. Lubricate all internal parts and sliding surfaces with, e.g., Molybdenum Disulphide, MoS 2. 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 discs and the two screws. When tightening the screws, the piston will compress the spring.

Lock the screws with locking device. For correct use of locking device, see Procedure 913-7. 9. Mount and tighten the top cover.

HM907-4.0 39 07

Tighten the screws continuously until the piston faces tightly against the spindle. Use the face wrench as a back-stop. See Data.

9.

Fit a new O-ring on the valve housing. 10. Check the starting air valve. See Procedure 907-2.1. If the valve is not to be mounted in the engine immediately, cover all openings with plastic to prevent dirt from entering the valve during storage.

HM907-4.0 39 09

D07-09


Page 5 (6)

907-2.4

Starting Air Valve Mounting Mounting 907-2.4

1.

1. Carefully clean the starting valve bore in the cylinder cover and, if necessary, recondition the seat for the starting valve in the bore, see Procedure 901-1.3. If not already done, fit a new O-ring on the overhauled valve and lubricate with ‘Never Seize’ or Molybdenum Disulphide, MoS 2. For overhaul, see Procedure 907-2.3 . 2. Mount the valve in the cylinder cover.

HG907-2.4 201 01

3. Mount the nuts and tighten-up in at least three steps, to reach the full tightening angle, see Data. Mount the control air pipe and turn on starting air and control air. 2.

HG907-2.4 201 02

D07-12

3.

HM901-2.2 114 03

D07-11

Page 6 (6)


908 - Exhaust Valve Documents in this Chapter 108-01 908-01 108-02 908-02 108-03 908-03 108-04 908-04 108-05 908-05 108-07 908-07 90851 90861 90862 90863 90864

0037 0226 0094 0269 0057 0227 0041 0222 0017 0219 0034 0228 0177 0022 0036 0015 0003

High-Pressure Pipe, Data High-Pressure Pipe Exhaust Valve, Data Exhaust Valve Exhaust Valve Actuator, Data Exhaust Valve Actuator Exhaust Valve Roller Guide, Data Exaust Valve Roller Guide Exhaust Valve Cam, Data Exhaust Valve Cam Exhaust Valve - Special Running, Data Exhaust Valve Exhaust Valve - Panel Exhaust Valve - Tools Exhaust Valve - Hydraulic Tools Exhaust Valve - Extra Tools Exhaust Valve - Extractor Tool

MAN B&W Diesel A/S

MAN B&W Diesel A/S

High-Pressure Pipe

108-1

Data SAFETY PRECAUTIONS Special Edition D10801 S80MC 108-1 Data 0037

High-Pressure Pipe

X

Stopped engine

X

Block the starting mechanism

X

Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil

X

Shut off lubricating oil Lock turbocharger rotors

Data Ref.

D08-01 D08-02 D08-03

Description

High-pressure pipe, tightening torque Distance of high pressure pipe lower edge to pressure flange High-pressure pipe


Value

Unit

170 Nm 20 mm 100 kg

Page 1 (2)

High-Pressure Pipe

108-1

Data


P90851

Page 2 (2)

Item No. Description

112

Grinding mandrel for high-pressure pipe


High-Pressure Pipe

908-1.2

Dismantling 908-1.2 Disling 908-1.2 Dismantling

1.

1. When replacing the hydraulic high-pressure pipe, the exhaust valve or the hydraulic actuator, check and, if necessary, recondition the high-pressure pipe sealing surfaces. 2. Before dismantling the high-pressure pipe, stop the camshaft oil pump. Loosen the screws for the high-pressure pipe and lift the pipe slightly away from the actuator to let the oil in the pipe drain through the drain holes in the actuator.

M908010226D01

D0803

M908010226D02

2.


Page 1 (3)

908-1.3

High-Pressure Pipe Overhaul 1. Check the contact surfaces of the pressure pipe for marks and, if necessary, grind the pipe ends by means of the grinding mandrel and the two guiding tools.

1.

M908010226O01

Start grinding with a coarse grinding paste, for example Carborundum No. 200, and finish with a fine grinding paste, for example Carborundum No. 500.

Carborundum

2. After reconditioning the contact surfaces of the pipe, measure the distance from the edge of the thrust bushing to the contact surface at both ends of the pipe. This measurement is to correspond with the value stated in Data. Check the thrust pads in the exhaust valve and the actuator for marks on the sealing surface.

2.

Replace the O-rings on the thrust pads. If considered necessary, replace the thrust pads.

M908010226O02

Lift the thrust pad free by, for example, using a screwdriver in the groove of the thrust pad.

Page 2 (3)

D0802


908-1.4

High-Pressure Pipe Mounting 1. Mount the hydraulic high-pressure pipe as follows:

1.

After fitting the pipe correctly in relation to the exhaust valve and actuator, tighten up the screws of the pressure flanges diagonally, see Data. 2. Check the whole system for tightness. See Procedure 908-3.1.

M908010226M01

Position the high-pressure pipe with the sealing surfaces of the pipe resting on the thrust pads of the exhaust valve/actuator. Take care not to damage the O-rings on the thrust pads.

D0801

M908010226M02

2.


Page 3 (3)

Exhaust Valve MAN B&W Diesel

108-2

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X X X X X X X X X X X


Data Ref.

Description

D08-04 D08-05 D08-06 D08-07 D08-09 D08-10 D08-11 D08-12 D08-13 D08-14 D08-15 D08-16 D08-17 D08-18 D08-19 D08-20 D08-21 D08-22 D08-23 D08-24 D08-25 D08-26 D08-27 D08-28 D08-29 D08-30

Safety valve, opening pressure Screws for lifting eye bolt, tightening torque Oil cylinder, tightening torque Safety valve, tightening torque Bottom piece seat, grinding angle Valve spindle seat, grinding angle Bottom piece seat, max. grinding Gap of bottom piece seat Spindle, max. burn-off Spindle, max. grinding Spindle stem, measuring area, min. Spindle stem, measuring area, max. Spindle stem, min. diameter Bushing max. diameter, top Bushing max. diameter, bottom Oil cylinder max. inside diameter Piston rings, min. thickness Damper piston, min. distance Damper piston, max. distance Exhaust valve, complete Exhaust valve housing Oil cylinder Air cylinder Spindle Bottom piece Air piston

D13-01 D13-02

Hydraulic pressure, mounting Hydraulic pressure, dismantling


Value

Unit

21 215 215 70 - 100 29.9 - 30.0 30.5 - 30.6 2.3 1.0 11.0 2.0 385 545 95.8 96.7 99.5 112.2 4.2 48,4 51,4 1700 950 230 70 180 220 22

bar Nm Nm Nm ° ° mm mm mm mm mm mm mm mm mm mm mm mm mm kg kg kg kg kg kg kg

900 800 - 990

bar bar

Page 1 (2)

Exhaust Valve

108-2

MAN B&W Diesel

Data


Plate

Item No.

Description

P90851

065

Lifting tool for exhaust valve

P90851

077

Cone ring for pneumatic piston

P90851

089

Pressure tester for safety valve

P90851

090

Gauge for exhaust valve spindle

P90851

136

Bridge gauge for exhaust valve

P90851

148

Tool for hydraulic piston

P90851

150

Gauge for exhaust valve bottom piece

P90851

161

Lifting tool for exhaust valve spindle

P90851

185

Grinding ring for exhaust valve bottom piece

P90861

Exhaust Valve - Tools

P90862

Exhaust Valve - Hydraulic Tools

P91351

010


P91351

046


P91351

060


P91351

117


Page 2 (2)



Checking

Checks during running: 1.

908-2.1

1.

Check of valve spindle rotation

The indicator will now follow the movements of the valve spindle and the air piston. During rotation of the valve spindle, the top position of the indicator will change about 6 mm, because of the groove in the piston. During engine operation, the spindle must rotate. The rotation can vary with unit and engine load. In the event of no rotation, attention should be paid to avoid seat problems. When check of the valve rotation is finished, lift the rotation indicator and lock it in the top position.

M908020252C01

The engine must run when the valve function and spindle rotation are checked. Lift the valve spindle rotation indicator, turn it 90° and let it rest on the air piston.

On Surface

InGroove

2.

The indicator must not be in constant operation.

2. Check of sealing oil unit Check that the injection indicator moves regularly with the valve opening. Alternatively, unscrew the sealing oil pipe, and check that oil is coming out (very small quantity).

M908020256C02

Exhaust valve performance condition See volume I chapter 706 Performance Evaluation

Depending on valve model the indicator is placed either on the manoeuvre side or the front side


Page 1 (25)

Exhaust Valve

908-2.1

Checking

MAN B&W Diesel

3. Check of bottom piece sealings 3. With the exhaust valve mounted in the cylinder cover, check the cooling water inlet and outlet to the cylinder cover and exhaust valve is open.

M908020254C03

Check the tightness of the sealing rings between the bottom piece and the exhaust valve housing. IF water flows from the small bore on the manoeuvring side of the exhaust valve, the lowermost sealing ring is leaking. If water flows from the any of the rings, the exhaust valve must be dismounted and the sealing rings replaced. Check with stopped engine: 4. In connection with port stays, at an interval of e.g. one month, an easy check of all exhaust valves is recommended. 4. Check of spindle dropdown time: Engage all rotation indicators on the exhaust valves. SAFETY AIR SUPPLY

Shut off and release the spring air on the valve, next to the engineside manoeuvring stand.

AIR SUPPLY EXHAUST VALVE

Check the drop down time for all spindles:

• Spindles dropping down within 30 min-

M908020256C04

utes: Check and overhaul, See next step “Check of Air Spring tightness”.

• Spindles dropping down between 30 minutes and 1 hour: Keep under observation. CONTROL AIR SUPPLY

• Spindles dropping down after 1 hour: OK. When check of drop down time is finished, lift the rotation indicators and lock them in the top position.

Page 2 (25)



908-2.1

Checking

5. Check of Air spring tightness 5. Connect compressed air to the non return (A) valve on the air cylinder. Disconnect and remove the drain oil pipe from the oil cylinder (C). Disconnect the sealing oil pipe and banjo coupling from the air cylinder (B).

B

Check if air is coming out from:

A

• The sealing oil bore (B): Leakage from spindle stem sealing , change and overhaul. • Hole for drain oil (C): If yes, the leakage comes from the safety valve or the air piston. Check the safety valve (D). If air still is coming out, the leakage comes from the air piston: change and overhaul.

A

D

• Remove the air supply to the nonreturn valve on the air cylinder and check the nonreturn valve for tightness. The checks is for guidance only, minor leaks is difficult to detect.

C

M908020256C05

D

C B


Page 3 (25)

908-2.2

Exhaust Valve Dismantling 1.

MAN B&W Diesel

Close off cooling water

1. Close the cooling water inlet and outlet connections, and drain the exhaust valve. Close the air supply to the exhaust valve. 2. Dismount the oil pipe connections Dismount the highpressure pipe for the hydraulic valve actuation. See Procedure 9081.2

M908020256D01

Dismount the return oil pipe from the exhaust valve.

M908020256D02

2.

Page 4 (25)



908-2.2

Dismantling

3. Disconnect pipe connections 3. Disconnect the cooling water connections from the exhaust valve and the air pipe for the air spring. Remove the plate jacket and insulation from the intermediate pipe.

Support the intermediate pipe by e.g. a chain block and remove the screws. 4. Dismantling of hydraulic nuts. Remove the protective caps from the exhaust valve studs.

M908020256D03

Loosen the screws which attach the intermediate pipe to the exhaust valve housing.

4. Loosen and remove the hydraulic nuts, see Data. See Procedure 9131.

M908020256D04

D1302


Page 5 (25)

Exhaust Valve

908-2.2

Dismantling

MAN B&W Diesel

5. Lift of exhaust valve 5.

D0824

Check all connections to the valve are removed. Attach the crane to the eye bolt fitted on top of the valve and start lifting the exhaust valve. During the lift check the valve goes clear of all other engine components. Land the exhaust valve on a wooden plate on the platform. Carefully clean the exhaust valve bore in the cylinder cover and recondition the seating and sealing surfaces of the bore, if required. See Procedure 9011.3.

M908020256D06

For overhaul of the exhaust valve, see Procedure 9082.3

Page 6 (25)


Exhaust Valve MAN B&W Diesel 1.

908-2.3

Overhaul

Oil cylinder 1. Place the exhaust valve on a wooden support on the platform.

D0826

Remove the nuts and the safety strap from the oil cylinder. Depending on valve model, remove the sealing oil pipe. Lift away and place the oil cylinder on a wooden support. 2. Conical locking ring

Remove the four screws from the flange on top of the air piston and dismount the flange.

2.

M908020256O02

Loosen the air piston from the conical locking ring by means of a tin hammer, and remove the conical locking ring.

M908020256O01

Relieve the air pressure through the nonreturn valve from below the piston. Use a small screwdriver to press the ball into the nonreturn valve. Cover the nonreturn valve with a rag to catch the oil drops.


Page 7 (25)

908-2.3

Exhaust Valve Overhaul

MAN B&W Diesel

3. Spindle 3.

D08-24

Use the oil cylinder as a lifting tool for the exhaust valve housing. Lift the oil cylinder with the crane, and guide it down over the studs for the oil cylinder. Mount four nuts so that the load from the valve housing is evenly distributed. Lift the valve housing clear of the valve spindle. Take care – when the internal Oring in the air piston and the internal rings for the sealing arrangement at the bottom of the air cylinder pass the groove for the conical ring at the top of the spindle. 4. Bottom piece

M908020256O04

Unscrew and remove the lock screws which retain the bottom piece. Lift the valve housing approx. 10 mm. If the bottom piece has become stuck, use a tin hammer to release it. Lift the valve housing away and land it on a couple of wooden planks.

4.

Remove the oil cylinder.

M908020256O05

D08-29

Page 8 (25)



908-2.3

Overhaul

5. Air piston and cylinder 5. Dismount the air piston from the air cylinder. Dismount the nonreturn valve from the air cylinder/valve housing.

D08-30

D08-27

Mount two eye bolts in the air cylinder and dismount the air cylinder.

6. Guide bushing Clean the exhaust valve housing. Inspect the bushing in the spindle guide for wear and measure the top and bottom diameters. See Data.

M908020256O06

Remove and discard the Oring on the air cylinder.

6.

D0818

M908020269O06

D0819


Page 9 (25)

908-2.3

Exhaust Valve Overhaul 7.

MAN B&W Diesel Bushing renewal

7. If it proves necessary to replace the bushing, remove the screws and knock out the bushing with a hammer and a suitable mandrel. Alternatively, if the extractor tool is available, mount the extractor tool and pull up the bushing. The extractor tool is optional, and can be ordered as spare part. When a new bushing is mounted, mount a new Oring for sealing between bushing and exhaust valve housing. Mount and tighten the screws for the bushing.

M908020269O07

8. Bottom piece inspection Before cleaning the bottom piece, See Volume I, supplement 70703 Inspect and evaluate the seating according to Volume I.

M908020256O09

8.

Page 10 (25)



908-2.3

Overhaul

9. Bottom piece Measuring 9. In connection with evaluation of the bottom piece according to Volume I, wear or the total amount the seat has been ground, is measured as described below.

G3 D0812

Use the bottom piece template and a feeler gauge, take measurements G2 and G3. All measurements should be taken at four diametrically opposite points on the circumference of the bottom piece seating. For maximum wear or grinding, see Data D0811 and D0812.

D0809

IF the template rests on the lower surface in the groove, i.e. G2 = 0, THEN Further grinding or reconditioning is not recommended. 10. Bottom piece sealing face If necessary grind the outside seating. Use carborundum 200 and the special grinding tool. Turn the special grinding tool by hand, turning alternately clockwise and anticlockwise. Grind until a smooth surface is achieved.

M908020255O14

If the seat or the recess G3 is ground, see Data D08 – 09 for correct grinding angle.

G2 D0811

10.

M908020255O15

Clean the bottom piece.


Page 11 (25)

908-2.3


MAN B&W Diesel

11. Bottom piece sealing rings 11. Make sure that the groove for the O-rings are clean. Mount the new O-rings on the bottom piece. 12. Bottom piece mounting Use the oil cylinder as a lifting tool for the exhaust valve housing. M908020269O11

Check the face on the valve housing is clean. If fitted, check that the guide pin in the bottom piece enters the hole in the bottom of the exhaust valve housing.

12. Land the exhaust valve housing on the bottom piece. Mount and tighten the retaining screws for the bottom piece.

M908020269O12

D0826 + D0825

Page 12 (25)



908-2.3

Overhaul

13. Spindle inspection 13. Before cleaning the spindle, See Volume I, supplement 70703 Inspect and evaluate the spindle according to Volume I.

In connection with evaluation of the spindle according to Volume I, burnoff and wear or the total amount the seat has been ground, are measured as described below. The burnoff F1 of the valve spindle is checked by measuring along the spindle template from point A to point D and in point E.

M908020256O14

14. Spindle burnoff and grinding check

14. For the maximum allowable burnoff, see Data D0813.

G1

The maximum seat grinding, gap G1 is measured between the spindle template, and the seating of the spindle with a feeler gauge.

D0814

For maximum seat grinding, see data D08 – 14. M908020256O15

If necessary to grind the seat, see Data D0810 for correct grinding angle.

F1 D0810 A D0813


D

E

Page 13 (25)

Exhaust Valve

908-2.3

Overhaul

MAN B&W Diesel

15. Spindle stem check 15. In connection with evaluation of the spindle according to Volume I, the spindle stem wear is measured as described below.

D0816 D0815 D0817

Check the spindle stem for wear in the area D0815 to D0816 measured from the top of the spindle. For minimum stem diameter, see data D08 17. If the exhaust valve spindle needs reconditioning, contact MAN B&W Diesel for advice. 16. Spindle transport

M908020252O19

When lifting or transporting the exhaust valve spindle, use the special valve spindle lifting tool.

16.

M908020255O16

D0828

Page 14 (25)



908-2.3

Overhaul

17. Spindle bushing sealingrings 17. Check the top of the spindle bushing and the face on the housing is clean. Fit new orings on the spindle bushing as shown in the sketch. 18. Spindle mounting

Use the oil cylinder as a lifting tool for the exhaust valve housing. Carefully land the exhaust valve housing with the bottom piece on the exhaust valve spindle.

M908020269O17

Lubricate the inside of the bushing in the spindle guide with plenty of lubricating oil.

18.

M908020256O19

Remove the oil cylinder.


Page 15 (25)

Exhaust Valve

908-2.3

Overhaul

MAN B&W Diesel

19. Air cylinder 19. Clean the air cylinder. Dismount the safety valve from the air cylinder, use the machined faces to unscrew the valve. Unscrew and clean the Banjo coupling for sealing oil to the spindle stem bushing. Blow through all bores in the air cylinder. Check the nonreturn valve in the Banjo coupling with compressed air. Clean the bottom of the air cylinder for possible coke. Remount the Banjo coupling. Mount a new Oring in the groove on the outside of the air cylinder.

Compressed Air

20. Safety valve

M908020256O20

Place the safety valve in the pressure testing device. Connect the testing device with the high pressure pump by means of a hose. Check the opening pressure, see Data. If the opening pressure is not correct, loosen the lock nut and, using a screwdriver, adjust the safety valve until the correct pressure is indicated. Tighten the lock nut and test the opening pressure once more.

20.

D08-04

Mount a new gasket and a new Oring on the safety valve. Mount the safety valve in the bore near the bottom of the air cylinder. When mounting the safety valve in the air cylinder, use only the machined faces on the valve housing and tighten, see Data.

M908020256O21

Finally, mount the protective cap.

D08-07

Page 16 (25)



908-2.3

Overhaul

21. Air cylinder mounting 21. Lubricate the Orings on the spindle bushing. Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. Some engines are not equipped with the locating pin

Take care not to damage the Orings on the outside of the spindle bushing.

22. Air piston seals Check the teflon guide ring and teflon sealing ring for wear, if it is necessary to replace the sealing rings on the air piston, cut them and remove them.

M908020256O22

Note!

22.

Be careful not to damage the edges of the ring grooves in the piston.

Before mounting, heat the new teflon rings in 100°C hot water for at least five minutes. When mounting the teflon rings, be careful not to damage the running surfaces.

M908020252O32

Note!

After mounting, compress the teflon rings by means of the conical ring from tool panel 908. This is done by pressing the air piston through the conical ring. Mount new Orings in the inside grooves of the air piston.


Page 17 (25)

908-2.3


MAN B&W Diesel

23. Air piston mounting 23. Fit the conical guide ring for the air piston on the air cylinder. Lubricate the guide ring and the running surface of the air cylinder. Lower the air piston over the valve spindle down into the air cylinder. Use a nylon block and a hammer to press the air piston down in the cylinder Remove the conical guide ring from the air cylinder. Mount the non return valve for spring air 24. Locking ring

M908020256O24

Mount the two part conical locking ring and apply compressed air below the air piston to lift the piston. Mount the flange on top of the air piston and, by means of the four screws, tighten the air piston and the flange together. On valve models where the bolts are designed for securing, secure the bolts. See Procedure 9137.

M908020256O25

24.

Page 18 (25)

Compressed Air



908-2.3

Overhaul

25. Oil cylinder 25. Loosen the screws and remove the lifting bracket from the oil cylinder to gain access to the orifice plug. Remove the sealing oil unit. Remove and discard the gasket. Unscrew and clean the orifice plug. Remove and discard the sealing disc. Check and clean the bore for the orifice plug in the top of the oil cylinder.

26. Sealing oil control unit.

26.

M908020255O37

Normally overhaul of the sealing oil unit should not be necessary. Check the unit according to Procedure 908 2.1. Before remounting the unit, carefully clean it on the machined faces. If the unit needs to be overhauled, send it to an authorised MAN B&W repair workshop.

D08-20

M908020256O26

Place the oil cylinder in a horizontal position. Remove the flange and take out the piston. Inspect the inside of the liner in the oil cylinder for scoring. Measure the cylinder diameter. If the diameter of the oil cylinder exceeds Data D0820, either renew the liner or send the complete oil cylinder to an authorised MAN B&W workshop for overhaul, depending on the valve model.


Page 19 (25)

908-2.3


MAN B&W Diesel

27. Oil piston 27. Top

Remove the piston rings from the oil piston and check them for wear. If the thickness of the rings has worn down to the minimum, see Data, discard the rings and mount new ones. Check that the TOP mark on the piston rings faces upwards, when mounting. Check the mesh once more.

M908020257O42

D0821

28. Oil piston damper check Mount the piston on top of the spindle. Connect compressed air supply to the space below the air piston, so as to keep the valve closed, and to keep the air cylinder in close contact with the valve housing.

28.

D0822 D0823

Place the measuring tool on the air cylinder across the piston. Check the mesh of the damper piston by checking the distance from the upper edge of the crossbar to the top of the damper piston. See Data.

M908020256O29

0

If the measurement is outside the value stated in Data, an adjustment must be made by changing the disc in the damper piston

Page 20 (25)



908-2.3

Overhaul

29. Oil piston damper adjustment 29. Place the piston in the special tool. Press out the damper piston and the disc with the centre screw. Inspect the spring and the piston.

Assemble the damper piston with the new disc in the special tool. Place the piston upside down in the tool and press the disc into place in the piston. Check the mesh once more.

M908020256O30

A thicker disk increase the mesh and a thinner disc decrease the mesh.

30. Oil cylinder assembly 30. Mount the piston and the flange in the oil cylinder. Tighten and lock the screws. Return the oil cylinder to an upright position. Mount a new sealing disc in the bore for the orifice plug. Screw the orifice plug into the bore. Place a new gasket on top of the oil cylinder. Mount the sealing oil unit. Mount the lifting bracket on the oil cylinder. Mount the screws and tighten to the torque stated in Data.

M908020256O31

D08-05


Page 21 (25)

Exhaust Valve

908-2.3

Overhaul

MAN B&W Diesel

31. Oil cylinder mounting 31.

D0806

Mount the overhauled oil cylinder on top of the air cylinder. Mount the safety strap and tighten the nuts. See Data.

M908020256O32

Mount the sealing oil pipe

Page 22 (25)


Exhaust Valve MAN B&W Diesel 1.

908-2.4

Mounting

Checks before mounting 1. Before mounting an overhauled exhaust valve in the engine, it is recommended that the valve is checked and prepared as follows:

D0824

Connect compressed air to the air cylinder to close the valve. Lift up the valve with the engine room crane. Check that a 1.0 mm feeler gauge can be inserted about 15 mm into gap G3, to ensure that there is a clearance between the outer parts of the seating faces of valve housing and spindle. Carry out the drop down test as described in procedure 9082.1.

2. Exhaust valve landing Close the valve with compressed air.

M908020256M01

Check the valve is fitted with new sealingrings in the grooves on the bottom piece.

G3

2.

Lubricate the sealing rings with vaseline and the threads of the studs with antiseizure paste. Position the valve in the cylinder cover bore, guiding it in accordance with the exhaust flanges and the guide pin on the exhaust side of the exhaust valve.

Compressed Air

Copper Grease

M908020256M02

Vaseline


Page 23 (25)

908-2.4

Exhaust Valve Mounting

MAN B&W Diesel

3. Mounting of hydraulic nuts. 3.

D1301

Mount and tighten the hydraulic nuts, see Data. See Procedure 9131. Mount the protective caps on the exhaust valve studs. 4. Mount the pipe connections

M908020256M03

Connect the intermediate pipe to the exhaust valve.

4.

Mount and tighten the screws to the exhaust valve housing. Mount the insulation and plate jacket for the intermediate pipe. Mount the cooling water connections for the exhaust valve and the air pipe for the air spring. 5. Mount the oil pipe connections

M908020256M04

Mount the highpressure pipe for the hydraulic valve actuation. See Procedure 9081.2 Mount the return oil pipe to the exhaust valve. Check that all pipe connections are properly tightened.

M908020256M05

5.

Page 24 (25)



908-2.4

Mounting

6. Open cooling water supply 6. Check that all water connections are mounted and tightened. Open the cooling water inlet supply, and vent the exhaust valve, open the cooling water outlet valve Open the air supply to the exhaust valve. Check the tightness of the sealing ring between the bottom piece and the exhaust valve housing. See Procedure 9082.1. 7.

Air spring check

If the lubricating oil pumps have been started before the exhaust valve pneumatic springs are pressurize: Engage the indicators on top of the exhaust valves and wait until the exhaust valves are closed.

M908020256M06

The air supply to the exhaust valve must always be connected and pressurized before turning on the oil supply to the exhaust valve actuator.

7.

M908020256M07

Closing of the exhaust valves are eased if the lubrication oil pumps are stopped and the actuators are drained at the drain screws.

Closed Valve


Open Valve

Page 25 (25)

Exhaust Valve Actuator MAN B&W Diesel

108-3

Data


X


Data Ref.

Description

D08-20

Oil cylinder max. inside diameter

D08-21

Piston rings, min. thickness

D08-32

Hydraulic actuator, tightening torque

D08-33

Locking plate, tightening torque

D08-34

Hydraulic actuator, tightening angle

D08-35

Hydraulic actuator


Value

Unit

112.2

mm

4.2

mm

1450

Nm

50

Nm

100/27 240

Nm/° kg

Page 1 (2)

Exhaust Valve Actuator

108-3

MAN B&W Diesel

Data


Plate P90851

Page 2 (2)

Item No. 041

Description Tightening template, actuator



908-3.1

Checking Exhaust Valve Actuator L60MC-C 0227 Checking 908-3.1

1.

1. The non-return valve A is built into the oil inlet pipe to the actuator. To check the valve, dismantle and clean it and connect a supply of working air (7 bar) to the outlet side of the valve (the side facing the actuator). If the air flow can be felt at the inlet side of the valve, the valve must be overhauled. 2. Leakages in the exhaust valve can be measured – during running of the engine – by collecting the oil from the drain pipe C leading from the exhaust valve to the hydraulic actuator. Leakages may also be caused by leaky non-return valves and loose pressure pipe connections. If the pipe connections are tight and the leak oil amount from the exhaust valve is normal, any abnormally large leakages must originate from the hydraulic actuator from which leak oil quantities cannot be directly registered.

HM908-3.0 70 1/3

The hydraulic actuator is then to be dismantled for checking of the parts. See Procedure 908-3.2


Page 1 (4)


908-3.2

Dismantling Dismantling 908-3.2

1.

1. Stop the engine and shut off the oil supply. Turn the camshaft so that the roller rests on the circular part of the cam. Remove the inspection cover of the roller guide housing to check the position of the exhaust cam. Dismount the inlet pipe and the drain pipe from the exhaust valve.

GM908-3.0 78 01

Dismount the high-pressure pipe. See Procedure 908-1.2. 2. Release the mountings for the indicator drive from the actuator housing. Fit eye screws in the lifting holes of the actuator housing and hook on a tackle.

2.

D08-35 Unscrew the nuts on the two short studs, then loosen the nuts on the long studs successively until the roller guide spring is relieved. Dismount the nuts and lift the housing carefully, leaving the piston on top of the roller guide.

HG908-3.3 201 02

Remove the spring. 3. Remove the locking plate for the piston. Turn the piston 90° to release it from the bayonet joint. 3.

Remove the piston from the roller guide.

HM908-3.0 70 03

4. Overhaul the actuator housing and the piston as required. See Procedure 908-3.3.

Page 2 (4)



908-3.3


1.

1. Clean the piston in kerosene and wipe dry with a clean piece of cloth.

D08-21

Take off the piston rings and check them for wear. If the ring thickness has worn down to the minimum (see Data), discard the rings and mount new ones. Check that the TOP mark on the piston rings faces upwards when mounting. 2. Inspect the sliding surfaces of the piston to ensure that there are no scratch marks or seizure marks. 3. Clean the oil cylinder and inspect the bores for deposits.

If the bore is seized or worn down to the measurement stated in Data, send the oil cylinder to an MAN B&W authorised workshop for reconditioning.

HM908-3.0 69 04

Check the bore of the oil cylinder for possible scores and measure it for wear.

3.

JM908-3.0 73 05

D08-20


Page 3 (4)

908-3.4

Exhaust Valve Actuator Mounting Mounting 908-3.4

1.

D08-33

1. Mount the actuator piston in the roller guide and turn 90° to lock it in the bayonet joint. Mount the locking plate and tighten as stated in Data. Lubricate the piston with plenty of camshaft lubricating oil. 2. Mount the spring on the roller guide. Carefully lower the actuator housing on to the piston, taking care not to damage the piston rings.

KC908-3.0 76 05

Mount the washers and nuts on the two long studs and tighten alternately until the actuator housing rests firmly against the roller guide housing. Mount the washers and nuts on the two short studs. Tighten all four nuts as stated in Data.

2.

Note! Use only the tightening angle OR the tightening torque, NOT both.

D08-32 or

3. Mount the oil inlet pipe and the drain pipe from the exhaust valve.

D08-34 HG908-3.4 201 02

Mount the hydraulic high pressure pipe. See Procedure 908-1.4.

HG908-3.4 201 03

3.

Page 4 (4)


Exhaust Valve Roller Guide MAN B&W Diesel

108-4

Data


X


Data Ref.

Description

Value

Unit

D08-36

Bushing/shaft pin, max. clearance

0.5

mm

D08-38

Roller guide complete

110

kg


Page 1 (2)

Exhaust Valve Roller Guide

108-4

MAN B&W Diesel

Data


Plate P90851

Page 2 (2)

Item No. 053

Description Lifting tool for roller guide


Exhaust Valve Roller Guide MAN B&W Diesel 1.

908-4.1

Checking

The exhaust valve roller guide can be partially checked while mounted on the engine, using the following procedure: Lift the roller guide. See Procedure 908-7.

2.

2. Remove the camshaft inspection cover. Turn the engine to provide the maximum space between the roller guide and the cam disc. 3. Check the movability of the roller by turning this by hand to ascertain if the roller moves freely and without unnecessary resistance or “hard” points.

4. Check the roller guide and the bearing clearance if the roller guide is dismounted. For dismantling of the roller guide see Procedure 908-4.2. 5. To measure the clearance in the roller guide slide bearing, place the roller guide vertically upside down on a couple of planks with the roller hanging freely.

M908040222C01

Inspect the surface of the roller for possible damage marks, seizures or scratches. Make sure that no traces of bearing metal exist in the roller guide housing.

5.

D0836

6. Place a dial gauge against the roller. Then lift the roller as much as the clearance permits, which makes it possible to read the clearance directly on the dial. See Data. 7.

It is recommended that the roller guide should ONLY be dismantled if: • irregularities when turning the roller, • damage to the roller, • suspect to larger clearance than stated on the Data sheet, • seizure marks on the slide surfaces,

Note! For disassembling of the roller guide, contact an MAN B&W authorized repair shop.

M908040222C02

have been observed during the checking of the roller guide.


Page 1 (3)

908-4 .2

Exhaust Valve Roller Guide Dismantling 1.

1.

MAN B&W Diesel

Dismantle the hydraulic actuator above the exhaust valve roller guide. See Procedure 908-3.2.

2. Mount the roller guide lifting tool as follows: • Lift the lock ring of the tool up on the shaft of the tool. • Place the tool in such a manner that its foot rests on the thrust piece in the bayonet joint of the roller guide. • Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint. • Lower the lock ring, thereby securing the foot in the locked position.

M908040222D01

Lift the roller guide out of the roller guide housing, using the crane. Take care not to damage the sliding surfaces of the roller guide when lifting.

2.

D0838

M908040222D02

90O

Page 2 (3)


Exhaust Valve Roller Guide MAN B&W Diesel 1.

90?-?.4

Mounting

Mount the lifting tool for the roller guide as follows:

1.

• Lift the lock ring of the tool up on the shaft of the tool.

D0838

• Place the tool in such a manner that its foot rests on the thrust piece in the bayonet joint of the roller guide. • Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint.

90O

• Lower the lock ring, thereby securing the foot in the locked position. Clean and lubricate the sliding surfaces of the roller and the roller guide and lower it carefully into the roller guide bushing.

2. Turn the camshaft so that the roller guide is lifted approx. 20 mm. Check that the clearance between the roller guide and the guide plate is the same at both sides ±0.1 mm.

M908040222D02

Remove the lifting tool.

2.

M908040222M02

3. Mount the actuator. See Procedure 908-3.4.


Page 3 (3)

Exhaust Valve Cam MAN B&W Diesel

108-5

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X X X X X X X X

X


Data Ref. D08-39

Description Check lifting height


Value

Unit 16

mm

Page 1 (2)

Exhaust Valve Cam

108-5

MAN B&W Diesel

Data


Plate

Item No.

P90661

Description Impact spanner for turning cam

P90851

173

Lifting tool for exhaust valve roller guide

P91351

010


P91351

034


P91351

058


P91351

154

Conical valve, 0 - 15

P91351

225

Disc, round-plain, Cu ø11x3 mm

P91366

073


Page 2 (2)


Exhaust Valve Cam MAN B&W Diesel 1.

908-5.1

Checking

Turn the crank throw of the cylinder concerned in AHEAD direction until TDC. Check and write down the angle indicated on the turning wheel.

1.

2. Remove the high pressure pipe, see procedure 9081.2

Mount a dial gauge (measuring range 0.00 20.00 mm) on the lifting tool for the exhaust valve roller guide. Reset the scale and the pointer. Press the dial gauge against the face of the actuator housing until the reading D0839 + 1.00 mm is obtained.

M90805-0219C01

Mount and tighten the lifting tool for the exhaust valve roller guide to the actuator piston (remove the screws for tightening to the actuator housing and do not lift the roller guide).

2.

Continue turning AHEAD until the roller guide again is lifted to D0839, and the dial gauge gives the reading 1.00 mm. Calculate the angle B, which is the number of degrees the crank throw has turned from TDC position to the present position.

M90805-0219C02

3. Turn the roller guide in AHEAD direction until lifted to D0839, and the dial gauge gives the reading 1.00 mm and calculate the angle A, which is the number of degrees the crank throw has turned from TDC position to the present position.

Note! When calculating the angles A and B, remember to take into account that the scale on the turning wheel shifts from 360 to 0 (zero) degrees.


Page 1 (4)

908-5.1

Exhaust Valve Cam Checking

MAN B&W Diesel

4. Calculate the lead angle as: 180° – (A° + B°)/2

4.

The lead angle is normally a negative figure. The illustration shows the position of the exhaust cam when the piston of the relevant cylinder is in TDC.

M90805-0219C04

D08-39

5.

The position of the cam must be correct within a tolerance of +/0.5°. See the Adjustment Sheet in Volume I, OPERATION, Chapter 701, for the “lead angle” of the plant in question.

D08-39

5. The cam lead angle can be checked visually by reading directly the scale position of the exhaust cam over the marking scratch on the camshaft and comparing this angle with the angle stated in the Adjustment Sheet.

M90805-0219C05

At the same time, it is recommended to check the position of the camshaft with the pin gauge. See Procedure 9063.1

Page 2 (4)


Exhaust Valve Cam MAN B&W Diesel

Adjustment

Normally, adjustment of the exhaust cams should not be necessary. Before adjustment of any cams, see Volume I, Chapter 706. 1.

908-5.3

1.

Remove the oil tray from the camshaft housing. See Procedure 906-4.2.

3. Turn the camshaft until there is access to the oil duct in the exhaust cam through the inspection hole. If fitted, remove the plugs from the oil duct (using, for instance, a screwdriver). Insert three copper gaskets in each oil duct.

M90805-0219O01

2. Dismount the exhaust valve highpressure pipe, see Procedure 9081.2.

3.

Mount snapon couplings in the oil duct, but do not tighten them.

4. Mount the special spanner on the exhaust cam disc, ensuring that the two pins enter the holes in the cam. Apply a light pressure to the hydraulic system and, after venting the system, tighten the snapon couplings. Raise the hydraulic pressure until oil seeps out along the camshaft under the cam disc.

M90805-0219O03

Fit hoses between the snapon couplings and the distributor block and between the distributor block and the hydraulic high pressure pump.

4.

Keep the cam pressurised for at least two to five minutes before turning the cam. Oil must sweep out with the pump running during the operation.

M90805-0219O04

Keep the cam pressurised during turning.


Page 3 (4)

908-5.3

Exhaust Valve Cam Adjustment

5.

MAN B&W Diesel

5. Turn the cam disc, using the fitted spanner, until the desired change of lead is obtained. Check the change on the cam scale To increase the lead angle and reduce the compression pressure: – turn the cam disc ASTERN. To reduce lead angle and increase the compression pressure: – turn the cam disc AHEAD. 6. After completing the desired turning of the cam disc, relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. Wait at least 15 minutes – the cam must be allowed time to “settle” – before mounting the plugs again in the oil ducts of the cam disc.

M90805-0219C05

After carrying out adjustment, measure the exhaust cam lead again. See Procedure 9085.1. Write down and file the new results for the purpose of comparing with future measurements and adjustment. 7.

Mount the oil tray on the camshaft housing. See Procedure 906-4.4.

8. Mount the high pressure pipe for the exhaust valve. See Procedure 9081.4 9. After any adjustment of the cam position, pcomp must be recorded and compared with pcomp at a known engine reference load.

Page 4 (4)


108-7

Exhaust Valve Special Running Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X


X


X


Data Ref.

Description


Value

Unit

Page 1 (2)

108-7

Exhaust Valve Special Running Data


Item No.

Description

P90851

124

Tool for emergency open exhaust valve

P90851

173

Lifting tool for exhaust valve roller guide

Page 2 (2)


Exhaust Valve

908-7

Special Running 0228 Exhaust Valve

S80MC

Special Running 908-7

3. Warning!

Engine trouble might require that a cylinder be taken out of action. The engine can continue operation with the fuel and exhaust systems of a single cylinder disconnected. See Volume I, Section 704. This can take place with the exhaust valve locked in either the open or the closed position. Either way, carry out the following procedure:

KM908-7.0 223 03

Disengagement or re-engagement of the fuel pump roller guide or the exhaust valve roller guide must only take place at engine standstill.

4.

1. Stop the engine. Stop the lubricating oil pump. Lift the relevant fuel pump roller guide. See Procedure 909-10.1.

3. Dismantle the non-return valve on the oil inlet pipe. Loosen the union nut in the bottom of the oil pipe and turn the pipe to one side. Mount the non-return valve on the oil pipe and blank off the non-return valve with the plug from tool panel 908.

HG908-4.1 201 01

2. Dismantle the hydraulic high-pressure pipe and the connecting sleeve. See Procedure 908-1.2.

5. 4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC. 5. Position the lifting tool on the actuator and screw the spindle into the top of the actuator piston.

Tighten the upper nut of the tool against the lower nut to secure the roller guide in this position.

JM908-5.0 55 03

Tighten the lowermost nut on the tool to pull up the roller guide as far as possible.


Page 1 (3)

908-7

Exhaust Valve Special Running

7.

6. If the cylinder is to operate with the exhaust valve closed, the air supply must remain connected to the air cylinder of the exhaust valve. No further action is required. If the cylinder is to operate with the exhaust valve open, continue the procedure as follows: 7. Shut off the compressed air supply and remove the air pipe connection to the exhaust valve and plug the pipe. Release the air from the air spring through the non-return valve on the side of the air cylinder. Hint!

KM908-2.1 236 05

Use a small screwdriver to press the ball into the non-return valve, and cover it with a rag to catch the oil drops. 8. Dismantle the rotation indicator on the air cylinder and mount the tool for opening of the exhaust valve. The tool will keep the piston of the air cylinder in the bottom position and thus keep the exhaust valve open.

KM908-7 228 08

8.

Page 2 (3)


Exhaust Valve

908-7

Special Running 9.

After overhaul of the cylinder unit, re-engage the exhaust valve gear as follows: 9. Loosen the nuts of the lifting tool to lower the roller guide on to the exhaust cam. Remove the tool. 10. If the engine has been running with the exhaust valve open, remove the tool mounted in the air cylinder and mount the rotation indicator. Note!

Leaving the rotation indicator in the engaged position continuously might damage the exhaust valve due to the formation of a wear groove in the air piston of the exhaust valve. Re-connect the air supply to the air cylinder.

JM908-5.0 55 06

The rotation indicator should only be left in the engaged position for short periods of time during operation of the engine.

11. 11. Remove the plug from the non-return valve and re-connect the oil inlet pipe and the connecting sleeve on the actuator housing, after fitting new sealing rings on the connecting sleeve. 12. Mount the hydraulic high-pressure pipe. See Procedure 908-1.4.

KM908-7.0 223 11

13. Engage the fuel pump roller guide. See Procedure 909-10.1.


Page 3 (3)

Exhaust Valve Panel

Plate P90851-0177

Exhaust Valve Panel 0177 P90851


Page 1 (2)

Plate P90851-0177 Item No. 016 028 041 053 065 077 089 090 112 124 136 148 150 161 173 185

Exhaust Valve Panel

Item Description

Item No.

Item Description

Tool panel Name plate Tightening template, actuator Lifting tool, roller guide Lifting tool for exhaust valve Cone ring, pneumatic piston Test equipment, exhaust valve Cauge exhaust valve spindle Grinding tool - h.p. pipe Tool, emergency open exhaust valve Bridge gauge, exhaust valve Tool for hydraulic piston Gauge exhaust valve bottom piece Lifting tool for exhaust valve Lifting tool - roller guide - exhaust valve Grinding ring - exhaust valve bottom piece

Page 2 (2)



Plate P90861-0022

Exhaust Valve - Tools 0022 P90861


Page 1 (2)



Item Description

Item No.

Item Description

Grinding machine, complete

Notes:

Page 2 (2)

When ordering spare parts, please refer to the Chris Marine manual When referring to this page, please quote Plate P90861 Edition 0022 MAN B&W Diesel A/S

Exhaust Valve Hydraulic - Tools

Plate P90862-0036

Exhaust Valve Hydraulic - Tools 0036 P90862


Page 1 (2)

Plate P90862-0036 Item No. 016 028 041 053 065 077 089

Exhaust Valve Hydraulic - Tools

Item Description

Item No.

Item Description

O-ring with back-up ring O-ring with back-up ring Hydraulic Jack Support Stud setter Hydraulic tool for exhaust valve, complete Tommy bar

Page 2 (2)


Exhaust Valve - Extra Tools

Plate P90863-0015


Page 1 (2)

Exhaust Valve - Extra Tools 0015 P90863

MAN B&W Diesel A/S


Exhaust Valve - Extra Tools

Item Description

Item No.

Item Description

Worktable

Page 2 (2)


Exhaust Valve - Extractor Tool


Plate P90864-0003

Page 1 (2)


Page 2 (2)

Exhaust Valve - Extractor Tool

Item Description

Item No.

Item Description

Extractor tool, complete


909 - Fuel Oil System Documents in this Chapter 109-01 909-01 109-02 909-02 109-03 909-03 109-04 909-04 109-05 909-05 109-06 909-06 109-07 909-07 109-08 909-08 109-09 909-09 10910 90910 10911 90911 10912 90912 10913 90913 10914 90914 10915 90915

0061 0241 0005 0206 0050 0234 0061 0224 0065 0234 0052 0220 0040 0214 0054 0217 0034 0216 0016 0218 0065 0249 0048 0228 0033 0206 0080 0255 0062 0236

Fuel Pump Settings, Data Fuel Pump Settings VIT System, Data VIT System Fuel Pump Cam, Data Fuel Pump Cam Fuel Pump, Data Fuel Pump Fuel Pump Top Cover, Data Fuel Pump Top Cover Fuel Pump Barrel Assembly, Data Fuel Pump Barrel Assembly Fuel Pump Suction Valve, Data Fuel Pump Suction Valve Fuel Pump Puncture Valve, Data Fuel Pump Puncture Valve Fuel Pump Shock Absorber, Data Fuel System Shock Absorber Lifting Gear Roller Guide, Data Lifting Gear for Roller Guide Fuel Valve, Data Fuel Valve Spindle Guide, Data Spindle Guide Non-Return Valve in Fuel Valve, Data Non-Return Valve in Fuel Valve Fuel Oil High-Pressure Pipes, Data Fuel Oil High-Pressure Pipes Fuel Pump Roller Guide, Data Fuel Pump Roller Guide

MAN B&W Diesel A/S

90951 90961 90966 90967 90968 90974 90977 90979 90980

0446 0069 0008 0001 0001 0001 0001 0001 0001

Fuel Valve and Fuel Pump - Panel Fuel Valve - Tools Fuel Valve Nozzle - Tools Fuel Puncture Valve - Tools Fuel Valve - Inspection Tools Fuel Valve Nozzle - Cleaning Tools Mounting Tools - Pump Barrel Seals Mounting Tools - Suction Valve Seals Mounting Tools - Air Piston Seals

MAN B&W Diesel A/S

109-1

Fuel Pump Settings Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X


X

Engage turning gear Shut off cooling water

X

Shut off fuel oil

X


Data Ref.

D09-02

Description

Value

Unit

2.0 - 3.0

bar

Change of one index mark, corresponds to p-max being altered approx.


Page 1 (2)

109-1

Fuel Pump Settings Data


Page 2 (2)

Item No.

Description


Fuel Pump Settings

909-1.3

Adjustment Fuel Pump Settings K98MC-C 0241 Adjustment 909-1.3

1.

Before adjustment of the fuel pump is carried out, see Volume I, Chapter 706, also the fuel cam lead should be checked, see Procedure 909-3.1. pmax adjustment:

2. Loosen lock nut B and then turn adjusting screw H. The link can be adjusted by approx. 3 index marks.

HN909-1.3 240 01

1. The Maximum Combustion Pressure (pmax) is adjusted for the individual units at the fuel pump VIT index arm. For collective adjustments of pmax on all units, see Procedure 909-2.

3. To increase p max, adjust to higher VIT index (advance injection).

2.

To decrease p max, adjust to lower VIT index (delay injection). One index mark will alter pmax approximately as given in Data D09-02. Note!

4. If the required p max adjustment cannot be attained by adjustment on the VIT index arm, it is possible to carry out the adjustment on the fuel cam disc. Contact MAN B&W Diesel for advice.

HN909-1.3 240 02

The individual p max value must not deviate more than 3 bar from the average value for all cylinders.


Page 1 (2)

909-1.3

Fuel Pump Settings Adjustment

5.

MIP adjustment: 5. The Mean Indicated Pressure (pi) for a certain cylinder is adjusted on the fuel pump index arm. Increase index for higher p i. Decrease index for lower p i.

HN909-1.3 240 05

Note!

6.

The mean indicated pressure is one of the most important parameters in obtaining good engine performance. The mean indicated pressure should not deviate more than 0.5 bar from the average value for all cylinders. See Volume I, Chapter 706.

M90901-0242O06

6. After adjustment of the fuel pumps a set of observations must be taken, to evaluate the adjustments see Volume I.

Page 2 (2)


109-2

VIT System Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X

Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description


Value

Unit

Page 1 (2)

109-2

VIT System Data


Page 2 (2)

Item No.

Description


VIT System

909-2.3

Adjustment VIT System K98MC-C 0206 Adjustment 909-2.3

1.

Before adjustment of any part of the VIT system, see Volume I, Chapter 706. All adjustments should be based on a set of observations including a set of indicator diagrams taken when the engine is running just above the breakpoint (90% MCR).

If the fuel quality has changed or if the fuel pumps are worn, the pmax will change, this change can be corrected by adjusting the pmax of all the cylinders with the VIT system, see “Fine adjustment”.

M90902-0206O01

The engine may be equipped with either a mechanical or an electronic VIT (Variable Injection Timing) system.

Normally the VIT system is adjusted to start at 40% engine load and to have break point at 90% of MCR engine output. Look in the test sheet for actual start- and break point.

2.

Mechanical VIT system Basic adjustment: When the basic adjustment is carried out the engine must be stopped, normally only fine adjustment is necessary. 1. Engage the manual engine control, and adjust the regulating shaft to a fuel pump index corresponding to 90% engine load. (The fuel index must correspond to 90% load taken by measurement or from the test bed sheet).

M90902-0206O02

2. Check that the VIT lever is resting on both rollers (break point for all cylinders).


Page 1 (5)

VIT System

909-2.3

Adjustment 3.

3. If necessary, adjust the lever by loosening the nut A and turn the clamping arm B, until lever contact with both rollers and tighten nut A.

C

4. Spare pilot valves should be pre-adjusted to 0.5-5.0 bar control air pressure, corresponding to 0.5-8.0 mm pressing-in of pin C.

M90602-0238O03

B A

4.

Adjust the VIT air pressure to 3.0 bar, by axial displacement of the bracket with the pilot valve and read the pressure on the pressure gauge C. See figure 2.

To check a pilot valve already mounted on the engine, remove the inlet and outlet pipe connections at A and P, and connect a pressure gauge at A and a pipe with working air (pressure 7 bar) at P on the pilot valve.

Pbar

5 4 3 2 1.5 0.5 1 0.1

Pressing in mm 0 1 2 3 4 5 6 7 8 0.5

C

Check that the pressure on the pressure gauge and the pressing-in of pin C is in accordance with the curve. Any necessary adjustment is done by turning adjusting screw B.

A

M90902-0206O04

B

Page 2 (5)

P


VIT System

909-2.3

Adjustment 5.

Fine adjustment: 5. When the fine adjustment is carried out, the engine must run at 90% load or just above. Take a new set of indicator diagrams and calculate the engine load. Adjust the VIT air pressure to obtain cylinder p max of 140 bar. The VIT air pressure must be maximum 5.0 bar. Increase the pmax pressure by moving the pilot valve toward the lever. Decrease the p max pressure by moving the pilot valve away from the lever.

6. Run the engine at maximum load and check that p max is 140 bar.

6.

M90902-0206O06

If the maximum combustion pressure deviates more than 3.0 bar from 140 bar, adjust the pressure by replacement of the lowermost roller.

M90902-0206O05

For adjustment of pmax on a single cylinder, see procedure 909-1.


Page 3 (5)

VIT System

909-2.3

Adjustment Pmax adjusted on lowermost roller

7. Pbar

Electronic VIT system

Break point Pmax adjusted on uppermost roller

8. The adjustment should be based on a set of indicator diagrams taken when the engine is running just above the breakpoint.

M90902-0206O07

Pcomp

40

90

100

%Load

9. On the panel in the engine room control room, change the p offset value in accordance with the required increase or decrease in the p max pressure. One graduation mark on the p offset scale corresponds to a change in p max of 1 bar. 10. Check the adjustment by taking a new set of indicator diagrams while the engine is running just above the breakpoint.

M90902-0206O08

8.

7. The uppermost roller is used to adjust the VIT start point (40% engine load).

Page 4 (5)


VIT System

909-2.3

Adjustment 11.

11. The I/P converter mounted on the engine receives a 4-20 mA signal I from the electronic governor system and converts this into a 0.5-5.0 bar control air pressure pcontrol . 12. To check the adjustment of the I/P converter, operate the panel in the engine control room to supply various signals I to the I/P converter. For operation of the panel, see the panel manufacturer’s instructions.

P control

P supply

On the pressure gauge mounted on the control air line after the I/P converter check that the control air pressures from the I/P converter are in accordance with the curve.

5 4 3

M90902-0206O11

13. If the control air pressure is not in accordance with the curve, the I/P converter must be adjusted. Remove the hood of the I/P converter and adjust the I/P converter according to the manufacturer’s instructions.

P control

1.5 0.5 0.1

2 1 I, mA

0 0


4

8

12

16

20

Page 5 (5)

109-3

Fuel Pump Cam Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X


X

Engage turning gear Shut off cooling water

X

Shut off fuel oil

X


Data Ref.

Description


Value

Unit

Page 1 (2)

109-3

Fuel Pump Cam Data


Item No.

Description

P90651

44

Impact spanner for turning cam

P90951

45

Measuring tool for fuel pump

P91351

10


P91351

46


P91351

58


P91351

154

Conical valve, 0 - 15

P91351

201

Quick coupling, male

P91351

225

Disc, round-plain, Cu ø11x3 mm

Page 2 (2)


Fuel Pump Cam MAN B&W Diesel

909-3.1

Checking

Fuel cam lead: 1. The lead C of the fuel cam is defined as the number of mm the plunger is lifted from its bottom position when the main piston is in TDC.

C X2

X1

Roller guide

1. To measure the fuel cam lead (top lift): Dismantle the puncture valve. See Procedure 9098.2.

Turn the engine until the lowest point of the cam is found, use a calliper to find the point. 3. Measure the distance x from the top of the measuring pin to the transverse piece.

M909030233C01

2. Push down the measuring pin through the top cover, until it rests against the pump plunger.

Fuel cam

Ahead

Lowest position of pump plunger

Main piston in TDC

2. X

Note down the result as x2. 4. Turn ahead until the main piston of the cylinder concerned is in TDC.

Calculate the fuel cam lead C (top lift) as: C = x1 – x2 (mm) 5. Note down the result for comparison with the testbed results and for future reference. For adjustment of the fuel cam lead, see Procedure 9093.3.

M909030233C03

Again measure the distance x from the top of the measuring tool to the transverse piece. Note down the result as x1.

3.

M909030233C04

Remount the puncture valve.


Page 1 (4)

Fuel Pump Cam

909-3.2

Adjustment

MAN B&W Diesel

Normally, adjustment of the fuel cam should not be necessary. Before adjustment of fuel equipment, see Volume I, Chapter 706.

1.

1. Remove the inspection cover from the camshaft housing. Note!

M909030233O01

Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off.

2. Dismount the puncture valve from the fuel pump top cover, and mount the measuring tool to check the cam adjustment.

2. X

3. Turn the camshaft until there is access to the oil ducts in the fuel cam through the inspection hole. If fitted, remove the plugs from the oil ducts (using, for instance, a screwdriver). Insert three copper gaskets in each oil duct.

M909030233C03

Mount snapon couplings in the oil ducts, but do not tighten them. Fit hoses between the snapon couplings and the distributor block and between the distributor block and the hydraulic highpressure pump.

M909030233O03

3.

Page 2 (4)


Fuel Pump Cam MAN B&W Diesel

909-3.2

Adjustment

4. Mount the special spanner on the fuel cam disc, ensuring that the two pins enter the holes in the cam.

4.

For better access to the cam, remove the oil tray and carry out the adjustment from the bottom of the cam shaft housing. See Procedure 9064.2

Raise the hydraulic pressure until oil seeps out along the camshaft under the cam disc. Keep the cam pressurised for at least two to five minutes before turning the cam.

M909030233O04

Apply a light pressure to the hydraulic system and, after venting the system, tighten the snapon couplings.

Oil must seep out with the pump running during the operation to keep the cam pressurised during turning. Turn the cam disc, using the fitted spanner, until the desired change of lead is obtained. To increase lead and pmax: – turn the cam disc AHEAD. To reduce lead and pmax: – turn the cam disc ASTERN. See Procedure 9091. 5. After completing the desired turning of the cam disc, relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. Wait at least 15 minutes – the cam must be allowed time to “settle” – before mounting the plugs again in the oil ducts of the cam disc. After carrying out adjustment, measure the fuel cam lead again. Note down and file the new results for purposes of comparison with future measurements and adjustment.


Page 3 (4)

909-3.2

Fuel Pump Cam Adjustment

MAN B&W Diesel

6. Mount the inspection cover on the camshaft housing. 7. Mount the puncture valve. See Procedure 9098.4. 8. After any adjustment of the cam position, pmax must be recorded and compared with pmax at a known engine reference load.

Page 4 (4)


Fuel Pump MAN B&W Diesel

109-4

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X X X X X X X X X


Data Ref.

Description

D09-18

Pump housing nuts, tightening torque

D09-19

Pump housing nuts, tightening angle

D09-20

Pump housing

D09-21 D09-39

Value

Unit

1980 100/50

Nm Nm/°

510

kg

Bottom plate

24

kg

Shock absorber

70

kg


Page 1 (2)

Fuel Pump

109-4

MAN B&W Diesel

Data


Plate P90951

Page 2 (2)

Item No. 070

Description Lifting tool for fuel pump housing


Fuel Pump

909-4.2

Dismantling Fuel Pump K90MC-C 0224 Dismantling 909-4.2

1.

1. Close the fuel oil inlet valve. Open the drain cock, enabling the oil to escape. Note!

2. Dismantle the fuel pump top cover and connected pipes. See Procedure 909-5.2. 3. Dismantle the barrel/plunger assembly. See Procedure 909-6.2.

MA909-1.1 223 03


4.

4. Remove the screws holding the fuel oil inlet pipe between the fuel pump and the fuel inlet valve.

D09-39

Remove the fuel oil inlet pipe. Remove the shock absorber. Remove the fuel oil outlet pipe. Discard the gaskets.

Remove the control air pipes from the actuator for the VIT index arm.

MA909-4.2 214 04

5. Remove the drain pipes from the fuel pump housing.


Page 1 (9)

909-4.2

Fuel Pump Dismantling

6.

6. Loosen the four nuts by means of a slugging spanner. Remove the nuts. 7. Fit the lifting tool using the top cover studs/ nuts, and lift the pump housing away. Take care not to damage the threads of the studs.

MA909-4.2 214 06

Land the fuel pump on wooden planks.

7.

MA909-4.2 214 07

D09-20

Page 2 (9)


Fuel Pump

909-4.3


3.

2. In order to carry out this overhaul, the top cover and plunger/barrel assembly of the fuel pump must have been removed, and the fuel pump must have been dismantled from the pump base and landed on wooden planks. See Procedure 909-4.2. See Procedure 909-5.2. See Procedure 909-6.2. 3. Dismantle the actuator and actuator bracket.

MA909-4.3 214 03

1. If the fuel index arm or the VIT index arm of the fuel pump is moving too tightly, the regulating and timing systems of the fuel pump must be overhauled.

4. Tilt the fuel pump housing into a horizontal position on the wooden planks.

4.

D09-20

5. Dismantle the screws and the bottom plate from the fuel pump housing.

MA909-4.3 214 04

If the bottom plate is stuck, loosen it by screwing two M10x80 mm screws into the holes of the bottom plate.

5.

MA909-4.3 214 05

D09-21


Page 3 (9)

909-4.3

Fuel Pump Overhaul

6.

6. Dismantle the: • Fuel index arm • Regulating guide • Sleeve 7. Dismantle the: • Guide screw

MA909-4.3 214 06

• VIT index arm • Timing guide 8. Remove the caps from the back of the fuel pump housing. 7. Remove the orifice plug from the front side of the fuel pump housing.

MA909-4.3 214 07

Discard all sealing rings and gaskets.

MA909-4.3 214 08

8.

Page 4 (9)


Fuel Pump

909-4.3

Overhaul 9.

9. Dismantle and inspect the plug screws in both sides of the fuel pump housing. If eroded, replace the plug screws. 10. Clean all the dismantled parts of the fuel pump thoroughly in diesel oil or kerosene. Dry all parts carefully. Clean all inside surfaces of the fuel pump housing. Check that all the bores of the fuel pump housing are clean.

Mount the caps and the orifice plug. Mount new sealing rings on the plug screws and mount the plug screws.

MA909-4.3 214 09

11. Mount new sealing rings and gaskets.

11. Note! Lubricate the threads of all the parts with Molybdenum Disulphide (MoS 2) before mounting.

Note!

MA909-4.3 214 11

12. Mount new sealing rings in the sleeves that are provided with a pointer scratch.

Soak the sealing rings in lubricating oil before mounting.

HC909-3.4 121 11

12.


Page 5 (9)

909-4.3

Fuel Pump Overhaul

14.

Mounting 13. Lubricate the following with molybdenum disulphide (MoS 2): • all internal surfaces of the fuel pump housing • the sliding surfaces of all parts of the regulating and timing systems. • the teeth of the:

MA909-4.3 214 14

regulating guide timing guide VIT index arm 15.

fuel index arm. 14. Mount the VIT index arm and the guide screw. Adjust the position of the VIT index arm so that the scratch mark is aligned with the centre of the fuel pump housing. 15. Mount the timing guide in the fuel pump housing.

MA909-4.3 214 15

The timing guide must be mounted in such a way that the scratch marks on the timing guide, on the VIT index arm and on the fuel pump housing are aligned.

MA909-4.3 214 16

16.

16. Mount the sleeve in the fuel pump housing, ensuring that the notch in the side of the sleeve is aligned with the pin hole in the fuel pump housing.

Page 6 (9)


Fuel Pump

909-4.3

Overhaul 17.

17. Mount the fuel index arm. Adjust the position of the fuel index arm so that the scratch mark on the fuel index arm is aligned with the centre of the fuel pump housing. 18. Mount the regulating guide in the fuel pump housing. The regulating guide must be mounted so that the scratch mark on the regulating guide is aligned with the scratch mark on the fuel index arm.

20. Return the fuel pump to a vertical position. Mount the actuator and actuator bracket on the side of the fuel pump.

MA909-4.3 214 17

19. Mount the bottom plate on the fuel pump housing.

MA909-4.3 214 18

18.

MA909-4.3 214 05

19.


Page 7 (9)

Fuel Pump

909-4.4


2.

D09-20

1. Before mounting the fuel pump housing, make sure that all sliding faces and threads are cleaned and lubricated with MOLYKOTE antifriction spray D321R or molybdenum disulphide (MoS 2). See Procedure 913-11. 2. Mount the lifting tool on the fuel pump top cover studs. Lift the fuel pump housing on to the pump base, taking care not to damage the threads of the studs. Remove the lifting tool. 3. Mount the nuts on the studs and tighten to the specified torque or angle, see Data. Note!

MA909.4.2 214 07

Use either the tightening torque or the tightening angle.

3.

MA909-4.2 214 06

D09-18 or D09-19

Page 8 (9)


Fuel Pump

909-4.4

Mounting 5.

4. Mount the drain oil pipes on the fuel pump housing. Connect the control air pipes to the actuator for the VIT index arm.

D09-39

5. Fit new gaskets on the fuel pump inlet pipe. Mount the pipe between the fuel pump housing and the fuel oil inlet and outlet valve. Mount the shock absorber.

7. Mount the top cover on the fuel pump housing. See Procedure 909-5.4. Mount the air pipe for the puncture valve.

MA909-4.2 214 04

6. Mount the barrel assembly in the fuel pump housing. See Procedure 909-6.4.

8.

MA909-1.1 223 09

8. Close the drain cock and open the fuel oil inlet valve.


Page 9 (9)

Fuel Pump Top Cover MAN B&W Diesel

109-5

Data



Data Ref.

Description

Value

Unit

D09-23

Top cover studs, screwing-in torque

400

Nm

D09-24

Top cover nuts, tightening torque

460

Nm

D09-26

Outlet seat, max.grinding diameter

26

mm

D09-27

Top cover


100

kg

Page 1 (2)

Fuel Pump Top Cover

109-5

MAN B&W Diesel

Data


Plate

Item No.

Description

P90951

069

Lifting tool for fuel pump

P90951

094

Milling tool for fuel oil pipe seats

Page 2 (2)


Fuel Pump Top Cover

909-5.1

Checking 1. Shut off the fuel oil inlet.

1.

Open the drain cock (at the bottom of the pump housing), and drain off any oil left in the high-pressure pipe and the fuel pump. Note!

Dismount all drain pipes and the pipe connections to the puncture valve. Dismount the high-pressure pipes between the top cover and the fuel valves. See Procedure 909-14.2.

M909050234D01


2.

Note!

2. Remove the top cover fixing nuts and mount the dismantling screws for top cover in the two threaded holes. Pull the top cover with suction valve and puncture valve (if still mounted) free by tightening the dismantling screws. When the top cover is loose, remove the dismantling screws and mount the lifting tool in the threaded holes instead.

M909050234D02

If the puncture valve is to be overhauled, remove the puncture valve from the top cover at this stage. See Procedure 909-8.2.

3.

D0927

3. Lift the top cover carefully off. For overhaul of top cover, puncture valve and suction valve, see Procedures 909-5.3, 909-7.3, 909-8.3.

M909050234D03

Discard the gasket.


Page 1 (3)

909-5.2

Fuel Pump Top Cover Dismantling 1. If not already done, dismount the protective cap and the puncture valve from the top cover. See Procedure 909-8.2.

1.

2. Mount the top cover in special bracket and dismantle the suction valve and the lock washer from the top cover. See Procedure 909-7.2. 3. Fill the oil ducts of the top cover with vaseline or heavy grease. M909050234O02

Screw the guide, with the miller, into the high-pressure pipe thread. Mill the seat until a smooth surface is achieved. For maximum seat diameter see Data.

2. After completing the milling, use compressed air to blow the vaseline/ grease out from the oil ducts.

D0926

Clean the top cover with diesel oil/gas oil, and blow dry with compressed air. Note!

M9099050234O03

Make sure that all bores and threads inside the top cover are absolutely clean.

4. Mount a new lock washer and a new or overhauled suction valve in the top cover. See Procedure 909-7.4.

M9099050234O04

3.

If necessary, recondition the seats of the fuel oil high-pressure pipes. See Procedure 909-14.3.

Page 2 (3)


909-5.2

Fuel Pump Top Cover Dismantling 1. Make sure that the inside of the fuel pump housing and the top of the fuel pump barrel is completely clean.

1.

D0927

2. Mount a new gasket on top of the pump housing.

Mount the overhauled top cover (with overhauled suction valve and reconditioned seatings for the high-pressure pipes) on the pump housing. Check that the guide pin in the top cover enters the hole in the pump housing. Warning!

M909050234M01

Lubricate all sliding faces, studs and sealing rings with molybdenum disulphide (MoS2). See Procedure 913-11.

3.

D0924

As a safety precaution, and before mounting the top cover nuts, turn the engine one revolution.

3. Mount the top cover fixing nuts, and tighten them diagonally to the torque indicated in Data. For adjustment of the fuel pump, see Procedure 909-1.1. 4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure 909-8.4.

M909050234M03

When doing this, the top cover must not move upwards!

4.

Mount the protective cap over the puncture valve and the two screws in the top cover. Mount the high-pressure pipes and the drain screw in the pump housing.

M909050234M04

Mount the drain pipes on the top cover and the connecting pipe to the puncture valve. Open the fuel oil inlet.


Page 3 (3)

Fuel Pump Barrel Assembly MAN B&W Diesel

109-6

Data



Data Ref.

Description

D09-29

Barrel assembly

D09-30

Plunger


Value

Unit

120

kg

24

kg

Page 1 (2)

Fuel Pump Barrel Assembly

109-6

MAN B&W Diesel

Data


Plate

Item No.

Description

P90951

057

Lifting tool for barrel and plunger

P90951

224

Tool for P. max rack

P90962

Page 2 (2)

Fuel Pump Seals - Mounting Tools



909-6.2

Dismantling Fuel Pump Barrel Assembly K90MC-C 0220 Dismantling 909-6.2

1.

1. Close the fuel oil inlet valve. Open the fuel pump drain cock, enabling the oil to escape. Note!

2. Dismantle the fuel pump top cover. See Procedure 909-5.2. 3. Position the lifting tool for the barrel/plunger assembly (without measuring pin) in such a manner that the two distance tubes of the tool rest on the pump barrel.

MA909-1.1 223 03


2.

Make sure that the two guide pins in the bottom of the lifting tool enter the holes in the top of the plunger. Secure the lifting tool by screwing the two screws into the pump barrel.

Turn the spindle in this position until the two guide pins engage with the two holes in the plunger top.

MA909-3.1 122 03

Loosen the stop ring on the spindle of the tool and press the spindle down against the pump plunger.

Tighten the centre screw of the spindle against the plunger.

NA909-6.2 211 03

3.


Page 1 (10)

909-6.2

Fuel Pump Barrel Assembly Dismantling

4.

4. Remove the pump barrel guide screw from the pump housing. 5. Disconnect the links for the timing drive and the regulating drive. Dismount the union and pointer for the timing drive and the regulating drive. Note the position of the scratch mark on the lever arm. Remove the locking plate and the lever arm.

MA909-3.1 93 05

Mount the extractor tool and connect the timing toothed rack to the pulling rod by means of the pin.

5.

6. Turn the nut at the end of the pulling rod, whereby the timing rack will move outwards. Continue turning the nut until the pin reaches the outer position of the slot in the tool, whereby the thread of the fuel pump barrel goes clear of the timing guide. Keep the toothed rack in this position during the overhaul or replacement of the pump barrel.

MA909-3.1 93 06 AB

There is now a distance between the lifting tool and the pump housing.

MA909-3.1 93 06 C

6.

Page 2 (10)



909-6.2

Dismantling 7.

7. Pull the regulating toothed rack outwards until the plunger foot has been turned clear of the bayonet joint in the roller guide. This can be ascertained by watching the handles on the spindle of the lifting tool. These will be parallel with the fore-and-aft direction of the engine when the plunger has been turned into position. Remove the cover of the pump base to make sure that the plunger is able to go clear of the bayonet joint. Lift the spindle so that the plunger foot goes clear of the bayonet joint.

8. Carefully lift the barrel/plunger assembly out of the pump housing. Dismount the tool.

MA909-6.2 213 07

Move the stop ring of the spindle into contact with the upper flange of the tool, and lock the stop ring in this position by means of the stop screw.

8.

Press the plunger upwards to the bottom of the barrel. Send the barrel/plunger assembly to an MAN B&W authorized workshop for repair, or overhaul it on board as described in Procedure 909-6.3.

MA909-6.2 213 08

D09-29


Page 3 (10)


909-6.3


1.

1. Place the pump barrel/plunger on a piece of plywood. Secure the plunger with a couple of wedges to avoid unwanted movements.

D09-29

Remove and discard the sealing rings from the barrel. 2. Pull the plunger carefully out of the barrel. Carefully clean the plunger (for example in clean kerosene) and dry it with a soft nonfluffy cloth.

MB909-6.3 220 01

Check the plunger for wear or seizure marks. Also inspect the top of the plunger for cavitation marks. 3. Clean the bores in the upper end of the plunger and blow dry with compressed air. Clean the barrel and dry it with a non-fluffy cloth.

2.

D09-30

For evaluation of the plunger/barrel condition see Volume I, Chapter 706. Check the barrel for wear or seizure marks. Note!

MB909-6.3 220 02

The plunger and the barrel are matched parts and cannot be replaced individually.

MA909-3.2 122 03

3.

Page 4 (10)



909-6.3

Overhaul 4.

4. Before mounting new sealing rings on the barrel, heat them to 200–220°C for at least five minutes. Note!

200-220 °C

5. When mounting the new sealing rings on the lower end of the pump barrel, the inner sealing ring must be mounted first. Mount the guide stick in the barrel and position the big cone on the barrel.

NA909-5.3 214 05

Take care not to exceed the temperature limits.

Place the spring-loaded sealing ring on the cone with the spring facing upwards, see the sketch.

5.

Use the pusher tool to push the sealing ring into the groove.

After mounting the sealing rings, compress them by pressing the “sizer” tool over the sealing rings.

MA909-6.3 213 05

6. When mounting the sealing ring in the outer groove, place the spacer tool inside the cone to obtain the correct distance to the groove, and repeat the above procedure.

MA909-6.3 213 06

6.


Page 5 (10)

909-6.3

Fuel Pump Barrel Assembly Overhaul

7.

7. Mount the guide stick and cone on the top end of the barrel and mount the uppermost sealing ring in the same way as above. Make sure that the spring faces downwards, see the sketch. 8. Lubricate the plunger with molybdenum disulphide (MoS 2).

MB909-3.2 95 06

Carefully slide the plunger into the barrel and press it to the bottom. Note! Do not use force as this will damage the sliding surfaces of the plunger or barrel 8.

MB909-6.3 220 08

If the barrel assembly is not to be mounted immediately, all openings must be covered with plastic to prevent dirt from entering the barrel assembly during storage.

Page 6 (10)



909-6.4


1.

1. Place the supplied measuring pin – which is of the same length as the plunger – on the spindle of the lifting tool, and fasten it by tightening the centre screw of the spindle. Loosen the stop ring on the spindle. Place the tool on the pump housing, and press the spindle down until the pointed end of the measuring pin is in contact with the thrust piece of the roller guide. Then press the stop ring down until it reaches the flange of the tool and lock it there by tightening the screw of the stop ring against the spindle.

The engine must not be turned until the mounting of the barrel/plunger assembly has been completed. 2. Dismount the tool from the pump housing and remove the measuring pin from the spindle. Then mount the tool on the barrel/ plunger assembly which is ready for mounting.

MA909-6.4 213 01

The stop ring is to remain tightened in this position until the plunger has been correctly mounted.

2.

Secure the tool to the barrel by tightening the two screws, and attach the plunger to the spindle of the tool by tightening the centre screw of the spindle. The tool is thus fixed on the barrel in such a way that its correct positioning is ensured during mounting. Before mounting the barrel/plunger in the pump housing, lubricate the thread for the timing guide and all sealing rings with molybdenum disulphide.

MA909-6.4 213 02

Using the spindle of the tool, pull the plunger as high up in the barrel as possible, at the same time turning the spindle so as to position the plunger foot correctly in relation to the cutout of the regulating guide.


Page 7 (10)

909-6.4

Fuel Pump Barrel Assembly Mounting

3.

3. Pull the regulating toothed rack as far out as possible and check that the extractor tool is mounted correctly on the timing toothed rack when this is in its outer position. 4. Check that the slot in the barrel coincides with the hole for the guide screw. Lower the barrel assembly carefully into the pump housing.

MA909-6.4 213 03

If necessary, turn the regulating guide a little (using the toothed rack) to make the foot and the regulating block of the plunger fit properly in the cutout of the regulating guide. Lowering the barrel assembly so far down into the pump housing that the sealing rings of the barrel are about to enter the bore in the pump housing.

4.

Then continue pressing down the barrel/ plunger assembly until the barrel assembly rests on top of the timing guide. There will be a gap between the tool and the pump housing.

MA909-6.4 213 04

D09-29

Page 8 (10)



909-6.4

Mounting 5.

5. Loosen the nut on the extractor, disconnect the pulling rod from the timing toothed rack, and remove the extractor. Engaging the thread of the fuel pump barrel with the timing guide is accomplished by pressing-in the toothed rack. (A pressure of about 30 kg may be required). Check that the toothed rack is correctly engaged by pressing-in the rack. When doing this, the pump barrel shall move downwards.

6. After ‘landing’ the barrel assembly, press the plunger down into contact with the thrust piece of the roller guide. Check that the stop disc of the spindle is in full contact with the flange of the tool, as when measuring.

MA909-6.4 213 05

The top flange of the tool is now resting on the top of the pump housing.

6. If necessary, turn the regulating guide a little (using the toothed rack) to make the plunger foot fit properly in the cutout of the roller guide. Inspect the position of the plunger foot through the inspection hole. When the plunger is in place, press the regulating rod in, thereby turning the plunger by means of the regulating guide and causing the plunger foot to “interlock” with the bayonet joint of the roller guide. Check that the plunger is correctly engaged by pulling at the spindle of the lifting tool. When doing this, it must not be possible to lift the spindle.

MA909-6.4 213 06

Mount the inspection hole cover.


Page 9 (10)

909-6.4

Fuel Pump Barrel Assembly Mounting

7.

7. Mount the pointer and union for the timing rack. Mount the links for the timing drive and the regulating drive in place in accordance with the marks.

MA909-6.4 213 07

8. Mount the guide screw for the pump barrel in the pump housing. Remove the centre screw from the plunger, and remove the tool. 8.

9. Mount the fuel pump top cover and the belonging pipes. See Procedure 909-5.4. 10. Close the fuel pump drain cock.

MA909-6.4 213 08

Open the fuel oil inlet valve.

MA909-1.1 223 09

10.

Page 10 (10)


Fuel Pump Suction Valve MAN B&W Diesel

109-7

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X X X X X X

X X


Data Ref.

Description

D09-33

Suction valve, tightening torque

D09-34

Suction valve


Value

Unit

1850 8

Nm kg

Page 1 (2)

Fuel Pump Suction Valve

109-7

MAN B&W Diesel

Data


Plate P90951 P90967

Page 2 (2)

Item No. 130

Description Crowfoot spanner Fuel Puncture Valve - Tools



909-7.1

Checking Fuel Pump Suction Valve S60MC-C 0214 Checking 909-7.1

1.

1. Using a brass mandrel, check that the valve slide can slide freely up and down inside the suction valve. 2. Check the seats for tightness by filling the inlet hole with diesel oil or gas oil, and wait five minutes. No oil may seep through the seats of the slide/housing.

HN909-7.1 207 01

3. If the suction valve is not to be mounted on the engine immediately after the checking, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage.

KB909-3.3 105 08

2.


Page 1 (4)

909-7.2

Fuel Pump Suction Valve Dismantling Dismantling 909-7.2

1.

1.

Note! Before dismantling the top cover, it is recommended to dismantle the fuel pump puncture valve, see Procedure 909-8.2. Dismantle the fuel pump top cover and suction valve assembly from the fuel pump housing. See Procedure 909-5.2.

2. Mount two eye bolts in the bottom of the top cover and turn it upside down. GN909-5.2 204 03

3. Mount the top cover in an upside down position in the top cover bracket mounted on the bulkhead inside the engine room. Tighten the nuts of the bracket to fix the top cover. 2. Release the suction valve lock washer. Dismount the suction valve from the top cover.

GN909-5.3 204 02

Remove and discard the lock washer.

KN909-7.2 213 03

3.

Page 2 (4)



909-7.3


1.

1. Set up the suction valve in a bench vice with “soft” jaws and, using a brass mandrel and a hammer, release the spring guide from the valve thrust piece. Disassemble the other parts of the suction valve and clean the parts thoroughly in clean diesel oil.

2. Inspect the seat of the valve slide and the seat in the thrust piece for damage. If the seats are damaged, both the suction valve and the valve slide must be discarded. Lapping of the seats must not be attempted.

KB909-3.3 105 05

Remove and discard the sealing ring from the valve thrust piece.

3. Mount the O-ring in the groove of the sealing ring and position the cone on the thrust piece.

2.

Note! Make sure that the sealing ring is mounted correctly. See the sketch.

KB909-3.3 105 06

Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on to the groove.

After mounting the sealing ring, compress it by pressing the “sizer” tool over the sealing ring.

3.

4. Clean and overhaul all internal parts, and lubricate them with molybdenum disulphide (MoS 2). 5. Re-assemble the suction valve.

XZ909-7.3 204 03

6. Check the suction valve after the overhaul. See Procedure 909-7.1.


Page 3 (4)


909-7.4


1.

D09-33

1. Mount the top cover in an upside down position in the top cover bracket mounted on the bulkhead inside the engine room. Tighten the nuts of the bracket to fix the top cover. Lubricate the thread of the suction valve with copper grease. Make sure that the bore for the suction valve in the top cover is absolutely clean. Fit a new lock washer and mount a new or overhauled suction valve in the top cover. Fit the two screws which secure the lock washer. Tighten the suction valve with a torque spanner. See Data.

KN909-7.4 213 01

Lock the suction valve in position by bending up an edge of the lock washer over one of the flats of the valve.

GN909-5.2 204 03

2.

2. Remove the top cover from the bracket and mount the top cover in the fuel pump housing. See Procedure 909-5.4.

Page 4 (4)


Fuel Pump Puncture Valve MAN B&W Diesel

109-8

Data


X


Data Ref.

Description

D09-35

Puncture valve, tightening torque

D09-36

Puncture valve


Value

Unit

1400 12

Nm kg

Page 1 (2)

Fuel Pump Puncture Valve

109-8

MAN B&W Diesel

Data


Plate P90951

Page 2 (2)

Item No. 141

Description Crowfoot spanner



909-8.2

Dismantling Fuel Pump Puncture Valve S60MC-C 0217 Dismantling 909-8.2

2.

1. Shut off the fuel oil inlet. Open the drain cock at the bottom of the pump housing and drain off any oil left in the fuel oil high-pressure pipe and fuel pump. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 2. Dismantle the control air pipe and the protective cap above the puncture valve.

4. After dismantling it is recommended always to overhaul the puncture valve.

3.

HN909-8.2 207 03

If the overhaul cannot take place immediately after the dismantling, it is recommended to place the puncture valve immersed in diesel oil until the overhaul.

HN909-8.2 207 02

3. Unscrew and remove the puncture valve from the fuel pump top cover.


Page 1 (4)

909-8.3

Fuel Pump Puncture Valve Overhaul Overhaul 909-8.3

1.

1. Remove and discard the O-rings from the puncture valve. Set up the puncture valve in a bench vice with “soft” jaws. Loosen and remove the four screws and dismount the plug. Use a screw to remove the air piston from the housing. Remove and discard the sealing rings from the air piston. Disassemble the other parts of the puncture valve, using a brass mandrel and a hammer. Take care not to damage the valve seat. Thoroughly clean all the parts in clean diesel oil. 2. Inspect the conical seats of the valve housing and the valve slide for wear marks or scratches. If the seats are damaged, the valve housing and the valve slide must be discarded.

HN909-8.3 207 01

Lapping of the valve seats must not be attempted.

HG909-8.2 201 02

2.

Page 2 (4)



909-8.3

Overhaul 3.

3. When mounting the new sealing rings on the spindle of the air piston, the inner sealing ring must be mounted first. Mount the O-ring in the ring groove and position the large cone on the spindle. Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on to the O-ring in the groove. After mounting the sealing ring, compress it by pressing the ‘sizer' tool, over the sealing ring. Mount the outer sealing ring in the groove using the short cone, and repeating the above procedure.

Before assembling the puncture valve, lubricate all parts with “MOLYKOTE anti-friction SPRAY D321R” or molybdenum disulphide (MoS 2).

GM909-3.3 89 10

4. The new sealing ring is mounted on the head of the air piston in accordance with the same procedure as above.

4. Mount new O-rings on the housing.

GM909-3.3 89 12

5. If the puncture valve is not to be mounted on the engine immediately after the overhaul, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage.


Page 3 (4)

909-8.4

Fuel Pump Puncture Valve Mounting Mounting 909-8.4

2.

1. Make sure that the bore for the puncture valve in the fuel pump top cover is absolutely clean. If this has not already been done, mount new O-rings on the puncture valve. Lubricate the thread of the puncture valve with copper grease.

D09-35

2. Screw the puncture valve into the bore in the top cover. Using a crowfoot wrench and a torque spanner, tighten the puncture valve to the torque stated in Data. 3. Mount the protective cap and the control air pipe on top of the puncture valve.

HN909-8.4 207 02

4. If open, close the drain cock on the fuel pump and open the fuel oil inlet valve.

HN909-8.4 207 03

3.

Page 4 (4)


Fuel Pump Shock Absorber MAN B&W Diesel

109-9

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X X X X X X X X


Data Ref.

Description

D09-37

Nuts, tightening torque

D09-39

Shock absorber


Value

Unit

260

Nm

70

kg

Page 1 (2)

Fuel Pump Shock Absorber

109-9

MAN B&W Diesel

Data


Plate

Page 2 (2)

Item No.

Description



909-9.1

Checking Fuel Pump Shock Absorber K98MC-C 0216 Checking 909-9.1

To ensure satisfactory operation, the functioning of the fuel pump shock absorber should be checked at regular intervals. Normally, inspection is necessary only at the intervals stated in the maintenance programme. The checks should be carried out while the engine is operating. 1. Remove the plug from the end cover of the shock absorber. Check that air is ‘pulsating’ through the threaded hole.

The air pulses occur when the shock absorber piston is working and the air below the piston is being compressed and forced out through the threaded hole.

NA909-9.1 207 01

Short bursts of air should be felt against the hand, corresponding to the strokes of the fuel pump.

2. To check the ‘tightness’ of the piston, measure the amount of leakage oil flowing from the drain pipe of the shock absorber housing. Note down the amounts measured and compare with earlier measurements. Increasing amounts indicate a deteriorating piston sealing. Excessive amounts indicate that the shock absorber requires overhauling. See Procedure 909-9.3.


Page 1 (3)

909-9.3

Fuel Pump Shock Absorber Overhaul Overhaul 909-9.3

1. Note!

D09-39


NA909-9.3 211 01

1. Remove the shock absorber drain pipe. Place a wire strap around the shock absorber and hook on the engine room crane. Loosen the screws holding the shock absorber and remove it from the fuel pump housing.

2.

2. Remove the plug from the end cover of the shock absorber. Fit a threaded rod between the piston and the end cover to counteract the force of the springs. Loosen the screws of the end cover and remove the end cover and piston. Discard the gasket. 3. Loosen the nut on the threaded rod to relieve the springs and remove the threaded rod. Remove and discard the sealing ring in the shock absorber housing and the wear ring on the piston.

NA909-9.3 207 02

4. Clean all parts and polish the sliding surfaces of the piston and the shock absorber housing. Mount a new sealing ring in the shock absorber housing and a new wear ring on the piston.

4.

5. Mount the springs and the spring guide between the end cover and the piston, using the threaded rod.

M90909-0216O04

Lubricate all sliding surfaces and assemble the shock absorber. Take care not to damage the sealing ring or wear ring when mounting the piston. Check that the piston slides easily in the shock absorber housing.

Page 2 (3)



909-9.3

Overhaul 6.

6. Mount the end cover. For tightening the nuts, see Data. Lock with the locking device. Remove the threaded rod and insert the plug.

If an excessive amount of drain oil is still observed after the overhaul, the shock absorber must be replaced and the damaged one sent to an authorized MAN B&W repair shop for reconditioning.

MB909-9.3 215 06

7. Fit a new gasket on the fuel pump housing and mount the shock absorber. Mount the shock absorber drain pipe.

D09-37


Page 3 (3)

109-10

Lifting Gear for Roller Guide Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X

Shut off star ting air supply – At star ting air receiver

X

Block the main star ting valve

X

Shut off star ting air distributor/distributing system supply

X


X


X


X


X


Data Ref.

Description


Value

Unit

Page 1 (2)

109-10

Lifting Gear for Roller Guide Data


Page 2 (2)



Lifting Gear

909-10.1

Checking Lifting Gear K90MC-C 0218 Checking 909-10.1

1.

The lifting gear for the fuel pump roller guide is checked and activated by manually operating the four-way valve of the lifting gear while the engine is running or being turned. Note! Whereas the roller guide may be lifted when the engine is running, the roller guide may only be lowered when the engine is stopped. Otherwise, damage may be caused to the roller guide.

Air inle t

Thereby compressed air is led to the bearing of the lifting device, causing the shaft, which functions as piston, to be pressed in against the roller guide. The air cylinder is constantly vented through a bore in the shaft until the shaft is in the correct position.

KC909-5.0 57 01

1. Lift the knob on the dial of the 4/3 directional control valve, and turn the dial to position 1.

2. A

2. When the shaft is pressed fully in, its lifting pin is positioned under the reversing arm of the roller guide, and the duct (which is connected to the lifting cylinder) is uncovered, thus activating the air cylinder. The air cylinder lifts the coupling arm, which turns the shaft, and the lifting pin on the shaft thus lifts the roller guide clear of the arm. When the roller guide has been successfully lifted, it is no longer possible, with the hand on the fuel oil high-pressure pipe, to feel the beat of the oil pressure pulse.

KC909-5.0 57 02

Air inle t


Page 1 (4)

909-10.1

Lifting Gear Checking

3.

3. When the roller guide has been lifted, the dial of the 4/3 directional control valve can be returned to zero position. Lift the knob to release the dial from position 1.

MB909-5.0 38 05

The roller guide is now locked in a position free of the fuel cam, and the engine can be operated on the remaining cylinders, see Volume I, Chapter 704.

Page 2 (4)


Lifting Gear

909-10.1

Checking 4.

Re-engagement of the fuel pump roller guide 4. Stop the engine and engage the turning gear. Remove the cover on the camshaft housing to inspect the position of the fuel cam. Turn the engine until the circular part of the fuel cam is facing upwards. To lower the roller guide again, lift the knob on the 4/3 directional control valve and turn the dial to position 2. Thereby air pressure is led both to the lifting cylinder and to the bearing for the lifting gear.

At the highest point of the cam the pin of the shaft clears the reversing arm of the roller guide, and the air pressure in the bearing presses the shaft back to its extreme position. Now the roller guide can pass the pin of the shaft unhindered.

KC909-5.0 57 05

The piston of the lifting cylinder is pressed back, thereby turning the shaft out of its ‘locked’ position and lowering the roller guide so much that the roller cannot go clear of the cam.

Air inlet

Return the 4/3 directional control valve to zero position.

Note! The engine is able to operate with a roller guide in the wrong position. Therefore, to ensure correct timing after lowering the roller guide, it is recommended to make a START/STOP manoeuvre. This will activate the air cylinder for the reversing mechanism and ensure that the roller guide is in its correct position.


Page 3 (4)

909-10.3

Lifting Gear Overhaul Overhaul 909-10.3

1.

1. In the event of leakage at the sealing rings of the lifting gear (the functioning is not satisfactory), the sealing rings are to be replaced. Dismount the pipe connections on the bearing. Disconnect the pull rod of the air cylinder from the coupling arm and remove the coupling arm. Remove the screws which fasten the flange and bearing to the roller guide housing. Dismount the flange, pull the shaft out of the bearing, and remove the bearing from the bore of the roller guide housing. Replace all O-rings A and the piston ring B.

MC909-5.0 48 06

Coat all sliding surfaces and sealing surfaces with molybdenum disulphide (MoS 2). Place the bearing in the bore of the roller guide housing, adjusting it in accordance with the threaded holes. Carefully press the shaft into the bearing. 2. Place the flange on the shaft end (adjusted according to the threaded holes in the bearing), tightening it all up by means of the screws. Mount the coupling arm and the pull rod of the air cylinder. Reconnect the pipes to the nipples of the bearing. 2. After the overhaul, activate the lifting gear. See Procedure 909-10.1. In the activated position, check that the adjusting hole in the coupling arm coincides with the adjusting hole in the flange. If this is not the case, loosen the lock screw on the pull rod and adjust the length of the pull rod until the adjusting holes coincide.

MC909-5.0 48 07

Tighten the lock nut.

Page 4 (4)


109-11

Fuel Valve Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X

Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water

X

Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description

Value

Unit

300 - 380

bar

D09-40

Fuel valve opening pressure

D09-42

Inlet seat, max. diameter

25

mm

D09-43

Fuel valve

16

kg


Page 1 (2)

109-11

Fuel Valve Data


Item No.

Description

P90151

71

Dismantling tool for fuel valve

P90951

94

Milling tool for fuel oil pipe seats

P90951

165

Grinding mandrel for valve head

P90951

189

Grinding mandrel for holder - outside

P90951

190

Grinding mandrel for holder - inside

P90951

297

Assembling tool for fuel valve

P90961

14

Page 2 (2)

Fuel Valve tester, complete


Fuel Valve MAN B&W Diesel

909-11.1

Checking

1. Fuel Valve 1. The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of the engine can be attributed to defects in these valves. If the engine gives normal performance in accordance with diagrams and exhaust temperatures, it is only necessary to inspect the fuel valves after the service period stated in the Checking and Maintenance Programme. See Chapter 9001.

Note! In the event that the slidetype fuel valve is pressure tested without being cleaned between the fuel nozzle and the cutoff slide, the opening pressure value measured might be considerably lower than specified.

M90911-0249C01

In order to obtain reliable results during testing of the fuel valves, all fuel valves that are dismantled from the engine must be disassembled, cleaned, inspected and reassembled before testing. See Procedure 90911.3 and 90912.3.

2.

All fuel valves must be functiontested before being mounted in the cylinder cover. Pressure testing pump Use only hydraulic oil (rustpreventing) with a viscosity of between 7 and 10 cSt at 50°C. For operation of the pressure testing pump, see the supplier’s instructions. Note that the highpressure pump should be periodically checked in accordance with the supplier’s instructions.

To ensure that over tightening has not taken place, check that the locking/indicating pin has not been bent or broken off. In the event of over tightening, replace the spring housing by a new one.

M909110240C02

2. Spring housing


Page 1 (13)

909-11.1

Fuel Valve Checking

MAN B&W Diesel

3. Settingup the fuel valve 3. Place the fuel valve in the test rig and secure it with the spring housings and nuts. Tighten the nuts until the top face of the pressure disc is flush with the top face of the spring housings. Mount the oil pipe between the pressure testing pump and the fuel valve.

M909110242C03

o

4.

Pressure testing procedure The following functions of the fuel valve must be checked: • Flushing and jet control • Opening pressure • Sealing test and sliding function • Pressure test, Oring sealing 4. Flushing and jet control Remove air in the system and check the fuel jet in the following way. Slowly increase the oil pressure until straight jets of oil are ejected from the nozzle holes (no atomization).

M909110240C04

Acceptance criteria: There is to be a continuous jet of oil through at least one of the nozzle holes. Owing to the geometry of the internal part of the nozzle and because of the height to which the spindle is lifted during pressure testing is lower than the height it is lifted during normal engine operation the fuel oil will not necessarily flow from all of the nozzle holes. Cause of fault: If the jets do not fulfil the above point, the cause may be: Dirt in the nozzle holes The nozzle is not mounted correctly

Page 2 (13)



909-11.1

Checking

5. Opening pressure 5. To check the opening pressure, increase the oil pressure until oil is admitted through the nozzle holes.

D0940

Acceptance criteria: Check the opening pressure on the pressure gauge and compare with Data D0940 on the datasheet. Note! Do NOT attempt to carry out an atomization test on the slide type fuel valvs, as this may damage the cutoff slide and nozzle.

If the opening pressure is higher than specified in D0940, the cause may be that a wrong type of spring is used replace the spring on the thrust spindle, if necessary, replace the complete thrust spindle. If the opening pressure is lower than specified in D0940, the cause may be that the spring has sagged replace the spring, or add a special thin disc.

M909110240C05

Cause of fault:

Note! Special thin discs are available as spares. If a spring or a disc has been changed, the pressure testing procedure of the fuel valve must be repeated.


Page 3 (13)

909-11.1

Fuel Valve Checking

6.

MAN B&W Diesel

6. Sealing test and sliding function To check the needle valve seat for tightness and the slide for correct closing. Slowly increase the oil pressure to about 50 bar below the opening pressure. Maintain the builtup pressure by closing for the oil supply. Acceptance criteria:

M909110240C06

Oil must not flow from the nozzle holes. The pressure drops relatively slowly to about 15 bar, after which it drops quickly to 0 (the slide is pressed against the conical seat and opens for circulation oil). Note! Oil flows out of the leak oil outlet when the fuel valve is full of oil. Cause of fault: If oil flows out of the nozzle holes, the cause is either: • Defective spindle guide at needle seat, or a sticking spindle. Examine and/or replace the spindle guide. See Procedure 90912.3. • Too quick pressure drop: the clearances of the movable parts, both of the spindle guide and of the nonreturn valve, are too large, or the seats between the thrust piece/spindle in the spindle guide or thrust piece/valve slide in the nonreturn valve are damaged. Examine and/or replace both the spindle guide and nonreturn valve. See Procedure 90912.3. See Procedure 90913.3. If a quick pressure drop from 15 to 0 bar cannot be registered: • The valve slide is sticking; or • The vent hole in the thrust piece is blocked. If so, disassemble and examine the spindle guide, replace if necessary. See Procedure 90912.3. Page 4 (13)



909-11.1

Checking

7. Pressure test, Oring sealing 7.

Max. 10 bar

To ensure that the leak oil (circulation oil) remains in the closed system, build up a working pressure of about max. 10 bar until oil flows out of the leak oil outlet. Close the leak oil outlet with a gasket and plug screw. Max. 100 bar

Increase the working pressure to about 100 bar. Acceptance criteria: The builtup pressure of about 100 bar should be maintained.

Max. 100 bar

If oil leaks out at the union nut, the Oring inside the fuel valve head is defective, and must be replaced. 8. Atomization test

M909110240C07

Cause of fault:

Note! 8.

The atomization test may damage the valve because it makes the needle oscillate, with a small lift at a very high frequency. The high pressure drop across the cutoff edge and the high contact pressure between slide and fuel nozzle, in combination with the poor lubricity of the test oil, increase the risk of seizures between cutoff slide and nozzle. All of these conditions involve the risk of seizure between the cutoff slide and the nozzle.

M909110240C08

Do NOT attempt to carry out an atomization test on slide type fuel valves, as this may damage the cutoff slide and nozzle.


Page 5 (13)

909-11.2

Fuel Valve Dismantling 1.

1.

MAN B&W Diesel

Close the fuel oil inlet and outlet valves, and drain the highpressure pipe and the fuel valve. Dismantle and remove the fuel oil highpressure pipe. See Procedure 90914.2. Disconnect the return oil pipe from the fuel valve.

M909110240D01

2. Remove the nuts and the spring housings. 3. Take out the valve. If the valve is sticking, use the fuel valve dismantling tool to pull the fuel valve clear of the top cover. If the valve is not to be overhauled immediately, the valve should be placed immersed in diesel oil until overhauling.

M909110240D02

2.

3.

M909110239D03

D0943

Page 6 (13)



909-11.3

Overhaul

When fuel valves are overhauled, all parts should be handled carefully and be kept clean.

1.

Use only clean, nonfluffy rags for wiping purposes. Make sure to remove all liquid or solid impurities. Whenever fuel valves are overhauled, all sealing rings should be discarded and replaced by new, faultless sealing rings before reassembly. Measure the length A of the protruding part of the nozzle, and write down the result for correct reassembling of the valve.

2. Place the valve holder in a machine vice, mount the fuel valve in the holder and fit the valve with the guide disc from the grinding tool.

A M909110240O01

1.

2.

3. Compress the fuel valve and the spring inside, by means of a drilling machine, to avoid seizures in the union thread. Hold the fuel valve compressed and unscrew the union nut with a hook spanner.

M909110240O02

Remove the valve from the valve holder.

M909110240O03

3.


Page 7 (13)

909-11.3

Fuel Valve Overhaul

4.

MAN B&W Diesel

4. Pull the valve head clear of the valve housing. Remove the: • Non return valve • Thrust spindle parts • Thrust foot • Spindle guide and fuel nozzle from the valve housing.

M90911-0249O04

Remove and discard all the Orings.

Page 8 (13)



909-11.3

Overhaul

5. Carefully clean and examine all surfaces of the:

5.

• Fuel valve housing • Fuel valve head

D09-42

• Thrust spindle If necessary, grind the seating surfaces by means of a finegrain abrasive (such as Carborundum No. 500). The grinding mandrels supplied are only purposed for: • The fuel valve housing bottom. • The underside of the fuel valve head. • The top of the non-return valve. This grinding must only be carried out manually. After the grinding, wash the parts in gas oil and blow clean by means of compressed air to remove any remains of the grinding compound. In the event of more serious damage to the seating surface for the highpressure pipe in the valve head, the milling tool can be used. Normally, the milling tool is turned by hand, but it may be fitted in the chuck of a columntype drilling machine provided that the number of revolutions is kept at a minimum (not exceeding approx. 100 r/min). An ample supply of cutting emulsion must be used. Note!

M90911-0249O05

Take care not to exceed the maximum diameter of the seat, see Data.


Page 9 (13)

909-11.3

Fuel Valve Overhaul

6.

MAN B&W Diesel

6. The complete spindle guide, including the fuel nozzle, should be sent to an authorised MAN B&W repair shop for overhaul. If this is not possible, the spindle guide may be overhauled on board. See Procedure 90912.3.

M909110240O05

Note!

7.

Do not attempt to remove the fuel nozzle from the spindle guide unless the spindle guide has been dismantled. Otherwise the cutoff slide on the spindle may be damaged. 7.

The nonreturn valve should be sent to an authorised MAN B&W repair shop for overhaul. If this is not possible, the nonreturn valve may be overhauled on board. See Procedure 90913.3.

M909110240O06

8. Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing.

Note! Make sure that the fuel nozzle and spindle guide engage correctly with the guide pin in the fuel valve housing. This can be ascertained by attempting to turn the nozzle after mounting. It must not be possible to turn the nozzle.

M908020253D05

8.

Carefully slide the spindle guide down into the valve holder, and turn the nozzle until the spindle guide engages correctly with the guide pin. Check that distance A corresponds to the measurement taken before the valve was disassembled.

Page 10 (13)



909-11.3

Overhaul

9. Mount:

9.

• the thrust foot • the parts of the thrust spindle • the nonreturn valve in the fuel valve housing. Mount a new Oring in the uppermost groove of the fuel valve housing. Lubricate the thread of the valve head with molybdenum disulphide (MoS2). For the correct use of this lubricant, see Procedure 91311.

10. Make sure that the guide pin between valve housing and valve head is intact, and press the valve head down into the valve housing. See that the guide pin between valve housing and valve head engages correctly so as to prevent relative turning of the parts.

M90911-0249O09

Fit the valve head with new Orings.

M909110240O09

10.


MoS 2

Page 11 (13)

909-11.4

Fuel Valve Mounting

11.

MAN B&W Diesel

11. Assemble the valve by means of the union nut. Place the valve in the valve holder in a drilling machine. Compress the fuel valve and the spring inside. Keep the valve compressed and tighten the union nut with a hook spanner. After overhaul, the fuel valve must be tested in the test rig. See Procedure 90911.1.

M909110240O10

12. If the fuel valve is not to be mounted in the engine immediately after the overhaul, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage.

Page 12 (13)


Fuel Valve MAN B&W Diesel 1.

909-11.4

Mounting

Before mounting the fuel valve, thoroughly clean the valve bore in the cylinder cover and check the seating in the bore for marks which, if any, must be eliminated. (For reconditioning of the valve bores in the cylinder cover, see Procedure 9011.3).

1.

D0943

If not already done, mount new Orings on the fuel valve. Lubricate the valve with molybdenum Disulphide (MoS2).

MoS 2

Mount the spring housings and the nuts. Tighten the nuts until the top face of the pressure disc is flush with the top face of the spring housing. This must be done with great care, as the spring tension in the housing determines the correct tightening of the fuel valve to the cylinder cover as well as the correct compression of the fuel valve.

M909110239M01

2. Mount the valve in position in the cylinder cover.

2.

O

3. Lubricate the thread on the union nipple of the fuel oil pipe with a heat resistant anti seize grease before mounting.

It is recommended to overhaul the fuel oil highpressure pipe before mounting. See Procedure 90914.3. As a minimum, the distance between the fuel oil pipe ends and the thrust bushings must be checked and, if necessary, adjusted.

M909110245M02

Note!

3.

Mount the overhauled fuel oil highpressure pipe and the return oil pipe. See Procedure 90914.4.

Note!

M909110242M03

All fuel valves must be functiontested before being mounted in the cylinder cover, see Procedure 90911.1.


Page 13 (13)

109-12

Fuel Valve Spindle Guide Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref. D09-70

Description

Value

Unit

Nozzel spray hole cleaning tool table

Nozzel spray hole

Cleaning drill

Test pin

Nozzel spray hole

Cleaning drill

Test pin

0.90

0.85

0.94

1.60

1.55

1.65

0.95

0.90

0.99

1.65

1.60

1.70

1.00

0.95

1.04

1.70

1.65

1.74

1.05

1.00

1.09

1.75

1.70

1.80

1.10

1.05

1.14

1.80

1.75

1.85

1.15

1.10

1.20

1.85

1.80

1.89

1.20

1.15

1.24

1.90

1.85

1.94

1.25

1.20

1.30

1.95

1.90

1.99

1.30

1.25

1.34

2.00

1.95

2.05

1.35

1.30

1.39

2.05

2.00

2.09

1.40

1.35

1.44

2.10

2.05

2.14

1.45

1.40

1.49

2.15

2.10

2.19

1.50

1.45

1.54

2.20

2.15

2.24

1.55

1.50

1.59

2.25

2.20

2.29


Page 1 (2)

109-12

Fuel Valve Spindle Guide Data


Page 2 (2)

Item No.

Description Fuel Valve Nozzle - Tools


Fuel Valve Spindle Guide

909-12.3

Overhaul

Note!

2.

This instruction is only valid for spindle guides of the slide valve design. Extreme care and accuracy should be exercised when carrying out this operation. Based on service experience it is recommended to replace the complete spindle guide after 16000 hours of operation. 1. Clean the outside of the spindle guide in pure gas oil or similar. The individual parts of the spindle guide are not interchangeable, therefore only one guide is to be disassembled at a time.

The spindle guide, thrust piece and spindle are matched parts and may not be re-placed individually. 2. Place the spindle guide in a bench vice provided with “soft” jaws, and use the brass mandrel as shown to disassemble the spindle guide.

M909120228O02

Note!

4.

3. Mount the pulling tool around the fuel nozzle on the spindle guide. Turn the nut to pull the fuel nozzle off the spindle guide. Note! The pulling tool is not standard for all engines, but may be delivered as an optional extra. 4. If no pulling tool is available, the fuel nozzle can be dismantled from the spindle guide using two screwdrivers.

M909120228O04

Place the screwdrivers opposite each other in the small gap between the fuel nozzle and the spindle guide and very carefully force the fuel nozzle off the spindle guide.


Page 1 (5)

909-12.3

Fuel Valve Spindle Guide Overhaul

5.

5. Clean all the parts of the spindle guide in gas oil and wipe dry with a clean piece of cloth. Clean all parts again in gas oil or ‘Electrocleaner’ and wipe dry with a clean piece of cloth. Place all the parts on a clean, soft, lint-free cloth and examine them through an 8-10 times magnification magnifying glass and an inspection lamp.

M909120228O05

During the examination, pay special attention to the seating surfaces and sliding surfaces of the parts.

6.

6. Remove any deposits or very fine scratches by placing the spindle, thrust piece or spindle guide respectively in a lathe, as shown, and polishing with a very fine conventional polishing linen ‘grade 360’. Use also a little oil for the polishing (a coarser polishing linen must absolutely not be used). Note!

M909120228O06

The sliding surface of the cut-off slide may only be polished VERY carefully. The sliding surface must not be damaged.

Page 2 (5)

After polishing, clean the parts again and re-check the seat on thrust piece/spindle, the seat on slide valve/spindle, and the seat on spindle/guide. Use an inspection lamp and an 8-10 times enlargement magnifying glass. If the seats are not in order, i.e. if there are pressing-in marks or similar on the seats, the complete spindle guide must be discarded.


909-12.3


8. Read the nominal hole size on the cylindrical part of the nozzle, as shown in the figure. The hole size is given in 1/100 mm. Depending on the engine model, there can be one or more different sizes of the holes. Find the correct drill size and matching test pin in the table, D09-70, on the data sheet, via the nominal hole size. Clean the spray holes, using gas oil and the special drills supplied.

7.

M909120228O07

7. Clean any carbon deposits from the central bore of the fuel nozzle by means of the special brass brush. Clean the fuel nozzle with gas oil and wipe dry with a clean cloth.

Note! During this operation be very careful not to push the drill too far to avoid scratching the snug-fit surface on the inside of the fuel nozzle.

8. 1 2

3 4

This also applies to nozzles with oval holes (can be ascertained with a magnifying glass). Check the fuel nozzle before mounting on the spindle guide, the cut-off slide must be able to move freely inside the nozzle.

M909120228O08

Then test the spray holes with the test pin. If the test pin is able to enter just one of the holes, the fuel nozzle must be discarded.

XXXXXX

X XX*XXXXX

9. Note!

M909120228O09

It is recommended that the fuel nozzle is changed whenever the spindle guide is being overhauled or at maximum 8000 running hours.


Page 3 (5)

909-12.3


11.

10. Lubricate the spindle and the thrust piece with the cut-off slide with a little Molybdenum Disulphide (MoS2), see Procedure 91311. 11. Assemble the thrust piece, the spindle and the spindle guide and carefully knock the parts together using a soft hammer.

M909120228O11

12. Shake the spindle guide back and forth. The spindle with the cut-off slide must be able to slide freely back and forth inside the spindle guide, with a ‘clicking’ sound.

M909120228O12

12.

Page 4 (5)


Fuel Valve Spindle Guide

909-12.3

Overhaul 13. Lubricate the sliding surfaces of the nozzle and the spindle with a little Molybdenum Disulphide (MoS2). See Procedure 913-11.

13.

Mount the nozzle on the spindle guide. Make sure that the half-circle shaped groove on the nozzle and the spring pin are in line. Spring pin

If nozzle and spindle guide are provided with scratch marks opposite the spring pin, they must be in line. Place the parts on the plane of a drilling machine or hydraulic press and position the mounting tool over the parts. Make sure that all the parts are perfectly aligned. Press the nozzle on to the spindle guide.

The mounting tools are not standard for all engines but may be delivered as optional extras.

M909120228O13

Note!

Scratch marks

If no mounting tools are available, the nozzle can be mounted on the spindle guide using a short piece of pipe. Place the pipe around the nozzle, so that the lower end of the pipe rests on the ‘foot’ of the fuel nozzle. Then press the parts together the same way as when using the mounting tools. Check that the spindle inside the spindle guide is able to move freely as in step 10. 14. If the spindle guide is not to be mounted in a fuel valve immediately after the overhaul, cover all openings of the spindle guide with plastic to prevent dirt from entering the spindle guide during storage.


Page 5 (5)

109-13

Non-return Valve for Fuel Valve Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 Stopped engine Shut off star ting air supply – At star ting air receiver Block the main star ting valve Shut off star ting air distributor/distributing system supply Shut off safety air supply – Not ME-engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description


Value

Unit

Page 1 (2)

109-13

Non-return Valve for Fuel Valve Data


P90951 P90968

Page 2 (2)


153

Flange for dismantling of non return valve Fuel Valve - Inspection Tools


Non-return valve

909-13.3

Overhaul Non-return valve K98MC-C 0206 Overhaul 909-13.3

1. Note! Extreme care and accuracy should be exercised when carrying out this operation. 1. Clean the outside of the non-return valve with pure gas oil. The individual parts are not interchangeable, therefore only one guide is to be disassembled at a time. Note! Except for the slide valve spring, defective parts cannot be replaced individually by new ones. Place the non-return valve as shown in Fig. 1 in a bench vice provided with “soft” jaws, and disassemble the non-return valve, using the disassembling tool and a hammer as shown. 2. Clean all the parts for the spindle guide in gas oil and wipe them dry with a clean piece of cloth. Finally, clean in either gas oil, kerosene or ‘Electrocleaner', and wipe the parts dry with a clean piece of cloth. 3. Now place the parts on clean, lint-free rags and examine with an 8-10 times enlargement magnifying glass, and an inspection lamp with magnifying glass as shown in Fig. 3.

& 0

A

2.

B

C

D

% 1

3.

& 0


Page 1 (2)

909-13.3

Non-return valve Overhaul

4.

4. Examine the slide faces of movable parts for coating. Vent slide B/housing A will be too tight if there is a coating. (The letters AD refer to the letters/parts in Fig. 2). Fix vent slide B and, subsequently, housing A in a lathe as shown in Fig. 4 and remove the coating by means of very fine conventional polishing linen ‘grade 360'.

MC909-6.2 69 04

Also a little oil should be used (a coarser polishing linen must absolutely not be used). 5. Check spring C for the thrust piece for outside wear marks. If defective, it should be exchanged. 5.

Check the seat on thrust piece D/vent slide, and the seat on vent slide/housing. Use an inspection lamp and an 8-10 times enlargement magnifying glass.

NA909-13.3 205 05

If the seats are not in order, i.e. if there are pressing-in marks or similar on the seats, the complete spindle guide must be discarded. 6. Mount the non-return valve as follows: • Lubricate all movable parts with molybdenum disulphide (MoS2). 6. • Place the loosely-assembled non-return valve on the plane of a drilling machine, with the tool positioned as shown in Fig. 6. • Make sure that the thrust piece and the other parts are perfectly aligned and that the thrust piece is guided in the vent slide.

MC909-6.3 69 06

• Press the handle until the housing and thrust piece meet.

Page 2 (2)

7. If the non-return valve is not to be mounted in a fuel valve immediately after the overhaul, cover all openings of the non-return valve with plastic to prevent dirt from entering the valve during storage.


Fuel Oil High-Pressure Pipe MAN B&W Diesel

109-14

Data


X


Data Ref.

Description

Value

Unit

D09-48

Fuel valve end, union nipples, tightening torque

190

Nm

D09-49

Fuel pump end, union nipples, tightening torque

190

Nm

D09-50

Union nuts, tightening torque

55

Nm

D09-52

Fuel oil pipe

20

kg


Page 1 (2)

Fuel Oil High-Pressure Pipe

109-14

MAN B&W Diesel

Data


Plate

Item No.

Description

P90951

104

Milling tool for fuel oil pipe

P90951

128

Crowfoot spanner

Page 2 (2)



909-14.2

Dismantling

MAN B&W Diesel HighPressure Pipe with Double Pipe

2.

1. Close the fuel oil inlet and outlet valves. 2. Unscrew the union nut and the union nipple from the fuel valve. 3. Unscrew the union nut and the union nipple from the fuel pump.

Note! It is recommended always to overhaul the highpressure pipe before remounting it on the engine. See Procedure 90914.3.

M909140254D02

4. Lift the pipe ends clear of the fuel valve/ fuel pump, and remove the highpressure pipe from the engine.

3.

M909140254D03

The overhaul should preferably take place immediately after the highpressure pipe has been dismantled.

4.

M909140254D04

D0952


Page 1 (5)


909-14.3

Overhaul

MAN B&W Diesel Whenever the fuel oil highpressure system has been dismantled, it is necessary, before remounting the highpressure pipes, to carefully inspect the tapered contact surfaces of the pipe ends, together with their seats in fuel valves and fuel pump top cover.

1. A

If the pipe ends require reconditioning, proceed as follows:

M909140254O01

1. Fasten the pipe in a vice with soft jaws. Mount the miller on the pipe end. A

Note! The two pipe ends are of different designs – see sketch.

2.

Turn the upper tightening ring (A) until the miller presses against the pipe end. Max. grindaway

Turn the miller with, for instance, a tap wrench while lightly tightening the upper tightening ring (A) to provide a suitable pressure between the miller and the pipe end.

M909140242O03

During the milling process, add drilling oil emulsion liberally.

3.

2. On both pipe ends a small groove has been ground to indicate the maximum allowable grinding of the pipe ends. The pipe ends may only be ground until the ground surface is flush with the bottom of the groove. If the pipe ends are still not in order, the pipe must be discarded.

M90914-0255O03

After completing the milling, carefully clean the highpressure pipe, and blow through the bore with compressed air.

Page 2 (5)

3. When the milling is finished: Lift up the union nut. Remove the spring ring from the twopart sleeve. Remove the sleeve.


Fuel Oil High-Pressure Pipe MAN B&W Diesel

909-14.3

Overhaul

4. Pull off the sleeves and union nuts and remove the sealing rings A, B and C. Clean all parts carefully.

4.

A

B

M90914-0255O04

C


Page 3 (5)

909-14.3

Fuel Oil High-Pressure Pipe Overhaul

5.

MAN B&W Diesel

5. Fit the union nuts and bushings with new seaing rings.

M90914-0255O05

Mount the twopart sleeve and lock the sleeve with the spring ring. Ensure that all parts are completely clean before mounting the highpressure pipe.

Page 4 (5)



909-14.4

Mounting

MAN B&W Diesel

1. Ensure that the fuel valve and the fuel pump end of the highpressure pipe are fitted with new Orings. Lubricate the thread of the fuel valve with a heat resistant grease.

3.

2. Ensure that the union nuts on both sleeves on the highpressure pipe is fitted. Lubricate the thread on the union nipple with a heat resistant grease.

D0952

3. Mount the highpressure pipe between the fuel valve and the fuel pump. First screw the union nipple onto the fuel valve to nearly full contact. Then fit the sleeve of the highpressure pipe in the fuel pump.

M909140254M03

Pull back both sleeves on the highpressure pipe as far as possisble.

4.

Note!

D09-48 D09-50

Tightening with a crowfoot wrench should only be done after both of the union nipples have been screwed into position. 4. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel valve to the torque stated in Data.

M90914-0255M04

The nipples must be screwed by hand, as the threads of the union nipples, fuel valve or fuel pump top cover might otherwise be damaged.

5. 5. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel pump to the torque stated in Data. Tighten both union nuts to the torque stated in Data.

D09-50

6. If dismantled, remount the return oil pipe on the fuel valve. Open the fuel oil inlet and outlet valves.

M90914-0255M05

D09-49

When referring to this page, please quote Procedure M90?914Edition 0255

Page 5 (5)

Fuel Pump Roller Guide MAN B&W Diesel

109-15

Data



Data Ref.

Description

Value

Unit

D09-53

Nut, reversing shaft, tightening torque

160

Nm

D09-57

Roller/bushing/shaft pin, max. clearance

0,5

mm

D09-61

Fuel pump roller guide

250

kg

D09-62

Pump base

250

kg


Page 1 (2)

Fuel Pump Roller Guide

109-15

MAN B&W Diesel

Data


Plate P90851

Page 2 (2)

Item No. 053

Description Lifting tool for roller guide



Checking

Roller guide mounted in engine 1.

909-15.1

2.

The fuel pump roller guide can be partially checked while mounted on the engine, using the following procedure:

2. Lift the fuel pump roller guide. See Procedure 909-10. Remove the cover on the camshaft housing to inspect the fuel pump roller guide. 3. Turn the engine to provide the maximum space between the roller guide and the cam disc.

Also inspect the surface of the roller for possible damage marks, seizures or scratches. Make sure that there are no traces of bearing metal left in the roller guide housing. Check the clearance in the slide bearing by lifting the roller relative to the roller guide and measuring the difference in distance between the cam disc and the roller in the upper and lower positions of the roller.

M90915-0236C02

Turn the roller by hand to check that it can move freely and without unnecessary resistance or “hard” points.

3.

M90915-0236C03

4. Lower the roller guide onto the fuel cam again. See Procedure 909-10.


Page 1 (10)

909-15.1

Fuel Pump Roller Guide Checking

MAN B&W Diesel

Roller guide removed from engine

5.

A more suitable and reliable method is to check the roller guide and the bearing clearance after the roller guide has been dismounted:

D09-61

5. Dismount the roller guide from the engine. See Procedure 909-15.2. 6. Check the surface of the roller and the sliding surfaces of the roller guide, and measure any ovalness. 7.

Turn the roller guide upside down and land it in a vertical position on a couple of wooden planks, with the roller hanging freely.

M90915-0236C07

8. Measure the clearance in the slide bearing by placing a dial gauge against the roller and lifting the roller as much as the clearance permits.

8.

M90915-0236C08

D09-57

Page 2 (10)



909-15.2

Dismantling 1. Note!

Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 1.

Dismantle the top cover and the barrel/ plunger assembly. See Procedure 909-5.2. See Procedure 909-6.2.

2. Dismantle the fuel pump housing. See Procedure 909-4.2. Note!

M90915-0236D01

When lifting the fuel pump housing, take care not to damage the threads on the studs.

M90915-0236D02

2.


Page 3 (10)

909-15.2

Fuel Pump Roller Guide Dismantling

3.

MAN B&W Diesel

3. Loosen and remove the locking wire and the screws from the disc on top of the roller guide inside the pump base. Remove the sealing cap from the roller guide/pump base.

M90915-0236D03

Dismantle the lubricating oil pipe and the drain pipe from the pump base. 4. Remove the cover on the camshaft housing to inspect the position of the roller guide. Turn the engine until the roller guide is at BDC.

M90915-0236C02

4.

Page 4 (10)



909-15.2

Dismantling

5. Loosen the nuts on the two threaded studs successively until the roller guide springs are relieved.

5.

Remove the nuts, mount two eye bolts in the pump base and lift it away.

D09-62

When lifting, take care that the bushing of the pump base slides against the upper part of the roller guide without scratching. Remove the springs from the roller guide. 6. Mount the roller guide lifting tool as follows: • Lift the lock plate of the tool up on the shaft of the tool.

• Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint. • Lower the lock plate, thereby securing the foot in the locked position. Lift the roller guide out of the roller guide housing, using the crane.

M90915-0236D05

• Position the tool so that its foot rests on the thrust piece in the bayonet joint of the roller guide.

6.

When lifting, take care that the slide surfaces of the roller guide do not scrape against the roller guide bushing.

D09-61

Land the roller guide on wooden planks. 7.

Check the roller guide. See Procedure 909-15.1.

M90915-0236D06

90°


Page 5 (10)

909-15.3

Fuel Pump Roller Guide Overhaul 1.

1.

MAN B&W Diesel Inspect and check the fuel pump roller guide. See Procedure 909-15.1.

2. It is recommended that the roller guide should ONLY be dismantled if

D09-61

• irregularities when turning the roller, • damage to the roller, • larger clearance than stated on the Data sheet, • seizure marks on the slide surfaces,

M90915-0236C07

have been observed when checking the roller guide. Note! For disassembling of the roller guide, contact an MAN B&W authorized repair shop. 3. If no irregularities are found, just clean and lubricate the roller guide before remounting it in the roller guide bushing.

M90915-0236O03

3.

Page 6 (10)


Fuel Pump Roller Guide MAN B&W Diesel 1.

909-15.4

Mounting

Lubricate the roller guide with plenty of lubricating oil, and mount it in the roller guide bushing, using the lifting tool.

1.

During mounting, take care not to scratch the sliding surfaces of the roller guide. Make sure that the pin of the reversing link fits in the guide of the reversing shaft.

D09-61

2. After mounting the roller guide with the reversing link, check the clearance between the roller guide and the guide plate mounted in the roller guide bushing.

90°

Turn the camshaft so that the roller guide is lifted approx. 20 mm.

The clearances A and B between the guideway and the pin of the reversing link (arm) must be checked in the AHEAD and ASTERN positions. Connect working air to the air cylinder, and check that the reversing mechanism is working smoothly.

M90915-0236M01

The clearance C between the roller guide and the guide plate must be the same at both ends ± 0.10 mm.

2.

The clearances A and B must be approx. the same in both positions.

C

Note that clearances A and B change position when changing from AHEAD to ASTERN.

A C

M90915-0236M02

B


Page 7 (10)

Fuel Pump Roller Guide

909-15.4

Mounting

MAN B&W Diesel

3. If adjustment is necessary, it must take place in the ASTERN position.

3.

D09-53

Loosen the nut on the reversing shaft and carry out the adjustment. After adjustment, shift to AHEAD position and check the clearances A and B once more. Finally, shift again to

ASTERN.

Tighten the nut on the reversing shaft, and lock the nut with Loctite, see Data. 4. Turn the engine until the roller guide is at the lowest point of the fuel cam. 5. Mount the new sealing ring in the groove inside the bushing of the pump base. Make sure to mount the sealing ring correctly. See the sketch.

M90915-0236M03

D09-53

M90915-0236M05

5.

Page 8 (10)



909-15.4

Mounting

6. Mount the spring and the spring seat discs over the roller guide.

6.

Mount the pump base over the roller guide and the springs. Mount the two special nuts on the threaded studs.

D09-62

Tighten the nuts until the pump base is fastened tightly to the roller guide bushing. Check the movement of the reversing link. See Procedure 909-15.1.

M90915-0236D05

7.

M90915-0236C03

7.


Page 9 (10)

909-15.4

Fuel Pump Roller Guide Mounting

8.

MAN B&W Diesel

8. Mount the lubricating oil pipe and the drain pipe on the pump base. Mount the sealing cap, the disc and the screws on top of the roller guide, over the sealing bush inside the pump base. Tighten the screws and lock with locking wire.

M90915-0236D03

9. Mount the fuel pump housing. See Procedure 909-4.4.

9.

10. Mount the barrel/plunger assembly. See Procedure 909-6.4. 11. Mount the fuel pump top cover. See Procedure 909-5.4. 12. Mount the fuel oil high-pressure pipes. See Procedure 909-14.4.

M90915-0236D02

13. Close the fuel pump drain cock. Open the fuel oil inlet and outlet valves.

Page 10 (10)


Fuel Valve and Fuel Pump Panel


Plate P90951-0446

Page 1 (2)

Plate P90951-0446 Item No. 010 021 045 057 069 070 094 104 128 130 141 153 165 177 189 190 200 224 236 248 250 261 273 297

Page 2 (2)

Fuel Valve and Fuel Pump Panel

Item Description

Item No.

Item Description

Panel for tools Name plate Measuring tool for fuel pump Lifting tool for fuel pump Lifting tool for fuel pump Lifting tool for fuel pump housing Milling tool for fuel oil pipe seats Milling tool for fuel oil pipe Crowfoot spanner Crowfoot spanner Crowfoot spanner Flange for dismantling of non-return valve Grinding mandrel for valve head Grinding mandrel for thrust spindle Grinding mandrel for holder, outside Grinding mandrel for holder, inside Screw Tool for P.max rack Pin wrench, speciale Hook spanner Drift for spindle guide Drift for puncture valve Drift for Non-return valve Assembling tool


Fuel Valve - Tools


Plate P90961-0069

Page 1 (2)

Plate P90961-0069 Item No. 014 026 038 040 051 063 075 087 099 109 122

Page 2 (2)

Fuel Valve - Tools

Item Description

Item No.

Item Description

High-pressure pump Table Rig fuel oil valve High-pressure hose Connection piece, M42x2 Test rig, complete Cover Angle union Gasket Plug screw Hose


Fuel Valve Nozzle - Tools


Plate P90966-0008

Page 1 (2)

Plate P90966-0008 Item No. 011 023 035 047 060 202

Fuel Valve Nozzle - Tools

Item Description

Item No.

Item Description

Tool box Extractor for atomizer Drift for atomizer Cleaning brush Instruction plate Toolset, complete Note: When odering new cleaning tool, please state P/N on fuel nozzle.

Page 2 (2)


Fuel Puncture Valve - Tools


Plate P90967-0001

Page 1 (2)

Plate P90967-0001

Fuel Puncture Valve - Tools

Item No.

Item Description

017

Tool for tightening of puncture valve

Page 2 (2)

Item No.

Item Description


Fuel Valve - Inspection Tools


Plate P90968-0001

Page 1 (2)

Plate P90968-0001

Fuel Valve - Inspection Tools

Item No.

Item Description

012

Probe light with magnifier, complete

Page 2 (2)

Item No.

Item Description


Fuel Valve Nozzle - Cleaning Tools


Plate P90974-0001

Page 1 (2)

Plate P90974-0001 Item No. 015 027 039 206

Fuel Valve Nozzle - Cleaning Tools Item Description

Item No.

Item Description

Drill* Test mandrel* Pin vice* Cleaning tool set, complete Note: * When ordering new cleaning tool, please state P/N on fuel nozzle.

Page 2 (2)


Mounting Tools - Pump Barrel Seals

Plate P90977-0001

Mounting Tools - Pump Barrel Seals 0001 P90977


Page 1 (2)

Mounting Tools - Pump Barrel Seals

Plate P90977-0001 Item No. 011 023 035 047 059 060 072

Item Description

Item No.

Item Description

Cone Pushing tool Compression tool Cone Pushing tool Compression tool Spacer ring

Page 2 (2)


Mounting Tools - Suction Valve Seals

Plate P90979-0001

Mounting Tools - Suction Valve Seals 0001 P90979


Page 1 (2)

Mounting Tools - Suction Valve Seals

Plate P90979-0001 Item No. 012 024 036

Item Description

Item No.

Item Description

Cone Pushing tool Compression tool

Page 2 (2)


Mounting Tools - Air Piston Seals

Plate P90980-0001

Mounting Tools - Air Piston Seals 0001 P90980


Page 1 (2)

Mounting Tools - Air Piston Seals

Plate P90980-0001 Item No. 018 020 031 043 055 067 079

Item Description

Item No.

Item Description

Cone Pushing tool Compression tool Cone Pushing tool Compression tool Cone

Page 2 (2)


910 - Turbocharger System Documents in this Chapter 110-01 910-01 110-02 910-02 110-03 910-03 110-04 910-04 110-05 910-05 110-06 910-06 91063 91063 91063 91064 91066

0051 0243 0009 0210 0031 0218 0005 0205 0010 0213 0032 0222 0018 0019 0020 0001 0002

Air Cooler Element, Data Air Cooler Element Non-Return Valve after Air Cooler, Data Non Return Valve after Air Cooler Auxilary Blower, Data Auxilary Blower Butterfly Valve, Data Butterfly Valves Turbocharger Turbine, Data Turbocharger Turbine Water Mist Catcher, Data Water Mist Catcher Air Cooler - Tools Air Cooler - Tools Air Cooler - Tools Travelling Trolley Air Cooler - Lifting Tools

MAN B&W Diesel A/S

MAN B&W Diesel A/S

110-1

Air Cooler Element Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X


X

Engage turning gear

X

Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description

D10-02

Aft end cover

D10-04 D10-05

Value

Unit

260

kg

Air cooler element, complete with covers, up to

2500

kg

Front end cover (waterflow reversing chamber)

260

kg


Page 1 (2)

110-1

Air Cooler Element Data


Item No.

Description

P91063

Air Cooler - Tools

P91064

Travelling Trolley

P91066

Air Cooler - Lifting Tools

P91356

Lifting Tools, Etc.

Page 2 (2)


Air Cooler Element MAN B&W Diesel

910-1.1

Checking

1. For the day-to-day checking of the scavenge air cooler, measure the drop in pressure and temperature of the scavenge air across the cooler while the engine is running.

1.

2. An increase in the air pressure drop across the scavenge air cooler indicates fouling of the air side of the cooler. A decrease in the air temperature drop across the scavenge air cooler indicates fouling of the water side of the cooler. 3. If the measurements indicate fouling of the water side of the air cooler element, the element must be overhauled/cleaned. See Procedure 910-1.3 – water side.

M910010243C01

Compare these measurements with the testbed data. For further evaluation of the measurements, see the OPERATION manual, Volume I, Chapter 706.

2.

If the measurements indicate fouling of the air side of the air cooler element, it is recommended to inspect the air cooler element as follows:

Unlock and swing open the inspection hatch at the bottom of the air cooler. 5. Visually inspect the air cooler element through the openings.

M910010243C02

4. Remove the top inspection cover of the air cooler.

3. For further information, see the OPERATION manual, Volume I, Chapter 702 “Checks during Standstill Periods”.

M910010243C03

If the air side of the element is fouled, clean the element using the spray pipe arrangement fitted above the air cooler element. See Procedure 910-1.3 – air side.


Page 1 (10)

910-1.2

Air Cooler Element Dismantling

1.

MAN B&W Diesel

The cooler element normally does not need to be dismantled for inspection purposes. It is only in the event that the cooler element has suffered damage that it has to be dismantled and replaced. Note!

M910010243C04

During dismantling, take care not to damage the cooler element.

2.

1. Close the cooling water inlet and outlet valves. Open the drain cocks to drain off the cooling water and dismantle the drain pipes. Dismount the screws which fasten the cooling water inlet and outlet flanges to the aft end cover. 2. Dismount the brackets which control the longitudinal position of the air cooler element.

M910010243C05

Dismount the sealing flanges around the aft end cover. For convenience, the sealing flanges may be left hanging on the cooling water pipes during dismantling and mounting of the cooler element. 3. Dismount the sealing flanges around the front end cover.

M910010243C06

3.

Page 2 (10)



910-1.2

Dismantling

4. Mount the pair of guide rails on the front of the cooler housing. Mount the lifting bracket on the front end cover of the cooler element.

4.

Mount a travelling trolley on the beam above the front end of the scavenge air cooler. Attach a tackle between the travelling trolley and the lifting bracket, and haul tight.

6. Mount a pair of guide rails on the rear end of the cooler housing.

M910010243D04

5. Mount the guide wheels on the aft end cover.

M910010243D05

5.

M910010243D06

6.


Page 3 (10)

Air Cooler Element

910-1.2

Dismantling

7. When mounting the guide rails, hold them up against the wheels of the cooler element and mount, but do not tighten, the lowermost screws. Mount and tighten the uppermost screws.

7.

1

MAN B&W Diesel

2

Tighten the lowermost screws and the thrust nuts on the uppermost screws simultaneously. This results in loosening and lifting the cooler element.

M910010243D07

8. Tighten the tackle until the front end of the cooler element comes loose. 9. Pull the cooler element out of the cooler housing by means of a tackle until the wheels engage with the holes in the guide rails on the front of the cooler housing.

M910010243D08

8.

M910010243D09

9.

Page 4 (10)

D1003


Air Cooler Element

910-1.3

Overhaul

MAN B&W Diesel 10. Mount a lifting bracket on the aft end cover.

10.

Fit a tackle to the lifting bracket on the aft end cover and lift away the cooler element and land it on a couple of wooden planks. Note!

M910010243D10

Depending on the engine and the engine room installation, it may be necessary to remove some pipes and floor plates.

When referring to this page, please quote M91001 Edition 0243

D1003

Page 5 (10)

910-1.3

Air Cooler Element Overhaul

MAN B&W Diesel

Cleaning the air side: 1. The air side of the cooler is cleaned by injecting a chemical fluid through the spray pipe arrangement fitted to the air chamber above the cooler element. It is recommended to use one of the following cleaning fluids, or a similar product. 1) Product: ACC 9, produced by Drew Chemical Corp., New York, USA 2) Product: 80B, produced by Vecom Int., Maassluis, Holland

M910010243O01

Cleaning should be carried out in the following sequence:

2.

1. Do not start cleaning until the engine has been at a standstill for about 30 minutes. Do not disconnect the compressed air supply to the exhaust valve. 2. Follow the detailed cleaning instructions displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of the cleaning fluid, the circulating pump pressure must be at least 0.7 bar. 3. Continue the cleaning process for at least 30 minutes. The time required depends on the frequency with which cleaning is carried out and on the chemical product used. 4. After cleaning, flush the cooler with clean water until the water appearing in the sight glasses is clean and pure.

M910010243O02

5. Inspect the element either by removing the cover on top of the cooler or by dismantling the charging air pipe.

Page 6 (10)



910-1.3

Overhaul

Cleaning the water side 6. 6. If necessary, remove the air cooler. See Procedure 910-1.2.

M910010243O06

For overhauling the air cooler, see manufacturer’s instruction.

When referring to this page, please quote M91001 Edition 0243

Page 7 (10)

910-1.4

Air Cooler Element Mounting

MAN B&W Diesel

1. Lift the air cooler element and land the aft end of the element on the guide rails mounted on the front end of the air cooler housing.

1.

Remove the tackle and the lifting bracket from the aft end of the cooler element. 2. Push the air cooler element fully into the air cooler housing

M910010243D10

3. Remove the guide rails from the aft end of the air cooler housing. Note! Before pushing the air cooler element fully in, make sure that the sealing flanges and a new O-ring are in position, hanging on the cooling water pipes.

M910010243D05

2.

D1003

M910010243D08

3.

Page 8 (10)



910-1.4

Mounting

4. Remove the guide wheels from the aft end cover.

4.

5. Remove the guide rails and the lifting bracket from the front end cover.

M910010243M04

6. Mount the sealing plate, a new O-ring and the frame around the front end cover.

M910010243M05

5.

M910010243C06

6.


Page 9 (10)

910-1.4

Air Cooler Element Mounting

7.

MAN B&W Diesel

7. Mount the sealing plate, a new O-ring and the frame around the aft end cover. Mount and tighten the brackets which control the longitudinal position of the air cooler element.

M910010243C05

8. Insert new gaskets between the aft end cover and the flanges of the cooling water pipes.

8.

Mount and tighten the screws which fasten the cooling water inlet and outlet pipes to the aft end cover. Mount the drain pipes, and open the cooling water inlet and outlet valves. Note!

M910010243M08

Remember to vent trapped air from the air cooler element.

Page 10 (10)


110-2

Non-Return Valve Data

N D R B I E

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X

Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description


Value

Unit

Page 1 (2)

110-2

Non-Return Valve Data


Page 2 (2)

Item No.

Description


Non-Return Valve

910-2.3

Overhaul Non-Return Valve .0&& 0210 Overhaul 910-2.3

1.

1. Access to the non-return valves in the scavenge air receiver takes place – after the engine has been stopped – through the inspection openings of the receiver.

Access to the scavenge air receiver must not be attempted until the air in the receiver is clean.

MA910-6.0 33 01

Warning!

2. Remove the two outermost and middle nuts (which fasten the valve assembly to the housing).

2.

3. Remove the spring pin from the valve shaft and knock the valve shaft out of the valve flap. 4. For further dismantling, remove the two screws which hold the clamp and the support together as an assembly.

MC910-6.0 26 01B

Lift the complete valve assembly out of the air receiver.

3.

Clean the valve shaft and the slide bearings inside the valve flaps. Lubricate the valve shaft and the slide bearings with molybdenum disulphide (MoS 2).

After the overhaul, it must be possible to move the valve flap by the light touch of a finger. 6. Re-mount the valve in the scavenge air receiver.

MC910-6.0 26 02

5. Assemble the valve

MC910-6.0 26 03

4.


Page 1 (1)

Auxiliary Blower MAN B&W Diesel

110-3

Data



Data Ref. D10-12

Description Electric motor, impeller and motorplate


Value 705

Unit kg

Page 1 (2)

Auxiliary Blower

110-3

MAN B&W Diesel

Data


Plate P91356

Page 2 (2)

Item No.

Description Lifting Tools, Etc.


Auxiliary Blower

910-3.3

Overhaul Auxiliary Blower 60&& 0218 Overhaul 910-3.3

1.

1. When cleaning and inspecting the auxiliary blower, disengage the cable connections to the blower motor. Wire ropes with shackle as well as two tackles suspended from mountings on the gallery bracket are to be hooked onto the blower flange, before removing the screw in the flange. 2. The end cover complete with blower can now be pulled free of the suction pipe by means of the two tackles. MC910-8.0 31 01

While pulling out the end cover with the blower assembly, make sure that the blower housing disengages from the air pipe without deforming it.

D10-12

2.

Then inspect and clean the blower wheel as well as the blower housing. For overhaul of blower wheel and bearings, see blower manufacturer’s instructions.

Exercise care when mounting the electric motor with blower wheel, as the blower wheel is to “catch” the guide in the blower housing.

MC910-8.0 31 02

Note!


Page 1 (1)

110-4

Butterfly Valves Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X


X

Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description


Value

Unit

Page 1 (2)

110-4

Butterfly Valves Data


Page 2 (2)

Item No.

Description


Butterfly Valves

910-4.1

Checking Butterfly Valves 60&& 0205 Checking 910-4.1

1.

1. It is important that the automatic non-return valves (butterfly valves) are always able to function easily and unimpeded. The movability of the valve flaps should therefore be checked at suitable intervals. The valves shall open for the air flow from the scavenge air cooler housings to the auxiliary blowers.

Flow direction

Reach down through the opening in the top of the valve and move the valve flaps. 3. If the valve flaps in one of the butterfly valves cannot be moved by a light touch of a fingertip, it must be dismantled and overhauled.

MN910-4.1 205 01

2. To check the valve, remove the cover on the top of the butterfly valve.

2.

XZ910-9.0 15 02

4. Re-mount the cover on the top of the butterfly valve.


Page 1 (1)

110-5

Turbocharger Turbine Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME-engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description


Value

Unit

Page 1 (2)

110-5

Turbocharger Turbine Data


Page 2 (2)

Item No.

Description


Turbocharger Turbine MAN B&W Diesel

910-5.3

Cleaning

The dry cleaning method employs compressed air to blow dry, solid, granules through the turbocharger, thus removing most of the deposits which may have formed on the nozzle vanes and turbine blades. On account of their hardness, nut-shells, or broken or artificially shaped pieces of activated charcoal with a size of between 2.0 and max. 2.8 mm are particularly suited as blasting agents. This size of granules is also known as Marine Grit No. 8. Note! We do not recommend the use of rice or grain as cleaning materials, as these may possibly stick in the exhaust gas boiler.

It is not always possible to remove thick deposits with this dry cleaning method. Therefore, in order to prevent the build-up of thick deposits, the turbine must be cleaned after every 24 to 100 hours of operation. Generally, turbocharger cleaning can be carried out without, or with very little, reduction of the engine load. More detailed information regarding the amount of granules to be used is stated on the instruction plate located close to the turbocharger. Note! Regarding water washing of turbocharger turbine, see turbine manufacturer’s instructions. See also Volume I, Chapter 706.


Page 1 (2)

Turbocharger Turbine

910-5.3

Cleaning

MAN B&W Diesel

Cleaning Procedure: 1. 1. Carry out cleaning for every 24 to 100 hours of operation, based on observations.

A

C

2. Preferably clean the turbocharger at full load, but not at TC rpm above those stated in table 2. Do not clean below half load.

B 3. Close valve A.

M910050211O01

4. Open valves B and C, to blow out any deposits and/or condensate in the connecting pipe. After about two minutes, close valves B and C. 5. Slowly open valve A to relieve the pressure in the tank.

2. TC type

TC max. RPM

MET 33 SD/E/EII/MA

23300

MET 42 SD/E/EII/MA

18800

MET 53 SD/E/EII/MA

14800

MET 60 MA

13300

MET 66 SD/E/EII/MA

11900

MET 71 E/EII/MA

11000

MET 83 SD/E/EII/MA

9400

MET 90 SE/MA

8500

6. TC type

7. Close valve A. 8. Open valves B and C, to blow-in the granules. After one to two minutes, close valves B and C. 9. Slowly open valve A to relieve the pressure in the tank.

Caution! Amount Dm3

MET 33 SD/E/EII/MA

0.4

MET 42 SD/E/EII/MA

0.7

MET 53 SD/E/EII/MA

1.6

MET 60 MA

2.1

MET 66 SD/E/EII/MA

2.6

MET 71 E/EII/MA

3.0

MET 83 SD/E/EII/MA

3.5

MET 90 SE/MA

3.5

Page 2 (2)

6. Fill the tank with the quantity of granules specified in the table.

1.The drain openings in the gas casings must remain closed while dry cleaning the turbine. 2. It is possible that during dry cleaning of the turbine, some of the blown-in solid particles or sparks will escape through the funnel.


110-6

Water Mist Catcher Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine

X


X


X


X


X

Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear

X

Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

D10-11

Description

Water mist catcher


Value

Unit

260

kg

Page 1 (2)

110-6

Water Mist Catcher Data


Page 2 (2)

Item No.

Description Lifting Tools, Etc.


Water Mist Catcher

910-6.2

Dismantling Water Mist Catcher K98MC 0222 Dismantling 910-6.2

2.

1. Normally it is not necessary to remove the water mist catcher element from the air cooler housing. If, however, the water mist catcher element has been fouled or damaged, it must be dismantled for cleaning or repair. 2. Dismantle the side covers from the air cooler housing.

4. Pull the water mist catcher half way out and screw a lifting eye bolt into the top of the water mist catcher.

NA910-6.2 210 02

3. Loosen the four screws which tighten the water mist catcher to the air cooler frame.

Attach a tackle to the eye bolt and tighten up the tackle.

3.

5. Pull the water mist catcher fully out of the air cooler housing and land it on a couple of wooden planks.

NA910-6.2 210 03

6. Clean or repair according to manufacturer’s instructions.

4.

NA910-6.2 210 04

D10-11


Page 1 (2)

910-6.4

Water Mist Catcher Mounting Mounting 910-6.4

1.

1. Tilt the water mist catcher to the correct angle and slide it into the scavenge air cooler housing.

D10-11

Note! Make sure the water mist catcher is mounted in the right direction. Check the air flow indicator on the water mist catcher. When the water mist catcher is half-way in, remove the tackle and the eye bolt, and push the water mist catcher fully into the air cooler housing.

NA910-6.4 210 01

2. Mount the screws which secure the water mist catcher to the air cooler frame.

NA910-6.4 210 02

2.

3. Clean the side covers and apply a thin layer of silicone paste along the edges of the covers. Mount the covers.

NA910-6.2 210 02

3.

Page 2 (2)


Air Cooler - Tools

Plate P91063-0018

Air Cooler - Tools 0018 P91063

Fore end


Page 1 (2)

Plate P91063-0018 Item No. 015 027 039

Air Cooler - Tools

Item Description

Item No.

Item Description

Guide rail, fore end - left Guide rail, fore end - right Screw

Page 2 (2)


Air Cooler - Tools


Plate P91063-0019

Page 1 (2)

Plate P91063-0019 Item No. 015 027

Page 2 (2)

Air Cooler - Tools Item Description

Item No.

Item Description

Guide rail, rear end Guide rail, rear

When referring to this page, please quote Plate

Edition MAN B&W Diesel A/S

Air Cooler - T ools Tools MAN B&W Diesel


Plate P91063-0020

Page 1 (2)

Air Cooler - T ools Tools

Plate P91063-0020 Item No. 015 027 039

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Wheel for air cooler, left Wheel for air cooler, right Screw


Travelling Trolley

Plate P91064-0001

Travelling Trolley 0001 P91064


Page 1 (2)


Travelling Trolley

Item Description

Item No.

Item Description

Travelling trolley

Page 2 (2)


Air Cooler - Lifting T ools Tools MAN B&W Diesel


Plate P91066-0002

Page 1 (2)

Plate P91066-0002 Item No. 011 023

Page 2 (2)

Air Cooler - Lifting T ools Tools MAN B&W Diesel

Item Description

Item No.

Item Description

Lifting attachment air cooler Screw


911 - Safety Equipment Documents in this Chapter 111-01 911-01 111-02 911-02 111-03 911-03

0026 0212 0013 0211 0001 0001

Safety Valve, Data Safety Valve Relief Valve, Data Relief Valve Scavenge Air Receiver Safety Valve, Data Scavenge Air Receiver Safety Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Safety Valve MAN B&W Diesel

111-1

Data


X X X X X X X


Data Ref.

Description

D11-01

Opening pressure

D11-02

Valve housing, tightening torque


Value

Unit

200± 5

bar

45

Nm

Page 1 (2)

Safety Valve

111-1

MAN B&W Diesel

Data


Item No.

Description

P91351

10


P91351

58


P90151

117

P91359

Page 2 (2)

Test equipment for combined safety valve Torque Spanners



911-1.2

Dismantling

When Side-mounted

1.

1. Remove the guard surrounding the safety valve. Unscrew the safety valve from the extension pipe.

When Top-mounted 3. Unscrew the safety valve from the cylinder cover.

2.

M911010211D02

Remove and discard the mild steel disc.

M911010211D01

2. Dismantle the indicator cock and the intermediate pipe.

M911010211D03

3.


Page 1 (5)

911-1.3

Safety Valve Overhaul (Adjustment)

1.

MAN B&W Diesel

1. If necessary, dismantle the safety valve and clean all the parts in either gas oil, kerosene, or ‘electro-cleaner’. 2. Assemble the safety valve in two steps:

• Insert the valve flap and the stop ring in the valve guide and screw on the valve housing.

• Tighten the housing to the torque stated M911010211O01

in the data, loosen and tighten again to the torgue stated in the data. 3. Then mount:

•

the valve spindle

•

the spring

•

the adjusting screw

•

the lock nut

M911010211O02

2.

M911010211O03

3.

Page 2 (5)



911-1.3

Overhaul (Adjustment)

4. To set the safety valve opening pressure:

4.

• Set up the safety valve in the Fuel valve test rig.

• Connect the testing device to the hydraulic pump. Alternatively the hydraulic hans pump can be used.

• Loosen the lock nut on the safety valve. • Turn the adjusting screw until the valve just closes.

• Bleed the valve and hose until oil, without air bubbles, flows out from the openings of the safety valve.

• Tighten the adjusting screw of the

• Tighten the lock nut. • Test the opening pressure. • Remove the valve from the fuel valve

M911010212O04

safety valve until the correct pressure is indicated (see Data).

test rig.


Page 3 (5)

911-1.4

Safety Valve Mounting

MAN B&W Diesel

When Side-mounted 1. 1. Pierce the bore in the cylinder cover, and blow it clean. 2. Clean the sealing ring grooves of the indicator cock. Mount the intermediate pipe and the indicator cock.

M911010211M01

3. Mount a new sealing ring and a new or overhauled safety valve. When mounting the safety valve, apply tools only on the hexagon on the safety valve. Mount the guard surrounding the safety valve.

M911010211M02

2.

M911010211M03

3.

Page 4 (5)



911-1.4

Mounting

When Top-mounted 4. 4. Pierce the bore in the cylinder cover, and blow it clean. Clean the thread and the sealing surface. 5. Mount a new or overhauled safety valve.

When mounting the safety valve on the cylinder cover, apply tools only on the hexagon on the safety valve.

M911010211M04

Mount a new mild steel disc in the bore.

M911010211M05

5.


Page 5 (5)

111-2

Relief Valve Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X

Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME-engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water

X

Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors

Data Ref.

Description


Value

Unit

Page 1 (2)

111-2

Relief Valve Data


Page 2 (2)

Item No.

Description


Relief Valve

911-2.1

Checking Relief Valve 60& 0211 Checking 911-2.1

1.

1. During running of the engine, check if there are any leaks. If a leak occurs, replace the O-ring inside the relief valve. See separate instructions from the valve manufacturer. 2. If work involving risks of mechanical damage to the flame arrester has taken place, a visual inspection of the flame arrester should always be performed before starting the engine.

If one or more plates in the flame arrester are damaged, the relief valve must be disassembled and the flame arrester replaced. See separate instructions from the valve manufacturer.

Note!

XZ911-2.1 209 01

Check on the whole circumference that all the plates in the flame arrester are evenly distributed and that no local openings exist.

The complete flame arrester has to be replaced after a crankcase explosion.

XZ911-2.1 207 03

2.


Page 1 (1)

Scavenge Air Receiver Safety Valve MAN B&W Diesel

111-3

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 X X X X

Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines

X

Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps

X

Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply

X


Data Ref.

Description


Value

Unit

Page 1 (2)

Scavenge Air Receiver Safety Valve

111-3

MAN B&W Diesel

Data


Page 2 (2)

Item No.

Description



911-3.1

Checking

1. The scavenge air receiver safety valve is calibrated at the factory and does not require any adjustment.

2.

2. Check the scavenge air receiver safety valve by loosening the counter nut and turn the forced opening screw to open the valve approx. 10 millimetres.

If this operation cannot be performed smoothly, the safety valve must be dismantled and cleaned.

M911030001C02

Use a piece of cloth to wipe out any dirt from the Oring packing and close the valve again. Tighten the counter nut.


Page 1 (5)

911-3.2

Scavenge Air Receiver Safety Valve Dismantling

1.

MAN B&W Diesel

1. Dismount the safety valve from the scavenge air receiver.

M911030001D01

2. On some engines, a cover has to be removed in order to gain access to the safety valve.

M911030001D02

2.

Page 2 (5)



911-3.3

Overhaul

1. Remove the split pin.

1.

Unscrew the nut thereby relieving the spring tension. Remove the nut, spring retainer and washers. Keep count of the washers.

2. Pull out the valve flap with spindle. If the Oring seal is damaged remove it without damaging the Oring groove. 3. Clean the metal surfaces thoroughly.

M911030001O01

Pull out the spring.

M911030001O02

2.


Page 3 (5)

911-3.3

Scavenge Air Receiver Safety Valve Overhaul

4.

MAN B&W Diesel

4. If the Oring seal has been removed mount a new one using Locktite type AVX and Loctite activator type T or similar. 5. Push in the valve flap and spindle while taking care not to damage the Oring seal. 6. Mount the spring, spring retainer and all the washers.

M911030001O04

Tighten the nut until the split pin can be mounted. 7. Check the valve according to 9113.1.

M911030001O05

5.

M911030001O01

6.

Page 4 (5)



911-3.4

Mounting 1.

M911030001M01

1. Mount the safety valve on the scavenge air receiver.


Page 5 (5)

912 - Assembly of Large Parts Documents in this Chapter 112-02 912-02 112-03 912-03 912-05 91261 91265

0015 0208 0027 0213 0201 0075 0002

Holding Down & End Chock Bolts, Data Holding Down and End Chock Bolts Stay Bolts, Data Stay Bolts Crankcase Oil Outlet Hydraulic Tools for Large Parts Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Holding Down And End Chock Bolts MAN B&W Diesel

112-2

Data

SAFETY PRECAUTIONS For detailed sketch, see 900-2 Stopped engine Shut off starting air supply – At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply Shut off safety air supply – Not ME engines Shut off control air supply Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. D12-02

Description

Value

Unit

Check holding down bolts and end chock bolts for correct tightening after the following service hours:

D13-01

1st check

500

hours

2nd check

1000

hours

3rd check

2000

hours

4th check

4000

hours

5th check

8000

hours

Subsequent checks at intervals of

8000

hours



900

bar

Page 1 (2)

Holding Down and End Chock Bolts

112-2

MAN B&W Diesel

Data


Item No.

P91263

Description Hydraulic Tools for Holding-Down Bolts and End Chock Bolts, Epoxy

P91351

010


P91351

058


Page 2 (2)



912-2.1

Checking Holding Down and End Chock Bolts .0& 0208 Checking 912-2.1

Note! The hydraulic jack used for tightening the holding down bolts is marked with: For: Holding down bolts The larger jack used for tightening the end chock bolts is marked with: For: End chock bolts Hydraulic tightening of holding down bolts and end chock bolts is carried out as detailed in Section 913-1. The normal tightening pressure is indicated on the Data sheet and is also stamped on the tightening tool.


Page 1 (5)

912-2.1

Holding Down and End Chock Bolts Checking

1.

Checking the Bolt Tightening 1. The holding down bolts and end chock bolts must be checked for correct tightness at the intervals indicated on the Data sheet. For this purpose, raise the pressure on the hydraulic tool slowly while constantly attempting to loosen the nut with the tommy bar. The oil pressure indicated on the pressure gauge when the nut comes loose (‘loosening pressure') is to be noted down in the checking tables, see pages 4 and 5, following which the bolts are tightened to the normal tightening pressure.

EN912-1.1 205 01

The condition of the bolted joints, and thus the general condition of the foundation, can be effectively checked by comparing the tables from successive bolt checks. If the ‘loosening pressure' is below 80 per cent of the tightening pressure, the relative chocks shall always be checked for possible defects. If the chocks are in position and in order, the bolts should be taken out for inspection of threads and contact faces. Checking of Epoxy Supporting Chocks 2. If a number of measuring pins have been welded to the tanktop, the heights of the epoxy supporting chocks are to be checked immediately after finishing the checking of the loosening pressures of the holding down bolts and the retightening of these. The distance between the measuring pins and the bedplate is to be measured with a blade gauge and noted down. Any possible settling of the chocks during the intervals between measurements can thereby be followed.

Page 2 (5)



912-2.1

Checking 3.

Side Chocks and Side Chock Liners 3. After fitting the liners to an 80 per cent contact area on both sides of the liners, knock the liners a further 3 to 4 mm inwards.

The first time the ship is sailing in a fullyloaded condition after the engine has been operating for 1,000 hours, all side chocks should be checked to see whether the liners can be knocked further inward. The fit of the side chock liners should be checked with a feeler gauge each time the loosening pressure of the holding down bolts is checked, and thus at the same time intervals.

GN912-2.1 203 03

The liners located in way of each main bearing on either side of the engine must be fitted and knocked into position simultaneously.

The feeler gauge is applied at the 7 points indicated in the table on page 5, and the measurements found are to be entered in the relevant table. These results are used to determine whether refitting or, possibly, replacement of the liners is necessary. If the measurements at 3 points or more have increased 5/100 mm or more from the initial results, we recommend that the following procedure is followed: 1. Loosen the hexagon screws. 2. Try to knock the liner further inward. 3. Measure again at the 7 points indicated in the table. If this procedure does not improve the situation, the liner must be removed, and it must be checked that the actual contact area is more than 80 per cent of the possible contact surface areas on both sides of the liner. The liners are secured in their correct position by means of hexagon socket set screws with cup point.


Page 3 (5)


912-2.1

Checking Holding Down Bolts Engine frame Bolt No. No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Page 4 (5)

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1

Port side pressure

% dev.

remarks

Cylinder No.

1 2 3

Starboard side pressure

% dev.

remarks

Bolt No.

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1

Engine frame No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14



912-2.1

Checking Side Chocks and End Chock Bolts

Port side Point c d e

Chock No.

A

Starboard side

B

f

g

Cylinder No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

B

Chock

f

d e f

B

c

g

g

c

B

f

Pres-

A

e

Port side

c, d, e, f, g

Starboard side

Devi-

Ch Bolt sure ation 2) No. No. (kp/cm % bar

No.

A, B

d

A

FORE

c, d, e, f, g

g

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3

A, B

E

A

Point c d e

Deviation

Point

Point

a b c d e

a b c d e

%

Pressure

(kp/cm 2 )

bar

1 2

Bolt Ch No. No.

1 E 2 b

c

a

d

d

e

e

c

b a

Contact face No. 1

No. 2

B1


B2

B2

B1

AFT

No. 2

Page 5 (5)

Stay Bolts MAN B&W Diesel

112-3

Data


X X X X X X


Data Ref.

Description

Value

Unit

D12-04

Check measurement

0.4

mm

D13-01


900

bar

D13-02


800 - 990

bar


Page 1 (2)

Stay Bolts

112-3

MAN B&W Diesel

Data


Item No.

P91261

Description Large Parts - Tools

P91351

010


P91351

046


P91351

058


P91351

105


Page 2 (2)


Stay Bolts

912-3.1

Checking Stay Bolts K90MC-C 0213 Checking 912-3.1

1.

1. Before retightening the stay bolts, remove the protective caps.

Connect the high-pressure pump by means of the high-pressure hoses, so that the two stay bolts are tightened in one operation. 3. If the engine is equipped with split staybolts and one or more staybolts have been dismantled, make sure that the staybolts are mounted in such a way that, when the uppermost staybolt nut is loosened, there is a clearance, as stated in Data, between the contact face of the lowermost nut and the bedplate. If the engine is equipped with staybolts in one piece, please disregard the above.

HM912-3.0 28 01

2. Clean the contact faces and mount the hydraulic tools on a pair of stay bolts positioned opposite each other on the middle of the engine.

2.

MB912-3.1 213 02

D13-01

3.

HM912-3.0 28 07

D12-05


Page 1 (2)

912-3.1

Stay Bolts Checking

4.

4. Start the retightening of the stay bolts and proceed to tighten the stay bolts in pairs, working from the middle toward one end of the engine and then from the middle again toward the other end. 5. Pump up the hydraulic pressure to 10% below the value indicated in D13-01, and retighten the stay bolt nuts with a tommy bar if possible. Before relieving the system of pressure, check with a feeler gauge that the nuts bear against the contact face.

HM912-3.0 28 03

6. Reconnect the hydraulic tools to the pair of stay bolts first tightened. Tighten to 10% below D13-01 and check if the nut is loose.

5.

D13-01 -10%

If the nut is not loose: Tighten the stay bolts to D13-01. If the nut is loose: Tighten all stay bolts once again to D13-01.

MB912-3.1 213 05

7. After completing the retightening procedure, mount the protective caps.

HM912-3.0 28 06

6.

Page 2 (2)


Crankcase Oil Outlet MAN B&W Diesel

912-5.1

Checking

The crankcase oil outlets guide the lubricating oil from the crankcase to the lubricating oil bottom tank. The sealings of the crankcase oil outlets must be checked at regular intervals, for example during dockings. The crankcase oil outlets may be equipped with either rubber diaphragm sealing or metal bellow sealing.

1.

E

F

G

D

C

B

A

If the water content of the main engine lube oil is rising, this may indicate that the crankcase oil outlet sealings are fractured. Rubber diaphragm sealing 1. To access the rubber diaphragm sealing remove: Screws A Grating B Screws C Cover plate D Screws E Steel ring F.

M912050201C01

Note!

2.

Note! It is strongly recommended to always replace the diaphragms during inspection. If unavailable, new diaphragms may be made from three layers of 2 mm thick oil and temperature resistant rubber.

M912050201C02

2. Lift away the rubber sealing diaphragms G and examine each diaphragm closely. In case of any rips or tears in the diaphragms, they must be replaced.

3. Mount: Rubber sealing diaphragms G Steel ring F Screws E Cover plate D Screws C Grating B Screws A. Note! Remember to fit new locking plates at screws A.


Page 1 (2)

Crankcase Oil Outlet

912-5.1

Checking

MAN B&W Diesel

Metal bellow sealing 4. 4. Remove all screws A and grating B.

C D

5. Remount four of the screws A at diametrically opposite positions.

B A

6. Remove: Screws C Cover plate D Screws E.

F

M912050201C04

E

G

H

7. Lift away metal bellow sealing F and examine it closely. If any cracks or punctures are found in the metal bellow sealing, it must be replaced. Note!

7.

It is recommended to always replace the metal bellow sealing during inspection.

8. Replace gaskets G and H. 9. Mount metal bellow sealing F.

M912050201C07

10. Mount: Screws E Cover plate D Screws C. 11. Remove the four screws A. 12. Mount grating B. 13. Mount all screws A.

Page 2 (2)


Large Parts - Tools


Plate P91261-0075

Page 1 (2)

Plate P91261-0075 Item No. 023 035 047 050 060 096 202

Page 2 (2)

Large Parts - Tools

Item Description

Item No.

Item Description

Hydraulic jack, complete Support Tommy bar Sealing ring with back-up ring Sealing ring with back-up ring Spanner Hydraulic tool set, complete


Hydraulic Tools - Holding Down Bolts (Epoxy Chocks)

Plate P91265-0002

Hydraulic Tools - Holding Down Bolts (Epoxy Chocks) 0002 P91265


Page 1 (2)

Plate P91265-0002 Item No. 013 025 037 049 050 062 098 108

Hydraulic Tools - Holding Down Bolts (Epoxy Chocks) Item Description

Item No.

Item Description

Wooden box Hydraulic jack, complete Support Tommy bar O-ring with back-up ring O-ring with back-up ring Key, hexagon socket screw Stud setter

Page 2 (2)


913 - General Tools Documents in this Chapter 913-01 913-03 913-04 913-05 913-06 913-07 91311 91351 91356 91357 91359 91360 91361 91362 91363 91364 91366 91368

0211 0007 0202 0205 0205 0207 0204 0034 0051 0006 0003 0005 0052 0060 0040 0059 0066 0011

Hydraulic Tools Working Platforms Standard Tightening Torques Torque Spanner Tightening Gauge Screws and Nuts Lubricating Accessories - Hydraulic Tools Lifting Tools, etc. Open-Ended Spanners Torque Spanners Pliers Combination Spanners Ring Slugging Spanners Spanners Open-Ended Spanners Instruments Working Platforms

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Hydraulic Tools

913-1

Hydraulic Tools 0211

A. Snap-on coupling 913-1

1.

B. Tool attachment thread C. Bleed screw D. Piston E. Cylinder F.

Sealing rings

G. Spacer ring

I.

Nut

J.

Stud or bolt

K. Extension stud S. Clearance U. Milled recess for feeler gauge

HM913-1.0 10 00

H. Tommy bar

2.

Studs or bolts provided with threads for attaching hydraulic tools and with circular nuts must only be loosened and tightened up by means of the hydraulic tools supplied. The jack(s) is/are connected, via a distributor block, to a high-pressure pump, which is set to deliver hydraulic oil at the pressure indicated on the jack and on the data sheet in the relevant section of this instruction book. The stud or bolt concerned is thereby lengthened relative to the oil pressure applied and the piston area, and the nut can be loosened or tightened, as required, with the aid of a tommy bar.

1. The hydraulic tools, except those for the main bearings, consist of a jack with an internal thread to suit the tool attachment thread on the stud or bolt, and a spacer ring which is to be placed under the jack and around the nut that is to be loosened or tightened.

KC913-1.0 17 02

The jacks must never be overloaded or exposed to blows or impacts. They are marked with a “Max. lift”, which must not be exceeded.

2. For the main bearings, an extension stud, three extra lower hydraulic jacks and a nut are added to each set. Each part is marked with a sign showing where to use the specific part.


Page 1 (12)

913-1

3.

Hydraulic Tools

3. The hydraulic jacks are so designed that, in the event that the “Max. lift” limit is exceeded, the pressure is relieved at the bottom of the pressure chamber, and the oil will be pressed out into the space between the stud and the spacer ring. When the pressure is relieved in this way, the lowermost sealing ring will in most cases be damaged. Therefore inspect and, if necessary, replace this sealing ring. The oil used must be pure hydraulic oil or turbine oil (with a viscosity of about SAE 20). Oils such as, for instance, lubricating oil (system oil) or cylinder lubricating oil must not be used, as these oils are normally alkaline and can thus damage the backup rings.

MB913-1.0 14 03

The following instructions must be closely followed to prevent accidents or damage. After use, the jacks should be cleaned and kept in the wooden boxes supplied. Warning! 4.

Eye protectors and gloves must be used when using hydraulic tools. Maintenance

KC913-1.0 17 04

4. Disassembling the piston and cylinder is best carried out by taking out one of the bleed screws and pressing the parts from each other by means of compressed air.

Page 2 (12)

After disassembling, check that there are no damage marks on the sliding surfaces of the parts. If metal particles are present, they will damage the sealing rings. Keep the sliding surfaces and threads coated with acid-free grease or molybdenum disuplhide. The hydraulic nuts do not require any maintenance other than replacement of defective sealing rings. These consist of an O-ring and a back-up ring, which are positioned in ring grooves in the piston and cylinder.


Hydraulic Tools

913-1

Loosening of Nut Loosening of Nut 913-1

1.

Single Hydraulic Jack 1. Carefully clean the tool attachment thread, the nut and the surrounding parts. Grease the tool attachment thread with molybdenum disulphide grease or with graphite and oil or similar. Place the spacer ring around the nut in such a position that the tommy bar can be applied through the slot when the nut is to be loosened.

Connect the jack, the distributor block, and the high-pressure pump by means of highpressure hoses.

HM913-1.1 10 01

2. Screw the jack on to the tool attachment thread of the bolt/stud, until the cylinder of the jack bears firmly against the spacer ring, and check that the parts are guided correctly together.

2.

Loosen the bleed screw and fill the system until oil, without bubbles, flows out of the bleed hole. Then tighten the bleed screw again. Adjust the clearance between the piston and cylinder of the jack (see the sketch and table) to provide for contraction of the bolt/ stud. If the clearance is too large, adjustment is made by loosening the bleed screw and turning the jack. The clearance is to have relation to the "Max. lift" of the jack and has the purpose of making it possible to dismount the jack after loosening the nut.

HM913-1.1 10 02

After adjustment, check again that there is no clearance between the cylinder/spacer ring/surface.


Page 3 (12)

913-1

Hydraulic Tools Loosening of Nut

3.

3. Increase the oil pressure to the prescribed value. If the nut does not come loose, the pressure may be increased by approx. 90 bar. 4. Unscrew the nut with the tommy bar, making sure that the nut is not screwed up against the jack.

HM913-1.1 10 03

5. Relieve the system of pressure, disconnect the high-pressure pump, and remove the hydraulic tools.

HM913-1.1 10 04

4.

HM913-1.1 10 01

5.

Page 4 (12)


Hydraulic Tools

913-1

Loosening of Nut 6. 7.

Triple Hydraulic Jack 6. Carefully clean the tool attachment threads, the main bearing studs, the nuts and the surrounding parts. Grease the tool attachment threads with molybdenum disulphide grease or graphite and oil or similar.

Using the lifting tool, place the spacer rings over the extension studs in such a position that the tommy bar can be applied through the slots for the purpose of loosening the nuts. 7. Press the pistons and the cylinders of all the hydraulic jacks firmly together.

KC913-1.1 17 06

Mount the extension studs on the main bearing studs.

Mount the three jacks (one by one using the lifting tool) over the extension stud and land them on the spacer ring.

8.

Make sure that both the cylinders of the jacks and the spacer ring are guided correctly together. Screw the upper nuts on to the threads of the extension studs until the cylinders of the jacks bear firmly against each other and against the spacer ring. 8. The clearance between the pistons and the cylinder of the top jack is adjusted by unscrewing the upper nuts 1 turn 3 mm.

Connect the hydraulic jacks, the distributor block and the high pressure pump by means of high pressure hoses. Loosen the bleed screws in all the jacks, and fill up the system until oil, without bubbles, flows out of the bleed holes.

KC913-1.1 17 08

The clearance between the jack and spacer ring has the purpose of making it possible to dismount the jack after loosening the nut.

Re-tighten the bleed screws.


Page 5 (12)

913-1

Hydraulic Tools Loosening of Nut

9.

9. Increase the oil pressure to the prescribed value. If the nut does not come loose, the pressure may be increased by approx. 90 bar. 10. Unscrew the lower nuts 1½ turns with the tommy bar, making sure that the nuts are not screwed up against the extension stud.

KC913-1.1 17 09

11. Relieve the system of pressure, disconnect the high-pressure pump, and remove the hydraulic tools.

KC913-1.1 17 11

11.

Page 6 (12)


Hydraulic Tools

913-1

Tightening of Nut Tightening of Nut 913-1

1.

Single Hydraulic Jack 1. Thoroughly clean the nut, the thread, the contact faces, and the surrounding parts. Clean and lubricate the tool attachment thread and the thread in the nut with molybdenum disulphide grease or with graphite and oil or similar. Fit the round nut on the thread and tighten it with the tommy bar.

Place the spacer ring around the nut in such a position that the tommy bar can be applied through the slot for the purpose of tightening the nut. 2. Press the piston and the cylinder of the jack firmly together.

HM913-1.1 10 01

Check with a feeler gauge that the contact face of the nut bears on the entire circumference.

2.

Screw the hydraulic jack on to the tool attachment thread. Make sure that the cylinder of the jack bears firmly against the spacer ring and that the parts are guided correctly together. Connect the hydraulic jack, the distributor block and the high-pressure pump by means of high-pressure hoses. Loosen the bleed screw in the jack and fill up the system with oil, until oil without bubbles flows out of the bleed hole.

HM913-1.1 10 02

Re-tighten the bleed screw.


Page 7 (12)

913-1

Hydraulic Tools Tightening of Nut

3.

3. Increase the oil pressure to the prescribed value, and tighten the nut by applying the tommy bar through the spacer ring slot. 4. While maintaining the pressure, check with a feeler gauge introduced through the recess at the bottom of the spacer ring that the nut bears against the contact face. 5. Relieve the system of pressure, disconnect the pump, and remove the hydraulic jack.

HM913-1.2 10 03

&DXWLRQ

KC913-1.2 17 04

4.

When new studs, bolts or nuts are tightened for the first time, do not remove the jacks, but loosen the nut as described under ‘Loosening’, points 3-4-5, and then tighten the nut again according to the procedure under ‘Tightening', points 3-45.

Page 8 (12)


Hydraulic Tools

913-1

Tightening of Nut 7.

Triple Hydraulic Jack 6. Thoroughly clean the nuts, the threads on the main bearing studs, the contact faces, and the surrounding parts. Clean and lubricate the tool attachment thread and the threads in the nuts with molybdenum disulphide grease or with graphite and oil. Fit the round nuts on the threads and tighten them with the tommy bar. Check with a feeler gauge that the contact faces of the nuts bear on the entire circumference.

Using the lifting tool, place the spacer ring over the extension studs in such a position that the tommy bar can be applied through the slots for the purpose of tightening the nuts.

KC913-1.2 17 07

Mount the extension studs on the main bearing studs.

7. Press the piston and the cylinder of all the hydraulic jacks firmly together.

8.

Mount the three jacks (one by one using the lifting tool) over the extension studs and land them on the spacer ring. Make sure that both the cylinders of the jacks and the spacer ring are guided correctly together. Screw the upper nuts on to the threads of the extension studs until the cylinders of the jacks bear firmly against each other and against the spacer ring. 8. Connect the hydraulic jacks, the distributor block and the high pressure pump by means of high pressure hoses.

Re-tighten the bleed screws.

KC913-1.2 17 08

Loosen the bleed screws in all the jacks, and fill up the system with oil until oil, without bubbles, flows out of the bleed holes.


Page 9 (12)

913-1

Hydraulic Tools Tightening of Nut

10.

9. Increase the oil pressure to the prescribed value, and tighten the nuts by means of the tommy bar applied through the slots of the spacer ring. 10. While maintaining the pressure, check with a feeler gauge introduced through the recesses at the bottom of the spacer ring that the nuts bear against the contact face.

KC913-1.2 17 10

11. Relieve the system of pressure, disconnect the pump, and remove the hydraulic tools.

KC913-1.2 17 11

11.

12. When new studs, bolts or nuts are tightened for the first time, do not remove the jacks, but loosen the nuts as described under ‘Loosening', points 9-10-11, and then tighten the nuts again according to the procedure under ‘Tightening', points 10-11-12.

Page 10 (12)


Hydraulic Tools

913-1

Maintenance Maintenance 913-1

1.

1. The hydraulic jacks require no maintenance except replacement of defective sealing rings, each of which consists of an O-ring and a back-up ring fitted in ring grooves in the piston and cylinder. The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart with the help of compressed air. Make sure that there are no marks or scratches on the sliding surfaces of the parts. The presence of metal particles will damage the sealing rings.

KC913-1.0 17 04

The pistons and cylinders of the lower jack are separated in the same easy way as described for the upper jack.


Page 11 (12)

913-1

Hydraulic Tools Maintenance

3.

2. When changing the sealing rings, first mount the back-up ring and then the O-ring. Note! Note that the back-up ring (1) must be away from the pressure chamber and the O-ring (2) close to the pressure chamber. See the sketch for the correct mounting of both the upper and the lower sealing rings. The same principle applies to all the jacks.

KC913-1.4 17 03

3. After fitting the sealing rings, coat the piston and cylinder with molybdenum disulphide grease and press the piston and cylinder together. See that the rings do not get stuck between the piston and cylinder.

HM913-1.4 10 02

4.

Page 12 (12)


S70MC

Working Platforms

913-3.4

Mounting WorkingPlatforms S70MC 0007 Mounting 913-3.4

1.

Before carrying out the checking and overhaul procedures underlined below in Items 1, 2 and 4, platform boards should be mounted inside the engine crankcase. During mounting of the platforms, always use the harness, lanyard and fall arrester. It is always recommended to clean and wipe off oil from steps, crankthrow, doorways and assembling surfaces.

1. Checking the crankshaft alignment, using an Autolog: Turn the engine into a position where it is possible to place the ladder on the crankpin bearing stud nuts.

2.

s913-3.4 0007 02

2. Piston rod stuffing box and telescopic pipe: Put in the standard platform board as a floor as shown on the sketch. Turn the engine to BDC. Mount the platform board from the exhaust side of the engine as shown.

s913-3.4 0007 01

The platform boards are placed inside the engine as shown in the following.


Page 1 (2)

913-3.4

Working Platforms

S70MC

Mounting 3.

3. The working platform support is mounted as shown in sketch 3.

s913-3.4 0007 03

4. Main bearing dismantling: Turn the engine to 80° after TDC. Mount the platform support in a longitudinal direction on the steps in the bedplate.

4.

5. Mount the longest platform board, with the ladder attached, on the support and, by means of a rope, lower the platform support ladder into place on the crankthrow. The double platform board can now be placed on the support and the long platform board.

Note!

s913-3.4 0007 04

Always remember to remove the platform boards on completion of each working procedure or before turning the engine.

s913-3.4 0007 05

5.

Page 2 (2)


Standard Tightening Torques

913-4

MAN B&W Diesel When tightening screws, studs or nuts for which no torque is specified in the instruction procedure or the related data sheet, the standard torques specified in this procedure are to be applied. 1.

4. Screwing-in of studs. The intention of this procedure is to ensure that the studs are screwed right to the bottom of the threaded holes.

Standard screws and nuts lubricated with a Molybdenum Disulphide (MoS2) based lubricant. Thread M8 M10 M12 M14 M16 M18 M20

Tightening torque 17 Nm 35 Nm 50 Nm 80 Nm 135 Nm 190 Nm 260 Nm

Thread M22 M24 M27 M30 M33 M36 M39

Carefully clean off any burrs and loose particles from the thread and contact faces, and coat the thread with a lubricant having a particle size of approx. 0.5 µm, for instance MoS2 (molybdenum disulphide) or a non-synthetic graphite mixed with oil.


The studs are to be screwed-in applying the torque specified in the instruction procedure in use. If nothing is mentioned in the instruction procedure, Fig. 4 indicates the torque. For thread sizes > M36 the curve indicates a screwing-in torque of 680 Nm.

2. Self-locking nuts.

M22 M24 M27 M30 M33 M36 M39

3. Screws and nuts locked with glue/Loctite. Thread M8 M10 M12 M14 M16 M18 M20


Thread M22 M24 M27 M30 M33 M36 M39


Screwing-in torque curve 1000 800

To r q u e (Nm )

M8 M10 M12 M14 M16 M18 M20

Thread


600 400

200

M913040202C04

Thread


100 10

20 40 60 Major diameter of thread (mm)


80 100

Page 1 (1)

Torque Spanner

913-5

Torque Spanner /0& 0205 913-5

Before screwing the nuts on, the threads and the contact faces should be greased with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient µ = 0.1-0.12 (e.g. MOLYKOTE paste type G). The nuts should fit easily on the thread, and it should be checked that they bear on the entire contact face. In the case of new nuts and studs, the nuts are to be tightened and loosened two or three times so that the thread may assume its definite shape; thus obviating the risk of loose nuts. Nuts secured with a split pin are to be tightened to the stated torque and then to the next splitpin hole. The torque spanner must not be used for torques higher than those stamped on it, and it must not be damaged by hammering on it or the like. Rahsol Torque Spanner The handle of the torque spanner is provided with a scale indicating the torques at which the spanner can be set. For setting the spanner at the required torque, there is a ball on a small arm at the end of the handle. When the ball is pulled, a small crank handle appears. A spring-loaded slide in the handle is provided with a mark which, when the crank handle is turned, can be set at the required torque on the scale. The torque spanner works as follows: The above-mentioned spring acts on a pawl system in the handle. When the pre-set torque has been reached, the pawl system is released, at which moment a small jerk is felt in the spanner, and a small click is heard. When the torque spanner is not in use, the spring inside should be released by adjusting to minimum torque.


Page 1 (1)

Tightening Gauge

913-6

Tightening Gauge 0205 913-6

Preparations Before screwing on the nuts, grease the threads and the contact faces with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient. µ = 0.1–0.12 (e.g. MOLYKOTE paste type G) The nuts should fit easily on the thread, and it should be checked that they bear on the entire contact face. Pre-tightening with a torque spanner Before tightening the nuts according to a tightening gauge or tightening angle, they must be pre-tightened with a torque spanner. See Procedure 913-5. Apply a pre-tightening torque of: – thread M8 – M20 = 50 Nm – thread M22 – M27 = 100 Nm – thread M30 – M39 = 150 Nm – thread M42 – M48 = 200 Nm This is in order to ensure a uniform basis for the subsequent tightening with gauge or tightening angle. Tightening with a tightening gauge After pre-tightening, place the tightening gauge round the nut, and mark off with chalk on the nut at slot A on the tightening gauge, and make another chalk mark on the contact face at slot B. Then tighten the nut until the two chalk marks coincide. Tightening without a tightening gauge For tightening angles of e.g. 30°–45° and 60°, we usually do not deliver a tightening gauge. Therefore, after pre-tightening, mark the angle on a corner of the nut and on the contact face, respectively. Then tighten the nut until the two marks coincide. When tightening new studs or bolts for the first time, loosen again and repeat the procedure – including pre-tightening with a torque spanner, to allow the parts to settle. See Procedure 913-5.

7 ; G Q D 0 +


Page 1 (1)

Screws and Nuts MAN B&W Diesel

913-7.1

Locking

Some screwed and bolted connections on the engine, as well as some movable joints, are secured against untimely loosening by means of different types of locking devices.

1.

When reassembling the engine after overhauls, it is vital that all such screws and nuts are again locked correctly.

Make sure only to mount locking devices on nuts and screws which have been mounted with locking devices by the engine manufacturer.

1. Lock washers, tab washers, locking plates, etc., must always be replaced. The tab-like projections, etc., on the washers are to be bent back over one of the flats of the screw or nut concerned.

M913070207C01

Note!

2.

2. Used spring washers must be replaced.

To tighten a self-locking nut to a specific torque, first measure the torque required to turn the nut itself, and then add this torque to the torque value stated on the data sheet of a procedure.

M913070207C02

3. Self-locking nuts may only be used five times. Therefore, give the nut a centre punch mark each time it is loosened.

M913070207C03

3.


Page 1 (4)

Screws and Nuts

913-7.1

Locking

Fig. 1

MAN B&W Diesel

Locking wire should be fitted after the screws or nuts have been tightened to the correct torque. Do not overtighten or loosen the units to get a correct alignment of the wire holes. Always fit new wire after tightening-up the units.

Fig. 2

Any tendency of the screws or nuts to loosen will be counteracted by a tightening of the locking wire. Do not secure more than four units in a series, unless otherwise specified.

Fig. 3

Fig. 1: Insert wire, grasp the upper end of the wire and bend it around the head of the screw, then under the other end of the wire, be sure that the wire is tight around the head. Fig. 2: Twist the wire clockwise until it is just short of the hole in the second screw. Keeping the wire under tension, twist it until tight. When the wire is tight, the wire shall have approximately 7-10 twists per 25 mm. One twist is a twist of the wires through an arc of 180°, equal to half of a complete turn.

Fig. 6

M913070207C04

Fig. 5

Fig. 4

Fig. 3: Insert the uppermost wire in the second screw, and pull it tight. Fig. 4: Bend the lower wire around the screw, and under the end protruding from the screw. Fig. 5: Keeping the wire under tension, twist it min. 3 twists, counterclockwise until tight.

Fig. 7

Fig. 6: During the final twisting motion, bend the wire along the screw head. Cut off excess wire.

Fig. 8

M913070207C05

Fig. 7-9: Show the preferred ways of mounting the locking wire on screws with wire holes oriented in different angles.

Page 2 (4)

Fig. 9


Screws and Nuts MAN B&W Diesel

913-7.1

Locking

Fig. 10: Shows how to route the locking wire on screws in different planes. Fig. 11: Wire that passes over the top of a nut is an acceptable alternative only if it routes around the protruding screw thread.

Fig. 10

Fig. 12: Wire that passes over the top of a nut is also an acceptable alternative if the hole is located as shown in the figure.

Fig. 11

Fig. 13: Where drilling of locking wire holes has caused a thin wall section, route the wire as shown in the figure, to prevent damage to the nut.

Fig. 12

Fig. 14: Locking wire can be mounted to any other part of the assembly if nothing else is possible.

M913070207C06

Fig. 13

Fig. 14


Page 3 (4)

913-7.1

Screws and Nuts Locking

Fig. 15

MAN B&W Diesel

Cam Lock Washers with rising cams on one side and radial teeth on the other. Fig. 15: The washers are installed in pairs, cam face to cam face. When the bolt and/or nut is tightened the teeth grip and seat the mating surfaces. The cam lock washer is locked in place, allowing movement only across the face of the cams. Any attempt from the bolt/nut to rotate loose is blocked by the wedge effect og the cams.

M913070207C15

Fig. 16: Different uses of the cam lock washers. Fig. 17: Don not use the cam lock washers in conjunction with other loose washers.

Fig. 16.

Note!

M913070207C16

Cam lock washers must be installed in pairs and are not to be substituted by other typers of washers.

M913070207C17

Fig. 17

Page 4 (4)


Lubricating Procedures

913-11

Lubricating Procedures .0&& 0204 913-11

Molybdenum Disulphide (MoS2) The following procedure is to be followed prior to the mounting of metal surfaced parts which are to function as seals. • Clean the surface with a cleaning fluid and ensure that the entire surface is completely free of grease. • Allow 5 minutes for the cleaning fluid to evaporate. • With a clean leathercloth, and using circular movements, rub a mixture of finegrained particles of Molybdenum Disulphide (MoS2) and mineral oil (e.g. Molycote G-n Plus, or the like) hard onto the metal surface. • Remove any excessive paste and ensure that the metal surface is only coated with a thin, uniform, layer of the above mixture. • Protect the wet paste and cloth from dust or other foreign particles.


Page 1 (1)

Accessories for Hydraulic Tools

Plate P91351-0034

Accessories for Hydraulic Tools 0034 P91351

Working Pressure 1500 Bar


Page 1 (2)

Plate P91351-0034 Item No. 010 022 034 046 058 060 105 117 129 154 166 201 213 225 237 249

Accessories for Hydraulic Tools

Item Description

Item No.

Item Description

Hydralic pump, pneumatic operated Hydralic pump, hand operated Hose with unions (1000mm), complete Hose with unions (1500mm), complete Hose with unions (3000mm), complete Hose with unions (5000mm), complete 2-way distributor block, complete 4-way distributor block, complete 6-way distributor block, complete Conical valve, 0 - 15 Angle union Quick coupling, male Quick coupling, female Disc, round-plain, Cu ø11x3mm Bleeder screw Disc, round-plain, Fe ø11x9mm

Page 2 (2)


Lifting Tools, Etc.

Plate P91356-0051

Lifting Tools, Etc. 0051 P91356


Page 1 (2)

Plate P91356-0051 Item No. 018 031 043 055 067 079 092 175 199 222 246 295 305 317 329 330 342 354 378 450

Lifting Tools, Etc.

Item Description Lifting eye bolts Lifting eye bolts Lifting eye bolts Lifting eye bolts Lifting eye bolts Lifting eye bolts Lifting eye bolts Chain tackle Chain tackle Chain tackle Wire rope Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Forged-bend screw Pull-lift

Page 2 (2)

Item No.

Item Description

shackle shackle shackle shackle shackle shackle shackle shackle


Open Ended Spanners

Plate P91357-0006

Open Ended Spanners 0006 P91357


Page 1 (2)

Plate P91357-0006 Item No. 013 037 050 074

Open Ended Spanners

Item Description Open-ended Open-ended Open-ended Open-ended

Page 2 (2)

spanner, spanner, spanner, spanner,

size size size size

Item No.

Item Description

NV65mm NV75mm NV85mm NV95mm


Torque Wrenches


Plate P91359-0003

Page 1 (2)

Plate P91359-0003 Item No. 014 026 038 040 051

Page 2 (2)

Torque Wrenches Item Description

Item No.

Item Description

Torque wrench, 8 - 400Nm Adapter for socket wrench, 10 x 12.5 mm Torque wrench, 40 - 200Nm Torque wrench, 140 - 760Nm Torque wrench, 750 - 2000Nm


Pliers MAN B&W Diesel


Plate P91360-0005

Page 1 (2)

Pliers

Plate P91360-0005 Item No. 010 021 033 045 069 128 130 141 153

Page 2 (2)

MAN B&W Diesel Item No.

Item Description

Item Description

Pliers for retaining ring, size 0.9mm Pliers for retaining ring, size 1.3mm Pliers for retaining ring, size 1.8mm Pliers for retaining ring, size 2.3mm Pliers for retaining ring, size 3.5mm Pliers for retaining ring, size 1.1mm Pliers for retaining ring, size 1.8mm Pliers for retaining ring, size 2.3mm Pliers for retaining ring, size 3.2mm


Combination Spanners MAN B&W Diesel


Plate P91361-0052

Page 1 (2)

Combination Spanners

Plate P91361-0052 Item No. 015 027 039 040 052 064 076 088 090 100 111 123 135 147 159 160 172 184 196 206 218 220 231

Page 2 (2)

MAN B&W Diesel

Item Description Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination Combination

spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners, spanners,

size size size size size size size size size size size size size size size size size size size size size size size

Item No.

Item Description

NV10mm NV11mm NV12mm NV13mm NV14mm NV15mm NV16mm NV17mm NV18mm NV19mm NV21mm NV22mm NV24mm NV27mm NV30mm NV32mm NV34mm NV36mm NV41mm NV46mm NV50mm NV55mm NV60mm


Ring Slugging Spanners

Plate P91362-0060

Ring Slugging Spanners 0060 P91362


Page 1 (2)

Plate P91362-0060 Item No. 022 034 046 058 060 071 083 095 105 117 120 130 142 154 178 180 225

Ring Slugging Spanners

Item Description

Item No.

Item Description

Slugging spanner, ring size NV30mm Slugging spanner, ring size NV32mm Slugging spanner, ring size NV34mm Slugging spanner, ring size NV36mm Slugging spanner, ring size NV41mm Slugging spanner, ring size NV46mm Slugging spanner, ring size NV50mm Slugging spanner, ring size NV55mm Slugging spanner, ring size NV60mm Slugging spanner, ring size NV65mm Slugging spanner, ring size NV70mm Slugging spanner, ring size NV75mm Slugging spanner, ring size NV80mm Slugging spanner, ring size NV85mm Slugging spanner, ring size NV95mm Slugging spanner, ring size NV100mm Slugging spanner, ring size NV120mm

Page 2 (2)


Spanners MAN B&W Diesel


Plate P91363-0040

Page 1 (2)

Spanners

Plate P91363-0040

MAN B&W Diesel

Item No.

Item Description

016 028 030 041 100 150 161

Tool set, complete, size 10-22 mm Tool set, complete, size 24-46 mm Hex key tool set, complete Adapter for socket wrench, 20->12.5 mm Socket spanner, S=46 mm Hex key, S=22 mm Hex key, S=24 mm

Page 2 (2)

Item No.

Item Description


Open-ended Spanners

Plate P91364-0059


Page 1 (2)

MAN B&W Diesel A/S

Plate P91364-0059 Item No. 011 023

Page 2 (2)

Open-ended Spanners Item Description

Item No.

Item Description

Open ring wrench, 14 - 17mm Open ring wrench, 19 - 22mm


Instruments


Plate P91366-0066

Page 1 (2)

Plate P91366-0066 Item No. 012 024 036 048 050 061 073

Page 2 (2)

Instruments Item Description

Item No.

Item Description

Indicator, complete Indicator paper Plainmeter, complete Autolog, measuring tool for crankshaft Feeler gauge Slide caliper Dial gauge and stand tool


Plate P91368-0011

Working Platforms Working Platforms 0011 P91368

A

A

A

A

B B

B


B

Page 1 (2)

Plate P91368-0011 Item No. 013 025 037 049 062 074 098 204

Working Platforms

Item Description

Item No.

Item Description

Working platform support Working platform support Platform board Platform board Platform board Platform board Platform board Working platform, complete

Page 2 (2)


Warning

S900-1

0001 S900-1

Warning! It is important that all MAN B&W Diesel A/S engines are operated within the given specifications and performance tolerances specified in the engines’ Technical Files and are maintained according to the MAN B&W Diesel A/S maintenance instructions in order to comply with given emissions regulations. In accordance with Chapter I of the Code of Federal Regulations, Part 94, Subpart C, §94.211 NOTICE is hereby given that Chapter I of the Code of Federal Regulations, Part 94, Subpart K, §94.1004 requires that the emissions related maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel A/S instructions, including, but not limited to, the instructions to that effect included in the Technical File.

When referring to this page, please quote S900 Edition 0001 MAN B&W Diesel A/S

Page 1 (1)

K80MC-C

VOLUME III COMPONENTS DESCRIPTION

900 - Introduction Documents in this Chapter

90001 90002 90003 90004

0040 0001 0001 0001

Table of Contents, Volume III Cross Section through Engine Ordering of Insulation Designations And Symb Software Licence, Std

90030

0006

Description

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Table of Contents

900

Volume III - Components Description No.

Edition

Title

900 - Introduction Table of Contents 90001 0040 Cross Section through Engine 90002 0001 Ordering of Insulation 90003 0001 Designations And Symb 90004 0001 Software Licence, Std 90030 0006 Description 901 - Cylinder Cover 90101 0180 Cylinder Cover 90103 0003 Indicator Cock - Mounting 902 - Piston with Rod & Stuffing Box 90201 0216 Piston and Piston Rod 90205 0117 Piston Rod Stuffing Box 903 - Cylinder Liner and Cylinder Lubrication 90301 0163 Cylinder Frame 90302 0161 Cylinder Liner and Cooling Jacket 90304 0035 Cylinder Liner - Details 90305 0143 Cylinder Lubricators 90307 0032 Cylinder Lubricator Unit 90308 0010 Cylinder Lubricator - Intermediate Box 90310 0012 Cylinder Frame - Rear Side 90312 0004 Electronic Components - Cylinder Lubrication 904 - Crosshead with Connecting Rod 90401 0172 Connecting Rod and Crosshead 90403 0012 Lubricating and Cooling Oil Flow 905 - Crankshaft, Thrust Bearing and Turning Gear 90501 0162 Crankshaft 90502 0052 Arrangement of Fore End 90505 0146 Thrust- and Guide Bearing 90510 0124 Turning Gear 90511 0039 Turning Wheel 90513 0041 Tacho System 906 - Control Gear 90600 0125 Arrangement of Chain Drive and Camshaft 90603 0111 Chain Tightener 90610 0131 Bearing Housing - Mounting 90611 0175 Camshaft and Chain Wheel 90612 0085 Arrangement of Indicator System 90613 0116 Camshaft Bearing MAN B&W Diesel A/S

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Table of Contents

900

Volume III - Components Description No. 90615 90618 90619 90620 90621 90622 90631 90632 90633 90634

Edition 0147 0134 0019 0097 0076 0070 0023 0003 0030 0041

Title Arrangement of Governor Regulating Shaft Load Transmitter Engine-Side Control Console Engine-Side Control Console - Details Arrangement of Layshaft Chain Drive Guidebars - Upper Part Chain Drive Guidebars - Lower Part Chain Drive Lubrication - Upper Part Chain Drive Lubrication - Lower Part

907 - Starting Air System 90702 0069 Main Starting Valve 90703 0129 Starting Air Distributor 90704 0053 Starting Valve 908 - Exhaust Valve 90801 0211 Exhaust Valve - Lower Parts 90803 0045 Exhaust Valve - Upper Parts 90804 0016 Exhaust Valve Upper Parts - Details 90805 0122 Exhaust Valve - Actuator 90806 0104 Exhaust Valve - Pipe System 90810 0089 Arrangement of Cooling Water Pipes 909 - Fuel Oil System 90901 0184 Fuel Pump 90902 0150 Fuel Pump Gear 90903 0040 Fuel Pump Gear - Details 90904 0061 Fuel Pump - Details 90905 0030 Reversing Mechanism 90907 0011 Lifting Device for Fuel Pump 90910 0143 Fuel Valve 90911 0022 Fuel Valve Function 90913 0158 High-Pressure Pipes 90914 0078 Fuel Oil System 90915 0060 Fuel Oil System - Details 90915 0080 Fuel Oil System - Details 90916 0006 Lifting Device for Fuel Pump - Cylinder No. 1 910 - Turbocharger System 91000 0017 Gas and Air System 91001 0166 Scavenge Air Receiver 91002 0142 Arrangement of Charging Air Pipe 91003 0225 Exhaust Pipes and Receiver 91004 0036 Exhaust Receiver - Details MAN B&W Diesel A/S

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Table of Contents

900

Volume III - Components Description No. 91005 91006 91007 91009 91011 91014

Edition 0140 0029 0018 0020 0026 0029

Title Air Cooler Arrangement of Auxiliary Blower Butterfly Valve Air Cooler System - Cleaning Arrangement of Non-Return Valve Arrangement of Suction Pipe

911 - Safety Equipment 91101 0037 Safety Valve - Cylinder 91102 0029 Relief Valve 91102 0035 Relief Valve 91103 0018 Safety Valve - Scavenge Air System 91104 0099 Arrangement of Safety Cap 912 - Assembly of Large Parts 91201 0096 Arrangement of Stay Bolts 91203 0005 Frame Box - Details 91205 0201 Frame Box 91206 0097 End Shields 91207 0093 Arrangement of Piston Cooling 91208 0009 Chain Wheel Frame - Upper 91210 0188 Bedplate 91211 0072 Axial Vibration Damper 91216 0008 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

MAN B&W Diesel A/S

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Cross Section through Engine MAN B&W Diesel


Plate P90001-0040

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Plate P90001-0040 Item No.

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Cross Section through Engine MAN B&W Diesel

Item Description

Item No.

Item Description


Ordering of Insulation MAN B&W Diesel


Plate P90002-0001

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Designations and Symbols MAN B&W Diesel

Normal layout

Plate P90003-0001

Forward (fwd)

Starboard (stbd) side of

Port side of ship

Fore end 1 2 3 4 5 6 7

Manoeuvring side of engine

Aft end

Cyl. nos. always counted from fore end

Exhaust side of engine

Propeller

Clockwise direction of rotation defined from aft end of engine


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Software License, Standard Conditions MAN B&W Diesel

Plate P90004-0001

Standard Conditions of Software Licence Software supplied by MAN B&W separately or included as a part of any system or embedded in any device is licensed by MAN B&W Diesel A/S (“MAN B&W”) subject to the customer's acceptance of the following standard conditions of licence. TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMER’S ACCEPTANCE OF THESE CONDITIONS. 1. Right of Ownership Software is delivered under a non-exclusive and non-transferable user's licence from MAN B&W against a once-for-all fee. MAN B&W and its software suppliers retain the right of ownership to the software. If the engine plant - for which the software is acquired - is transferred to a third party the customer has the right to assign the licence to this third party, provided that the third party agrees to the terms of this licence agreement and provided that the customer does not retain any copies of the software. 2. Copyright The customer must not copy the software or any part thereof. Furthermore the customer is not allowed to make the software available to a third party or to reverse engineer, decompile or disassemble the software. 3. Support If required by the customer MAN B&W shall provide technical support for installation and training in use of the software against separate payment. 4. Updating The non-exclusive user's licence does not include any updating of the software. If and to the extent MAN B&W updates the programs or develops new versions, such updates or new versions shall be made available to the customer against separate payment. 5. Warranty & Liability MAN B&W warrants that the software and data media containing the software are free of defects in material and workmanship at the time of delivery. If the software and data media are found to be defective and are returned to MAN B&W within 90 days from the date of delivery, they will be replaced free of charge. Except as stated above, MAN B&W disclaims liability for breach of conditions or warranties, either expressed or implied, with respect to the software and data media, including warranties of suitability and applicability for a particular purpose.


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Plate P90004-0001

Software License, Standard Conditions MAN B&W Diesel

MAN B&W's liability for damages to the customer for any cause whatsoever, regardless of the form of any claim or action, shall not exceed the total licence fee paid by the customer for the license to use this software under this license agreement. MAN B&W shall in no event be liable for any damages resulting from loss of data, profits or use of equipment, or for any special, incidental consequential damages arising out of or in connection with the use or performance of the software. The limitations in liability stipulated above in this clause 0 shall also apply to MAN B&W’s software suppliers. 6. Law MAN B&W's tenders and contracts with customers regarding delivery of data and programs, including the present licence agreement, shall be interpreted according to Danish Law.

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Engine Types 35-98MC/MC-C

Description A90030-0006

Engine Types 35-98MC/MC-C 35-98MC 0006 A90030

901 Cylinder Cover Cylinder Cover

The cylinder cover is made of steel. On the 70-98MC type engines the cylinder cover is provided with weldedon heat resistant material at the points of fuel oil injection in order to improve the service condition.

Valve bores

The cover has a central bore for the exhaust valve, which is attached by means of four studs and nuts. The cover furthermore has bores for the fuel valves, starting valve, starting air inlet, safety valve and indicator cock.

Cooling

A cooling jacket is mounted on the lower part of the cylinder cover, whereby a cooling water space is formed. Another cooling water space is formed around the exhaust valve seat, when the exhaust valve is installed. These two spaces communicate through a large number of cooling bores in the cover. The water is supplied from the cooling jacket surrounding the cylinder liner and passes through water connections to the cooling jacket surrounding the cylinder cover and, further on, through the cooling bores, to the space around the exhaust valve seat. From here the water is discharged to the main cooling water outlet pipe: On some engine types, an amount of water is also passed directly from the cylinder cover to the exhaust valve housing through a cooling water connection.

Tightening

The cylinder cover is tightened against the top of the cylinder liner with nuts and long studs fitted in the cylinder frame. The nuts are tightened with hydraulic tools. Sealing between the cylinder cover and cylinder liner is obtained by means of a sealing ring of mild steel.

902 Piston with Rod and Stuffing Box Piston

The piston consists of two main parts: • Piston Crown • Piston Skirt The piston crown is tightened to the upper end of the piston rod, and the piston skirt is tightened to the piston crown.

When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Copenhagen

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Engine Types 35-98MC/MC-C The piston crown is provided with one groove all the way around, or with three smaller grooves for the fitting of lifting tools. The piston crown is provided with chromium-plated grooves for four piston rings. Piston ring No. 1 is a Controlled-Pressure Relief ring (CPR). Piston rings Nos. 2, 3 and 4 have oblique cuts: • piston ring No. 3 has a right-hand cut, and • piston rings Nos. 2 and 4 have left-hand cuts. On some engines, the piston rings are provided with Alu-coating to improve the running-in stability and to reduce the running-in period. Handle with care, as impact may cause the coating to crack and peel off. Stationary Engines: The CPR ring may have been coated with PM14 on the external surface. Handle with care, as impacts may cause the coating to crack and peel off.

Piston Rod

The piston rod has a through-going bore for the cooling oil pipe, which is secured to the piston rod top. Cooling oil is supplied through a telescopic pipe connection on the guideshoe or on the crosshead and passed through a bore in the piston rod foot and, through the cooling oil pipe in the piston rod, to the piston crown. The oil is passed on, through a number of bores in the thrust part of the piston crown, to the space around the cooling oil pipe in the piston rod. From the bore in the piston rod foot, the oil is led through the crosshead to a discharge spout and to a slotted pipe inside the engine framebox as well as through a control device for checking the flow and temperature. The piston rod foot rests on a face cut out in the crosshead pin. A shim is inserted between the piston rod and the crosshead. The thickness of the shim is predetermined to match the actual engine layout. The piston rod is fastened to the crosshead pin with screws or studs and nuts. The nuts are tightened with hydraulic tools.

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When referring to this text, please quote Description A90030 Edition 0006 MAN B&W Diesel A/S, Denmark

Engine Types 35-98MC/MC-C Stuffing Box


The bore for the piston rod between the scavenge air space and the crankcase is fitted with a piston rod stuffing box, which is designed to prevent the lubricating oil in the crankcase from being drawn up into the scavenge air space. The stuffing box also prevents scavenge air (in the scavenge air space) from leaking into the crankcase. The stuffing box housing consists of two parts, which are bolted together.

Scraper/sealing rings

The housing is provided with a number of machined ring grooves: • The uppermost groove holds a scraper ring with oblique edges, which serves to prevent sludge from the scavenge box from being drawn down to the other rings. Furthermore, a sealing ring is fitted below the scraper ring (except on 35MC type engines). • The ring grooves in the middle are fitted with sealing rings. • The lowermost ring grooves are fitted with scraper rings which scrape the lubricating oil off the piston rod. Oil which is scraped off the piston rod is returned to the crankcase through bores in the stuffing box housing. Through bores in the housing and a pipe, the stuffing box communicates with a control funnel on the outside of the engine, which enables the sealing/ scraping performance to be checked. Gaps at the ends of the ring segments ensure that the rings will bear against the piston rod even in worn condition.

903 Cylinder Liner and Cylinder Lubrication Cylinder Frame

The cylinder section of the engine consists of a cylinder frame with a bolted-on or integrated camshaft housing. The cylinder section is tightened together with the engine framebox and the bedplate by means of stay bolts.

Bores and openings

Central bores at the top of the cylinder frame enclose the cylinder liners. Central bores in the bottom of the cylinder frame enclose the piston rod stuffing boxes. On the exhaust side of the cylinder frame there are openings which connect the scavenge air space around the cylinder liner with the longitudinal scavenge air receiver of the engine.


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Engine Types 35-98MC/MC-C There are also inlet pipes for cooling and lubricating oil. The cylinder frame is provided with cleaning and inspection covers giving access to the scavenge air spaces.

Cylinder cover studs

Studs for fastening the cylinder cover are mounted in the cylinder frame.

Cylinder Liner and Cooling Jacket

The cylinder liner is fitted with a cooling jacket. The cooling water is supplied at the lower part of the cooling jacket. On slim-type liners, the water continues directly to the upper part of the cooling jacket, whereas on the bore-cooled type liner, the water first passes through the cooling bores. From the top of the cooling jackets, the water flows through water connections to the cooling jacket on the lower part of the cylinder cover. Leakage of cooling water is prevented by silicone rubber rings. The cylinder liner is tightened against the top of the cylinder frame by the tensioning force from the cylinder cover studs being transmitted via the cylinder cover.

Scavenge air ports

The part of the cylinder liner which is located in the scavenge air space of the cylinder frame is provided with a number of scavenge air ports, which are uncovered by the piston when this is in its bottom position. The scavenge air ports are bored at an oblique angle to the axis of the cylinder liner so as to give the scavenge air a rotary movement in the cylinder.

Cylinder lubrication

In the free part of the cylinder liner, between the cooling jacket and the cylinder frame, there are a number of bores with non-return valves for the supply of lubricating oil to the cylinder.

PC-ring

On 80-98MC type engines a piston cleaning (PC) ring is mounted at the top of the cylinder liner. The purpose of the PC-ring is to prevent the building-up of deposits on the piston topland and, in turn, prevent the wiping away of the cylinder lubricating oil. Consequently, the PC-ring contributes to reducing the wear of liners and rings.


The engine is equipped with mechanically or electronically controlled cylinder lubricators for lubrication of the running surface of liners and rings. Regarding the cylinder lubricators proper, reference is made to the special instruction manuals supplied. See also Volume I, OPERATION, Chapter 707.

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904 Crosshead with Connecting Rod Crosshead

The crosshead is provided with two guide shoes fitted on the crosshead ends. The centre part of the crosshead is designed as a bearing journal which is housed in the crosshead bearing. The crosshead bearing cap is provided with a cut-out enabling the piston rod to be assembled with the crosshead journal. The crosshead is equipped with steel shells lined with bearing metal. The lower shell is provided with an overlayer coating. See also Volume I, OPERATION, Chapter 708.

Piston rod foot

The piston rod foot is fastened to the crosshead. To match different engine layouts, a shim of predetermined thickness is inserted between the piston rod and the crosshead.

Lubrication

The crosshead is provided with bores for distributing the oil supplied through the telescopic pipe, partly as cooling oil for the piston, partly as lubricating oil for the crosshead bearing and guide shoes and – through a bore in the connecting rod – for lubricating the crankpin bearing. The piston cooling oil outlet is led through a control device for each cylinder for the purpose of checking the temperature and flow before the oil is passed on to the lube oil tank.

Guide shoes

The sliding faces of the guide shoes are lined with cast-on bearing metal. The guide shoes are guided by crosshead guides in the engine framebox and properly secured against displacement by guide strips fastened to the guide shoes. On some engines, the guide shoes are provided with counterweights.

Tightening

The crosshead bearing is held together by studs and nuts. The nuts are tightened with hydraulic tools. The crankpin bearing is fitted with steel shells lined with bearing metal and assembled in the same way as the crosshead bearing.

905 Crankshaft and Turning Gear Crankshaft

The crankshaft is either of the semi-built type, where the parts are shrunk together, or it is a one-piece forging. The main bearings are lubricated via a main lubricating oil pipe that branches off to the individual bearings, whereas oil for lubricating the crankpin bearings is supplied from the crossheads through bores in the connecting rods.


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Engine Types 35-98MC/MC-C The crankshaft is provided with a chain wheel for the camshaft drive and a turning wheel. Furthermore, a tuning wheel, a torsional vibration damper and a chain wheel drive for 2nd order and 4th order moment compensators are installed, if required according to vibration calculations. Marine engines (except geared plants): At the aftmost end of the engine, a thrust bearing is fitted. The thrust bearing serves the purpose of transmitting the axial thrust of the propeller through propeller shaft and intermediate shafts to the ship’s hull. The crankshaft is provided with a thrust collar which transmits the thrust to a number of segments mounted in a thrust shoe on either side of the thrust collar. The thrust shoes rest on surfaces in the thrust bearing housing and are held in place by means of stoppers or cross bars. The segments have white metal cast onto the wearing faces against the thrust collar. See also Volume I, OPERATION, Chapter 708. The thrust bearing is lubricated by the pressure lubrication system of the engine. The oil is supplied between the segments through spray pipes and spray nozzles. The thrust bearing is provided with alarm, slow-down, and shut-down devices for low lube oil pressure and high segment temperature. See also Volume I, OPERATION, Chapter 701. Stationary engines and geared marine plants: The crankshaft is provided with a collar for the guide bearing. The purpose of the guide bearing is to keep the crankshaft in its proper position in the axial direction.


To counteract heavy axial vibrations, and any resultant adverse forces and vibrations, the crankshaft is provided with an axial vibration damper. See also Section 912, “Assembly of large parts” further on in this text. The damper consists of a ‘piston’ and a slit-type housing. The ‘piston’ is made as an integrated collar on one of the main bearing journals, and the housing is mounted on the pertaining main bearing support. The axial movement is damped as a result of the ‘restrictions’ incorporated in the bores which interconnect the oil-filled chambers on the two sides of the ‘piston’. Lubricating oil is supplied to both sides of the ‘piston’ from the main system.

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Engine Types 35-98MC/MC-C Turning Gear


The turning gear is attached to the engine bedplate and is driven by an electric motor incorporating a disc brake. Through a planetary gearing, the motor drives a horizontal shaft equipped with a gear wheel which can be axially displaced manually, so as to engage with the turning wheel of the engine. The turning gear is provided with a safety arrangement consisting of a safety lever which must be lifted before the gear wheel of the turning gear can be made to engage with the turning wheel. When the safety lever is in its bottom position, it prevents the gear wheel of the turning gear from engaging with the turning wheel. Immediately the lever is lifted away from the disengaged position, an interlock valve inserted in the starting air system of the engine is actuated. This interlock prevents starting air from being supplied to the engine as long as the turning gear is in the engaged position. See also Volume I, OPERATION, Chapter 703.

Warning!

Dismantling of working parts:

During any dismantling of working parts of the engine, the turning gear must be in the engaged position in order to prevent outside forces from turning the engine, thus causing injuries to personnel or damage to the machinery. See Volume II, MAINTENANCE, ‘DATA’ pages.

Pressure testing of starting valves:

The turning gear must be in the disengaged position during pressure testing of starting valves, as a leaky valve may cause the engine to rotate, and damage the turning gear. See Volume I, OPERATION, Chapter 703.

906 Mechanical Control Gear Chain Drive

The camshaft with cams for operating the fuel pumps, exhaust valves and indicator drive (option) is driven from the crankshaft through a chain drive. The chain drive consists of one or more roller chains running on chain wheels fitted on the crankshaft and the camshaft. The chain is kept tightened by a chain tightener placed in the chain casing between the crankshaft and the camshaft. The long free lengths of the chain are guided by rubber-clad guide bars. Lubricating oil is supplied through spray pipes fitted at the guide bars and chain wheels.


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Description A90030-0006 Camshaft

Engine Types 35-98MC/MC-C The camshaft is made in one or more sections. If it is made in two or more sections, the sections are assembled by means of flange couplings. The camshaft has, for each cylinder: • one cam for operation of the fuel pump • one cam for operation of the exhaust valve • one cam for operation of the indicator drive (option) The fuel pump and exhaust valve cams are shrunk on to the shaft by heating, whereas the indicator cams are in two parts, which are assembled with fitted bolts. The camshaft rotation constantly follows that of the crankshaft.

Bearings

The camshaft is carried in bearing assemblies which are fitted in the roller guide housings. See also Volume I, OPERATION, Chapter 708.

Engine timing

The engine timing is adjusted by forcing lubricating oil in between the cams, couplings or chain wheel and the shaft, which enables the parts to be turned in relation to each other. See Volume II, Chapters 906, 908 and 909.

Pin gauges

After the engine has been testrun, the camshaft parts and the cylinder frame will be provided with pin gauge marks, and the necessary pin gauges are delivered together with the engine, enabling the camshaft timing to be checked and readjusted if the parts have been dismantled.

Indicator Valve

Each cylinder is fitted with an indicator valve, which communicates with the combustion chamber of the cylinder through a bore. Operating Instructions When opening the indicator valve, the spindle must be screwed right back to the stop in order to avoid burns and carbon in the guide.

Note! For indicator valves of the double-seated design with a spring-loaded closing face: In order to prevent overstressing, close the valve lightly before starting the engine, and retighten the valve when the engine has reached its normal service temperature.

PMI-System

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See separate instructions for operating the PMI-system (option).


Engine Types 35-98MC/MC-C Moment Compensators


On the basis of calculations, the engine may be provided with flyweights to counteract engine forces and moments.

Caution! If the chain drives for the compensators have been dismantled, the flyweights must be positioned correctly in relation to the crankshaft. See the instruction book, Volume II, MAINTENANCE. Incorrectly fitted moment compensators may excite heavy vibrations.

1st order moment

Applicable on 4-cylinder engines. The moment compensator is arranged as adjustable flyweights on both ends of the crankshaft. Alternatively, the 1st order moment compensator can be positioned in the main chain drive. This moment compensator consists of a (new) chain-tightener wheel with an incorporated flyweight and a flyweight rotating with the crankshaft.

2nd order moment

Applicable on 4-5 and 6-cylinder engines. The moment compensator is arranged as flyweights built into the main chain drive. On some engines, flyweights are built into a second chain drive, which is driven from the opposite end of the crankshaft. This chain drive is equipped with a spring-loaded chain tightener, which on some engines is equipped with a hydraulic damper. Optionally, an electrically driven compensator can be installed.

4th order moment

The moment compensator is arranged as flyweights built into chain drives on both ends of the camshaft. Each chain drive is equipped with a spring-loaded chain tightener, and each chain casing is fitted with a relief valve.

907 Starting Air System Starting Air System

The starting air system consists of the manoeuvring system and the starting air components, which comprise: • Main Starting Valve • Starting Air Distributor • Starting Valves The manoeuvring system is of electric/pneumatic design. See also Volume I, OPERATION, Chapter 703.


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Description A90030-0006 Main Starting Valve

Engine Types 35-98MC/MC-C The main starting valve is interposed in the starting air main pipe. The main starting valve consists of a large ball valve and, optionally, a smaller ball valve for slow-turning prior to starting the engine, which is fitted as a by-pass for the large valve. Both valves are operated by pneumatic actuators. If the smaller ball valve is installed, an adjusting screw will be mounted for setting the slow-turning speed. Furthermore, a non-return valve is incorporated to prevent blow-back in the event of excessive pressure in the starting air line. The main starting valve is equipped with a blocking device consisting of a plate which, by means of a handwheel, can be made to block the actuators. The ball valves and their actuators are, together with the non-return valve and blocking device, built together to form a unit. Warning! During all inspections of the engine, the blocking device of the main starting valve must be in the BLOCKED position. The only exception is when the starting valves are being tested for tightness, in which case the blocking device of the main starting valve must be in the WORKING position and the shut-off valve for the starting air distributor must be in the CLOSED position. See Volume I, OPERATION , Chapter 703, ‘Operations after arrival in port’.


The starting air distributor controls the opening and the closing of the starting valves.

Starting Valve

The starting valve (spring-loaded) is fitted on the cylinder cover. It is controlled by control air from the starting air distributor. When the main starting valve is open, the chamber below the piston of the starting valve is pressurised through the starting air pipe. The starting valve is kept closed by the spring. When the chamber above the piston of the starting valve is pressurised with control air from the starting air distributor, the starting valve opens, and starting air now flows from the starting air pipe to the cylinder. When the starting period is finished, the chamber above the piston is vented through the vent pipe of the starting air distributor, and the starting valve will close. The starting air in the chamber below the piston and the starting air pipe is vented slowly through small holes in the starting air pipe.

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908 Exhaust Valve Exhaust Valve

Each cylinder is equipped with an exhaust valve, which is mounted in a central bore in the cylinder cover. The valve housing is attached with four studs and nuts to form a gas-tight seal against a seat in the cylinder cover.

Valve housing

The valve housing has an exchangeable bottom piece. The bore for the valve spindle is provided with an exchangeable spindle guide liner.

Cooling

The valve housing is water cooled. The cooling water is passed to the valve housing after it has passed the cylinder cover. The water is discharged from the upper part of the valve housing. On the front of the valve housing there is a cleaning cover through which the cooling water space can be checked and cleaned.

Valve spindle

The part of the spindle stem which travels within the sealing arrangement of the air cylinder is coated with a wear resistant mixture of metal carbide and super alloy, applied by the HVOF process. On the lower cylindrical part of the valve spindle a vane wheel is fitted which causes the valve spindle to rotate while the engine is running. Lifting/rotation check rod: To enable checking the functioning of the exhaust valve while the engine is running, a ‘lifting/rotation check rod’ is mounted on top of the hydraulic cylinder on the exhaust valve. Spindle rotation is indicated by regular changes in the top and bottom positions of the check rod. Note! This check rod is only for checking purposes, and must not be permanently activated. Pistons At the top of the spindle, two pistons are fitted: 1. Air piston The piston serves to close the exhaust valve. The piston is locked to the spindle by a two-piece conical ring. 2. Hydraulic piston The piston serves to open the exhaust valve. The hydraulic piston has two piston rings and a damper arrangement, designed to dampen the closing of the valve.


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Caution! After the exhaust valve has been overhauled, it is important to check the damper, to avoid knocking. See Volume II, MAINTENANCE, Procedure 908.

Air cylinder

The air cylinder is mounted on top of the valve housing. Air for closing the exhaust valve is supplied through a non-return valve to the space below the piston. A safety valve is mounted in the bottom of the air cylinder. The safety valve is connected to the drain pipe which leads to the camshaft housing.

Hydraulic cylinder

The hydraulic cylinder is attached with studs and nuts on the air cylinder on top of the exhaust valve housing. The exhaust valve is opened by the valve spindle being forced down by the piston in the hydraulic cylinder. Throttle/valve: On some engine types, a combined throttle/valve designed for deaerating the oil system is fitted at the top of the cylinder. When the exhaust valve is closed, the pressure in the hydraulic cylinder is low. A thrust spring opens the valve, enabling oil and air, if any, to escape through the throttle. The oil is led through a duct to the space around the air cylinder and is drained off through a bore X, together with leakage oil from the piston. When the exhaust valve is activated, the high oil pressure closes the valve, and the oil flow stops.

Sealing System

Sealing air (where used): A sealing air arrangement is fitted around the spindle shaft below the air cylinder. The sealing air is supplied from the air cylinder via a sealing air control unit. The sealing air will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear. The oil content in the air from the air cylinder improves the service condition of the sealing rings. The sealing air control unit contains a valve which automatically cuts off the air flow when the engine is in FINISHED WITH ENGINE status, and a filter housing.

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Sealing oil (where used): A sealing oil arrangement is fitted around the spindle shaft below the air cylinder. The sealing oil is supplied from a control unit fitted on top of the exhaust valve hydraulic actuator. During the exhaust valve lifting period, oil escapes from the hydraulic actuator through the restriction chamber to the control unit which, in turn, gives a certain amount of oil (dosage oil) to the exhaust valve spindle. The sealing oil will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear. The oil improves the service condition of the sealing rings.

Hydraulic Valve Actuating Gear

The exhaust valve is actuated by a cam on the camshaft through a hydraulic transmission.

Hydraulic cylinder

The hydraulic cylinder is attached to the camshaft housing by studs and nuts. A piston enclosed in the hydraulic cylinder rests on a thrust piece in the neck of the roller guide and is locked to the roller guide by a bayonet joint. The hydraulic cylinder on the camshaft housing is connected to the hydraulic cylinder on the exhaust valve by a high-pressure pipe. Oil is supplied from the lubricating oil system through a non-return valve. Leakage oil from the hydraulic cylinder on the exhaust valve is drained through a pipe connection.

Puncture Valve

On 4-cylinder reversible engines as well as on 5-cylinder reversible 50MC engines, a puncture valve may be mounted on the exhaust valve actuator. During starting, this valve prevents the exhaust valve from opening during the first part of the actuator piston’s upward stroke. This function prevents the starting valve and exhaust valve from being open at the same time, thus ensuring a safe start.


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909 Fuel Oil System Fuel Pump

Each engine cylinder is equipped with its own fuel pump, which is mounted on the camshaft housing over the camshaft section corresponding to the cylinder concerned. The pump housing is attached to the camshaft housing by studs and nuts. The square base of the fuel pump housing is provided with a groove to receive any leakage oil, which is subsequently drained off through a drain pipe. In the base, a bore is provided for at toothed rack, i.e. the regulating guide, which controls the quantity of fuel oil delivered by the pump. Furthermore, for the VIT-type fuel pump, another bore is provided above the bore for the regulating guide. This bore is provided with a rack, i.e. the timing guide, which controls the engine timing. At the top, the pump housing is closed by a top cover. The top cover is provided with a suction valve and a puncture valve. These two valves are on some engine types combined into one unit. The pump housing contains the plunger and barrel. The plunger and barrel are matched parts, and must not be replaced individually. The pump plunger is provided with a guide block designed to travel in the milled keyway in the regulating guide. At the bottom it has a foot which rests on a steel disc in the bayonet joint at the roller guide neck. A clearance of approx. 0.1 mm between the plunger foot and the roller guide permits turning of the plunger in the roller guide. The regulating guide is able to turn in the bottom of the pump housing. On the outside the regulating guide has a toothed rim to mesh with the above-mentioned toothed rack at the base of the pump housing. The toothed rim and toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The toothed rack is linked together with the regulating gear of the engine through a spring-loaded connection. Thus, in the event of a sticking pump plunger, the regulating gear for the remaining fuel pumps will not be blocked. The pump barrel is provided with oil cut-off holes, which are covered and uncovered during the travel of the plunger within the barrel. This function, in conjunction with the turning of the plunger effected by the regulating gear, serves to regulate the amount of oil injected into the engine cylinder. Two screw plugs are fitted in the pump housing opposite the cut-off holes of the barrel. The oil jets which are ejected through the cut-off holes at the end of the delivery stroke will hit the screw plugs, which can be replaced when they are eroded.

Page 14 (23)


Engine Types 35-98MC/MC-C Injection timing


Fuel pumps without VIT (Variable Injection Timing): The pump barrel is attached to the top cover by means of screws. The lower part of the barrel is guided in the bore of the pump housing. Two sets of O-rings and back-up rings are fitted in grooves on the outside of the barrel and the pump cover to seal between pump barrel/pump cover and housing. A number of semi-circular shims are inserted between the top cover and the pump housing. By removing or inserting such shims, the pump barrel can be slightly lowered or raised in relation to the plunger, and in this way the initial moment of fuel oil injection into the engine cylinder can be adjusted, and the maximum combustion pressure thus changed. Refer to Volume II, Chapter 909, regarding adjustment of the maximum combustion pressure. VIT-type fuel pumps: The pump barrel is guided at the top and bottom of the pump housing. Low friction sealing rings are fitted in grooves in the barrel to seal between barrel and housing. The barrel is provided with a drain bore between the sealing rings at the lower end. The pump barrel has a threaded lower end which fits into the internal threads of the timing guide. The timing guide has a gear rim to mesh with the upper toothed rack at the base of the pump housing. The gear rim and toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The toothed rack is linked to a servo-air cylinder which is controlled mechanically or electronically in relation to the engine load. The position of the upper toothed rack determines the vertical position of the barrel relative to the plunger through the threaded connection. In this manner the initial moment of fuel oil injection into the cylinder can be adjusted by a servo-air cylinder. The pump barrel is prevented from turning by a guide screw mounted in the pump housing.

Puncture valve

In the top cover of the pump, a puncture valve is fitted. The puncture valve consists of a piston which communicates with the control air system of the engine. In the event of actuation of the shut-down system, and when STOP is activated, compressed air is supplied to the top of the piston, causing the piston with pin to be pressed downward and keep the suction valve in the open position. This will ‘puncture’ the oil flow to the fuel valve. As long as the puncture valve is activated, the fuel oil is returned through bores to the pump housing, and no injection takes place.


Page 15 (23)



Fuel Oil Injection

During the suction stroke, the spring-loaded suction valve opens and the delivery chamber is filled with oil. As soon as the plunger has covered the cut-off holes during its upward movement in the pump barrel, the injection commences through the fuel valves. The injection will last until the cut-off holes are uncovered by the oblique cut-off edges of the plunger, following which the oil is forced through two milled grooves at the side of the plunger and out through the cut-off holes of the barrel during the rest of the delivery stroke.

Shock absorber

A shock absorber is installed on each pump housing or in the main fuel pipe to take up pressure variations.

Fuel Pump Actuating Gear

The camshaft housing contains the fuel pump and exhaust valve actuating gear for each cylinder. The fuel pump is actuated by a cam on the camshaft. The movement is transmitted through the roller guide to the plunger in the barrel of the pump housing which – through the high-pressure pipes – is connected with the fuel valves on the cylinder cover. Reversible engines: The roller guide of each fuel pump incorporates an angular displaceable reversing link. Reversing is achieved by shifting the roller in the fuel pump drive mechanism at each cylinder. The link connecting the roller guide and roller is provided with a reversing arm, and a pivot is mounted at the top end of the reversing arm. The pivot travels in a reversing guide connected to an air cylinder. The link is self-locking in either the AHEAD or ASTERN position without the aid of external forces. Each cylinder is reversed individually, and the reversing mechanism is activated by compressed air. The reversing arrangement may incorporate a damper in order to reduce the mechanical stresses.

Fuel Oil HighPressure Pipes

All high-pressure pipes in the system are provided with a protective outer pipe. The space between the pipe and the protective outer pipe communicates, through bores in the union nipples, with a drain bore in the pump top cover.

Fuel Oil Leakage Alarm

A fuel oil leakage alarm is required for Unattended Machinery Spaces, UMS. 35-98MC: Each fuel pump is, via drain pipes, connected to a common drain tank, which incorporates a level switch. The drain tank is also equipped with an overflow pipe, which has a small drain bore below, whereby oil from small leakages can be drained to the outlet, without actuating the level switch.

Page 16 (23)




In the event of pipe fractures or major leakages in the system, the abovementioned bore will not be large enough to allow the increased oil quantity to pass, and the oil level in the drain tank will rise until it reaches the level of the overflow pipe. The rising oil level will cause the level switch to set off an alarm. 50-98MC: Alternatively to the common drain tank, the drain pipes on 50-98MC engines can be connected to a diaphragm valve, which sets off an alarm and activates the puncture valve in order to stop the fuel oil flow from the pertaining pump. On 60-98MC engines, which are provided with pneumatically operated fuel pump roller guide lifting gear, automatic activation of the lifting gear by the diaphragm valve can be arranged in order to stop the fuel oil flow from the pertaining pump.

Fuel Valve

The fuel valve consists of a valve head and a valve housing. Fitted within the valve housing is a non-return valve and a spindle and spindle guide with a pressure spring, and a nozzle. The spindle may be provided with a cut-off slide. When the fuel valve is fitted in the cylinder cover, the valve parts are tightened together by the pressure from the securing nuts.

Functioning

The functioning of the fuel valve is as follows: The electrical fuel oil primary pump circulates preheated oil through the fuel pump and fuel valve. The fuel oil passes through the fuel valve, leaving through a circulation bore and the return oil pipe on the valve head. When the pressure at the beginning of the fuel pump’s delivery stroke has reached the predetermined pressure, the circulating bores is closed. When the pressure has reached the predetermined opening value for the fuel valve, the spindle will be lifted and oil injected through the nozzle into the engine cylinder. On completion of the fuel pump’s delivery stroke, the valve spindle is pressed against its seat and injection now ceases. Then the circulating bore is uncovered, and oil starts to recirculate through the valve.

910 Turbocharger System Air System

The engine is supplied with scavenge air from one or more turbochargers, depending on the engine type and layout. The engine exhaust gas drives the turbine wheel of the turbocharger and, through a common shaft, the turbine wheel drives the compressor wheel.


Page 17 (23)


Engine Types 35-98MC/MC-C The compressor draws air from the engine room, through the air filters. From the compressor outlet, the air passes through the charging air pipe to the charging air cooler where the air is cooled down. The charging air pipe, with compensator, is insulated. The air cooler incorporates a water mist catcher, which is designed to separate condensate from the air. See also ‘Charging Air Cooler’ further on in this Section. When the air has passed the water mist catcher, it is pressed into the scavenge air receiver through non-return valves. The non-return valves open by pressure from the turbocharger. From the scavenge air receiver, the air flows to the cylinder through the scavenge air ports when the piston is in the bottom position. When the exhaust valves open, the exhaust gas is pressed into a common exhaust gas receiver, from where the gas drives the turbine of the turbocharger with an even and steady pressure

Scavenge Air Receiver

The scavenge air receiver is a container having a large volume. The receiver is bolted on to the cylinder frame. Scavenge air is collected in the receiver after the air has passed through the cooler, the water mist catcher and the non-return valves. The receiver and the cylinder frame communicate through large openings. The scavenge air receiver is provided with man-hole covers and a safety valve.

Auxiliary Blowers

The engine is provided with two or more auxiliary blowers. The suction sides are connected to the space after the water mist catcher. The discharge sides are connected to the scavenge air receiver. Separate nonreturn valves are installed at the suction side or discharge side of the auxiliary blowers, in order to prevent reversed air flow. See also item, “Non-return valves”, further on.

El. panels for auxiliary blower

See special instructions supplied by the engine builder.

Running with auxiliary blowers

During the starting of the engine, and when the engine is running at low load, the turbocharger is not able to supply enough air for the engine process. In these cases a pressure switch will automatically start the auxiliary blowers. When the auxiliary blowers are operating, they draw air from the engine room through the turbocharger’s air filter and compressor side.

Page 18 (23)




Warning! If the auxiliary blowers do not start during low-load running (because of faults, or because the switch for the blowers is not in “AUTO” position), unburned fuel oil may accumulate on top of the pistons. This will involve the risk of a scavenge air box fire. In order to avoid such a fire: – obtain permission to stop the engine – stop the engine – remove any unburned fuel oil from the top of the pistons – re-establish the supply of scavenge air – start the engine Note: the switch for the auxiliary blowers should be in “AUTO” position during all modes of engine control, i.e.: – remote control – control from engine side control console. The non-return valves fitted after the water mist catcher are now closed as a result of partial vacuum and gravitation acting on the valve flaps. There will be a lack of air supply if the non-return valves do not close.

Non-Return Valves

It is of the utmost importance that the non-return valves of the auxiliary blowers always function correctly and move easily. This can be checked either by moving the valves manually in connection with the regular scavenge port inspections, or via locally placed inspection covers. The non-return valves protect the blowers and engine during: • Start-up of the auxiliary blowers • Running with auxiliary blowers. Starting the auxiliary blowers: 1. Owing to the relatively high starting current, the blowers start in sequence, with 6-10 seconds in between. The non-return valve of the blower that has not yet started must be in the closed position to prevent the blower from rotating backwards. Otherwise, there is a risk that the electric motor will burn out when it starts. 2. If an auxiliary blower fails to start, the non-return valve must be in the closed position. Otherwise, the operating blower will not be able to draw fresh air in through the turbocharger and air cooler. This is due to differences in the air flow resistance.


Page 19 (23)


Engine Types 35-98MC/MC-C Running with auxiliary blowers: If an auxiliary blower fails during running, the non-return valve must close to ensure the continued supply of fresh air to the engine. See ‘Starting the auxiliary blowers‘, Item 2, above.

Exhaust Gas Receiver

From the exhaust valves, the exhaust gas is led to the exhaust gas receiver where the pulsatory pressure from the individual exhaust valves is equalized and led to the turbocharger at a constant pressure. The exhaust gas receiver is fastened to the seating by flexible supports. Compensators are inserted between the receiver and the exhaust valves, and between the receiver and the turbocharger. Inside the exhaust gas receiver, a protective grating is mounted before the turbocharger. The exhaust gas receiver and the exhaust pipe are insulated.

Charging Air Cooler

The charging air cooler insert is of the block type. It is mounted in a housing which is welded up of steel plates. The cooler housing is provided with inspection covers. The cooler is designed with an air reversing chamber which incorporates a water mist catcher. The water mist catcher is built up of a number of lamellas which separate the condensation water from the scavenge air during the passage of the air flow. The separated water is collected in the bottom of the cooler housing from which it is removed by a drain system.

Caution! It is important to check that the drain functions correctly, as otherwise water droplets may enter the cylinders. See Volume I Operation, Chapter 706, ‘Cleaning of Turbochargers and Air Coolers’.

An alarm device for high water level in the drain system is installed.

911 Safety Equipment Safety Valves, Cylinder Cover

Page 20 (23)

Each cylinder cover is provided with a spring-loaded safety valve which is set to open at a pressure somewhat higher than the maximum firing pressure in the cylinder.


Engine Types 35-98MC/MC-C Relief Valves


On the exhaust side of the engine a number of spring-loaded relief valves are fitted, which will open in the event of excessive pressure in the crankcase/chain casing, for instance as a result of the ignition of oil mist. Warning! Keep the areas around the relief valves free of oil, grease, etc. to prevent the risk of fire caused by hot air/gas emitted in the event that the relief valves open.

Regarding how to: • avoid evaporation of the lubricating oil in the crankcase, • detect oil mist in the crankcase using an ‘Oil Mist Detector’. see Volume I, OPERATION, Chapter 704. Warning! Do not stand near crankcase doors or relief valves – or in corridors near doors to the engine room casing in the event of an alarm for: a) oil mist b) high lube oil temperature c) no piston cooling oil flow, or d) scavenge box fire Alarms b, c and d should be considered as pre-warnings of a possible increasing oil mist level. See also our Service Letter SL97-348/ERO.

Note! If there has been a crankcase explosion, the complete flame arrester of the relief valves must be replaced.

Safety Valve, Scavenge Air Receiver

The scavenge air receiver is fitted with a safety valve which is set to open should the pressure in the scavenge air receiver exceed a value somewhat higher than the normal scavenge air pressure of the engine. In some cases it may be necessary to open the valve manually, see Volume I, Chapter 704, "Turbocharger Surging".


Page 21 (23)

Description A90030-0006 Safety Cap in Starting Air Line

Engine Types 35-98MC/MC-C Each starting valve inlet pipe is provided with a safety cap. The safety cap consists of a bursting disc enclosed by a perforated cylinder and a perforated cover in order to protect any bystanders, in the event of a burst. The cover is provided with a check plate, which shows if the bursting disc has been damaged. If the bursting disc of the safety cap is damaged by excessive pressure in the starting air line, overhaul or replace the starting valve which caused the burst, and fit a new disc. If a new disc is not available immediately, turn the cover in relation to the cylinder, in order to reduce the leakage of starting air. Fit a new bursting disc and return the cover to the open position at the first opportunity.

912 Assembly of large Parts Bedplate

The bedplate is made in one or more sections, depending on the number of cylinders. If there are two or more sections, these are joined together with fitted bolts. The bedplate consists of two welded, longitudinal girders and a number of cross girders which support the main bearings. The main bearings consist of steel shells, lined with bearing metal. See also Volume I, OPERATION, Chapter 708. Each main bearing has one or two main bearing caps which are secured by studs and nuts, designed for tightening with hydraulic tools. The bedplate is fitted with an axial vibration damper. For the design and functioning of the axial vibration damper, see Section 905 “Crankshaft”. Marine engines (except geared plants): The aft end of the bedplate incorporates the thrust bearing. See also Section 905 “Crankshaft”. Stationary engines (and geared marine plants): The bedplate incorporates the guide bearing. See also Section 905, “Crankshaft”.

Framebox

A framebox is bolted on to the top of the bedplate. Like the bedplate, the framebox consists of one or more sections. Together, the bedplate and the framebox constitute the crankcase of the engine. The framebox is fitted with steel-plate doors for access to the crossheads and to the main and crankpin bearings. For each cylinder, the framebox is equipped with a slotted pipe in which the piston cooling oil outlet pipe fitted to the crosshead or guide shoe is

Page 22 (23)




able to travel. From the slotted pipe the cooling oil is, through an outlet pipe, led to the oil tray of the bedplate. Equipment for local checking of the cooling oil temperature and flow, and for temperature and flow alarms, is installed in conjunction with the outlet pipe. See also Volume I, OPERATION, Chapter 701.

Staybolts

The bedplate, framebox and the cylinder frame are tightened together to form one unit by means of staybolts.

Engine Seating

Regarding the engine seating for the specific engine, see the supplier’s special instructions.


Page 23 (23)

901 - Cylinder Cover Documents in this Chapter 90101 90103

0180 0003

Cylinder Cover Indicator Cock - Mounting

MAN B&W Diesel A/S

MAN B&W Diesel A/S



Plate P90101-0180

Page 1 (2)

Cylinder Cover

Plate P90101-0180 Item No. 018 031 043 067 080 102 114 126 151 163 175 187 209 210 222 234 246 271

Page 2 (2)


Item Description

Item Description

Nut Washer Stud Cylinder cover O-ring Cooling jacket Screw Gasket Screw Protective cap Nut Stud for exhaust valve Nut Spring house, complete Stud with guide face for fuel valve Stud for fuel valve Pipe for fuel valve Drain pipe


Indicator Cock - Mounting


Plate P90103-0003

Page 1 (2)

Plate P90103-0003 Item No. 019 020 032 056 068 081 093 103 127 140 152 164 176 188 223 235

Page 2 (2)

Indicator Cock - Mounting

Item Description

Item No.

Item Description

Indicator cock Packing Packing Disc Plug screw Sundry chain Key ring Eye screw Packing Screw Nut Locking plate Flange Extension Screw Extension


902 - Piston with Rod & Stuffing Box Documents in this Chapter 90201 90205

0216 0117

Piston and Piston Rod Piston Rod Stuffing Box

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Piston and Piston Rod

Plate P90201-0216


Page 1 (2)

MAN B&W Diesel A/S

Plate P90201-0216 Item No. 011 023 035 047 059 060 072 084 096 106 118 143 155 167 179 180 192 202 214

Page 2 (2)

Piston and Piston Rod

Item Description

Item No.

Item Description

Screw Screw D-ring D-ring Piston skirt Screw Screw Locking wire Piston ring No.1 Piston ring No. 2+4 Piston ring No. 3 Piston crown Pipe for cooling insert Disc Piston rod Stud Sealing ring Disc Nut




Plate P90205-0117

Page 1 (2)

Plate P90205-0117 Item No. 013 025 037 049 074 086 098 121 145 169 170 182 204 228 265 277 300

Page 2 (2)


Item Description

Item No.

Item Description

O-ring Scraper ring Sealing ring Sealing ring Nut Housing stuffing box Flange Screw Fitted bolt Screw Scraper ring Scraper ring Cylindrical pin Spring pin Lamella Spring Spring


903 - Cylinder Liner and Cylinder Lubrication Documents in this Chapter 90301 90302 90304 90305 90307 90308 90310 90312

0163 0161 0035 0143 0032 0010 0012 0004

Cylinder Frame Cylinder Liner and Cooling Jacket Cylinder Liner - Details Cylinder Lubricators Cylinder Lubricator Unit Cylinder Lubricator - Intermediate Box Cylinder Frame - Rear Side Electronic Components - Cylinder Lubrication

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Cylinder Frame MAN B&W Diesel


Plate P90301-0163

Page 1 (2)

Cylinder Frame

Plate P90301-0163 Item No. 135 159 160 172 184 196 206 218 231 255 267 279 292 302 314 338 351 363 387 399 410 422 446 458 471 483 495 517 529 530 542 566 578 591 601 625 637 650 662 674 686 698 721 733 745 757

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Cylinder frame Distance pipe Bushing Stuffing box housing Screw Screw Washer Cover Nut Stud for cylinder cover O-ring O-ring Nut Distance pipe Stud Stud Distance pipe Nut Screw Distance pipe Protective pipe Gasket Cylinder frame Gasket Cover Stud Nut Fittes stud Stud Nut Stud Fitted stud Stud Nut Stud Cleaning cover Gasket Screw Rail for sealing Packing Stud Nut Distance pipe Distance pipe Fitted stud Stud




Plate P90302-0161

Page 1 (2)

Plate P90302-0161 Item No. 000 071 083 095 105 117 129 130 142 166 178 191 201 213 225 237 249 262

Page 2 (2)


Item Description

Item No.

Item Description

O-ring O-ring Cooling jacket Clamp Screw Cylinder liner Cooling water connection Packing O-ring Pipe Screw Pipe Pipe Spring pin Plug screw for thermo sensor hole Gasket Piston cleaning ring


Cylinder Liner - Details

Plate P90304-0035

Cylinder Liner - Details 0035 P90304

Camshaft side


Page 1 (2)

Cylinder Liner - Details

Plate P90304-0035 Item No. 023 035 060 072 084 096

Item Description

Item No.

Item Description

Stud Nut Non-return valve Housing, non-return valve Non-return valve Head

Page 2 (2)




Plate P90305-0143

Page 1 (2)

Plate P90305-0143 Item No. 017 029 030 042 066 101 113

Page 2 (2)


Item Description

Item No.

Item Description

Bracket Stud Nut Washer Screw Stud Nut


Cylinder Lubricator Unit MAN B&W Diesel


Plate P90307-0032

Page 1 (2)

Plate P90307-0032 Item No. 018 031 043 055 079 080 092 102 126 138 175 187 199 210 222 258 271 283 295 305 317 329 330 342 354 366 378 391 413 425 449 450 462 486 498 521 533 545 557 569 582 594 604 616 628

Page 2 (2)

Cylinder Lubricator Unit MAN B&W Diesel

Item Description

Item No.

Item Description

Straight stud coupling Distributor block Stud Nut Distributor block Ball valve Distributor block Stud Adjustable elbow coupling Quick coupling, minimess O-ring Gasket Membrane accumulator Lubricator, complete Screw Straight stud coupling Adjusting screw O-ring Spacer, tubular Cover O-ring Non-return valve O-ring Cylinder block O-ring Spring Plunger Actuator piston Screw Screw Membrane accumulator Gasket Cylinder housing Solenoid valve complete Screw O-ring O-ring Inductive sensor Plug Housing Cable Cable gland Screw Cable gland Plug


Intermediate Box


Plate P90308-0010

Page 1 (2)

Plate P90308-0010 Item No. 013 037 049 062

Page 2 (2)

Intermediate Box

Item Description

Item No.

Item Description

Intermediate box, complete Electric enclosure with cables Circuitboard assy Diode


Cylinder Frame, Studs on Exhaust Side MAN B&W Diesel


Plate P90310-0012

Page 1 (2)

Plate P90310-0012 Item No. 014 026 038 054 063 075

Page 2 (2)

Cylinder Frame, Studs on Exhaust Side MAN B&W Diesel

Item Description

Item No.

Item Description

Distance pipe Nut Stud Distance pipe Nut Stud


Cylinder Lubrication - Electronic Components


Plate P90312-0004

Page 1 (2)

Plate P90312-0004 Item No. 015 027 039 040 052 064 076 088 111 159 160 184 196 206

Page 2 (2)

Cylinder Lubrication - Electronic Components

Item Description

Item No.

Item Description

Name plate Pilot lamp Name plate Selector switch Terminal Terminal Din rail Terminal Terminal HMI panel Mounting plate Nut Screw Terminal


904 - Crosshead with Connecting Rod Documents in this Chapter 90401 90403

0172 0012

Connecting Rod and Crosshead Lubricating and Cooling Oil Flow

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Connecting Rod and Crosshead MAN B&W Diesel


Plate P90401-0172

Page 1 (2)

Plate P90401-0172 Item No. 019 020 032 056 068 093 103 127 139 152 164 176 188 223 235 247 260 272 284 296 318 331 343 367 379 392 402 414 426 438 463 475 487 509 510 522 546 558 583 595 617

Connecting Rod and Crosshead MAN B&W Diesel Item No.

Item Description

Item Description

Screw Outlet pipe Guide shoe Lock washer Stop screw Screw Nut Thrust piece Screw Telescope pipe Distance tube Bend Stud Plug Guide pin Throttle plug Locking wire Crosshead Crosshead bearing shell, complete Guide strip Crankpin bearing cap, complete Guide screw Crankpin bearing cap Guide pipe Nut Nut Washer Stud Screw *) Shim Nut Crosshead bearing cap Stud *) Shim *) Shim Stud Guide pin Connecting rod Nut Stud Connecting rod, complete Note: *) Please state thickness of shim

Page 2 (2)


Lubricating and Cooling Oil Flow MAN B&W Diesel


Plate P90403-0012

Page 1 (1)

905 - Crankshaft, Thrust Bearing and Turning Gear Documents in this Chapter 90501 90502 90505 90510 90511 90513

0162 0052 0146 0124 0039 0041

Crankshaft Arrangement of Fore End Thrust- and Guide Bearing Turning Gear Turning Wheel Tacho System

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Crankshaft

Plate P90501-0162

P90501 Crankshaft 0162


Page 1 (2)

Plate P90501-0162 Item No. 012 024 061 073 097 107 119 120 132 144 156 203 215 227

Crankshaft

Item Description

Item No.

Item Description

Flange Screw Screw Crankshaft Guard Guard Nut Packing Cover Screw Locking wire Fitted bolt Split pin Chain wheel

Page 2 (2)


Arrangement of Fore End


Plate P90502-0052

Page 1 (2)

Plate P90502-0052 Item No. 018 024 043 055

Page 2 (2)

Arrangement of Fore End

Item Description

Item No.

Item Description

Stud Nut Tuning wheel Disc


Thrust and Guide Bearing

Plate P90505-0146

Thrust and Guide Bearing 0146 P90505


Page 1 (2)

Plate P90505-0146 Item No. 014 026 038 051 063 075 087 109 110 122 134 158 171 195 205 217 229 242 254 266 278 291 301 313 337 350 362 386 408 421 433 445 457 469 494 504 516 541

Thrust and Guide Bearing

Item Description Lubricating oil pipe Screw Nut Lubricating oil pipe Lubricating oil pipe Stopper Segment holder Locking wire Screw Segment Segment Lubricating oil pipe Nut Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Screw Lubricating oil pipe Lubricating oil pipe Segment holder Segment holder Lubricating oil pipe Screw Lubricating oil pipe Oil throw ring Screw Nut Scraper ring housing, Scraper ring housing, Bolt Screw Scraper ring housing, Nut Scraper ring housing, Bolt Screw Nut

Page 2 (2)

Item No.

Item Description

complete upper

lower complete


Turning Gear


Plate P90510-0124

Page 1 (2)

Plate P90510-0124 Item No. 011 023 035 047 059 072 084 096 106 131 143 155 167 192 202 214 226 251 263 299 309 310 322 334 346 358 405 417 429

Page 2 (2)

Turning Gear

Item Description

Item No.

Item Description

Bracket Nut Screw Spring washer Cam Switch Spring washer Screw Lever 3/2-way valve Screw Spring washer Chain Nut Distance pipe Pin Turning gear Distance pipe Screw Gear wheel Disengaging divice, complete Screw Cam Spring washer Shaft Bush Spring ring Eye screw Circlip


Turning Wheel


Plate P90511-0039

Page 1 (2)

Plate P90511-0039 Item No. 017 029 030 054 066 078 101 113 125 137

Page 2 (2)

Turning Wheel

Item Description

Item No.

Item Description

Guide pin Nut Nut Screw Screw Dead centre pointer Fitted bolt Nut Turning wheel Locking wire


Tacho System MAN B&W Diesel


Plate P90513-0041

Page 1 (2)

Tacho System

Plate P90513-0041 Item No. 018 031 043 055 067 080 092 114 126

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Tacho pick-up Screw Spring-lock Nut Bracket Screw Spring-lock Cylindrical dowel Nut


906 - Control Gear Documents in this Chapter 90600 90603 90610 90611 90612 90613 90615 90618 90619 90620 90621 90622 90631 90632 90633 90634

0125 0111 0131 0175 0085 0116 0147 0134 0019 0097 0076 0070 0023 0003 0030 0041

Arrangement of Chain Drive and Camshaft Chain Tightener Bearing Housing - Mounting Camshaft and Chain Wheel Arrangement of Indicator System Camshaft Bearing Arrangement of Governor Regulating Shaft Load Transmitter Engine-Side Control Console Engine-Side Control Console - Details Arrangement of Layshaft Chain Drive Guidebars - Upper Part Chain Drive Guidebars - Lower Part Chain Drive Lubrication - Upper Part Chain Drive Lubrication - Lower Part

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Arrangement of Chain Drive and Camshaft


Plate P90600-0125

Page 1 (1)

Chain Tightener

Plate P90603-0111

Chain Tightener 0111 P90603


Page 1 (2)

Plate P90603-0111 Item No. 017 029 030 042 054 066 078 091 113 125 150 162 174 186 198 208 221 233 245 270 282 294 304 316 328

Chain Tightener

Item Description

Item No.

Item Description

Chain wheel Cup point screw Bushing Flange bearing Locking wire Screw Screw Bracket Shaft Flange bearing Distance piece Distance piece Screw Grease nipple Shaft Guide nut Locking plate Nut Tightening bolt Shaft Guide nut Retaining ring Retaining ring Shaft Bushing

Page 2 (2)


Bearing Housing - Mounting MAN B&W Diesel


Plate P90610-0131

Page 1 (2)

Plate P90610-0131 Item No. 015 039 052 064 088 111 123 147 159 172 184 196

Page 2 (2)

Bearing Housing - Mounting MAN B&W Diesel

Item Description

Item No.

Item Description

Bearing housing Bearing shell Nut for hydraulic tightening Stud Lock washer Screw Guide pin Guide pin Shim Bearing housing Guide disc Screw


Camshaft and Chain Wheel MAN B&W Diesel


Plate P90611-0175

Page 1 (2)

Camshaft and Chain Wheel

Plate P90611-0175 Item No. 010 034 058 071 083 095 117 130 154 166 191 213 225 249 250 274 298 321 345

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Camshaft, fore O-ring Exhaust cam Fuel cam Sealing flange Coupling O-ring Camshaft Indicator cam Fitted bolt Nut, self-locking O-ring Fitted bolt Chain wheel Camshaft Guide pin Disc Nut Plug


Arrangement of Indicator System


Plate P90612-0085

Page 1 (2)

Plate P90612-0085 Item No. 016 028 041 053 065 077 089 090 100 112 124 136 148 161 173 185 197 207 219 220 232 244 256 268 281 293 303 315 327 555 567 579 580

Page 2 (2)

Arrangement of Indicator System

Item Description

Item No.

Item Description

Nut Screw Washer Bracket Screw Housing Liner Spring pin Roller guide, complete Circlip Washer Screw Circlip Roller guide Liner Liner Spring Key Screw Shaft Needle bearing Pointed screw Bracket Screw Screw Handle Bracket Washer Screw Guide roller Shaft Circlip Washer


Camshaft Bearing

Plate P90613-0116

Camshaft Bearing 0116 P90613


Page 1 (2)

Camshaft Bearing

Plate P90613-0116 Item No. 023 035 047 059 060 072 084 131 143 155 167 179 192 202 214 226 238 251 263 275 287

Item Description

Item No.

Item Description

Housing Guide pin Screw Screw Shield, upper part Rubber corol Shield, lower part Cover Gasket Nut Nut Screw Oil pan Stud Bearing shell Pin Bearing cap Screw Flange, complete Gasket Cover

Page 2 (2)


Arrangement of Governor MAN B&W Diesel


Plate P90615-0147

Page 1 (2)

Plate P90615-0147 Item No. 012 036 048 061 073 085 107 119 120 132 156 168

Page 2 (2)

Arrangement of Governor MAN B&W Diesel

Item Description

Item No.

Item Description

Electrical governor actuator Screw Spring lock Screw Nut Bracket Pull rod, complete Fitted bolt Washer Nut, self-locking Terminal Screw


Regulating Shaft


Plate P90618-0134

Page 1 (2)

Plate P90618-0134 Item No. 019 020 032 044 068 081 093 103 115 127 139 140 164 176 188 211 223 260 272 284 296 306 318 331 343 355 367 392 402 414 426 438 451 475 487 499 509 510 522 534 546 571 595 630 642 654 666 678 691 701

Page 2 (2)

Regulating Shaft

Item Description

Item No.

Item Description

Shaft Circlip Pull rod, complete Fitted bolt Screw Lock washer Arm holder Pin Recilient arm, complete Circlip Nut Spring Screw Lock washer Nut Washer Fitted bolt Sleeve coupling, complete Pin Self-locking nut Washer Moveable arm Circlip Pin Key Lever Self-locking nut Shaft Shaft Screw Spring washer Sleeve coupling Nut Ball bearing Shim Bearing housing Screw Shaft Bracket Bearing housing Screw Bracket Washer Key Screw Lever Nut Bracket Dog point screw Spring pin


Load Transmitter MAN B&W Diesel


Plate P90619-0019

Page 1 (2)

Load Transmitter

Plate P90619-0019 Item No. 014 026 038 051 075 087 099 109 110 122 134 146 171 183 195

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Clamping arm Screw Lock washer Nut Fitted bolt Self-locking nut Washer Pull rod, complete Clamping arm Screw Lock washer Nut Bracket Potentiometer Screw


Plate P90620-0097

Engine Side Control Console Engine Side Control Console 0097 P90620

A

A


Page 1 (2)

Plate P90620-0097 Item No. 021 033 045 057 069 070 082 094 104 116 128 141 153 165 177 189 190 200 212 224 248 261 273 285 307 319 320 332 368 381 415 427 476 488 511 523 535 547 559 631 643 655 667 680 692 714 726

Engine Side Control Console

Item Description Distance pipe Screw Switch 0-110 volt Spring lock Name plate Pressure switch Screw Name plate Name plate Spring lock Nut Stud Handle Key Grease nipple Nut Washer Engine side console Forked lever Key Clamping arm Screw Nut Lock washer Cover Screw Hand wheel Thrust ring Locking plate Nut Clamping block Spindle Ball bearing Circlip Screw Name plate, astern Name plate, start Name plate, aahead Name plate, stop Screw Sealing ring Name plate, remote Name plate Thrust ring Name plate, emergency Ball bearing Circlip

Page 2 (2)

Item No. 738 751 763 775

Item Description Bearing flange Shaft Studs Ball handle


Engine - Side Control Console, Details

Plate P90621-0076

Engine - Side Control Console, Details 0076 P90621


Page 1 (2)

Plate P90621-0076 Item No. 027 039 040 052 076 088 111 123 135 147 159 160 172 196 206 218 231 255 267 279 280 302 314 326 338 351 363 375 387 399 410 422 434 446 458 483 495 505 517 529 542 554 566 578 591 613 637

Engine - Side Control Console, Details

Item Description Screw Self-locking nut Washer Fitted bolt Key Coupling Split pin Bearing Screw Angle lever Circlip Non-return valve Nut Flange bearing Screw Manual valve 5/2 way Screw Pointer Screw Shaft Manual valve 3/2 way Circlip Circlip Ball bearing Flange bearing Manual valve 3/2 way Clamping arm Lock washer Nut Screw Nut Slide shoe Circlip Screw Lock washer Coupling Coupling Non-return valve Banjo coupling Coupling Screw connection Coupling Coupling Coupling Coupling Coupling Coupling

Page 2 (2)

Item No. 650

Item Description Coupling


Arrangement of Layshaft


Plate P90622-0070

Page 1 (2)

Plate P90622-0070 Item No. 010 022 034 046 058 071 083 095 105 117 129 130 178 191 201 213 225 237 249 250 262 274 286 298 308 321 333 345 357 369 370

Page 2 (2)

Arrangement of Layshaft

Item Description

Item No.

Item Description

Flange bearing Washer Self-locking nut Lever Lever Grease nipple Fitted bolt Spindle Cone Guide pin Distance ring Ball bearing Lever Plate Disc Nut Locking plate Screw Bushing Locking arm Washer Screw Spring washer Screw Switch Stop screw Cam Impact socket Impact handwheel Washer Self-locking nut


Chain Drive Guidebars - Upper Part MAN B&W Diesel


Plate P90631-0023

Page 1 (2)

Plate P90631-0023 Item No. 021 045 069 070 094 104 116 128 141 153 165

Chain Drive Guidebars - Upper Part MAN B&W Diesel

Item Description

Item No.

Item Description

Chain link, complete Chain, complete Outer link Inner link Locking wire Disc Screw Beam for guidebar Guidebar Screw Bracket for guidebar Note: *

Page 2 (2)


Chain Drive Guide Bars - Lower Parts


Plate P90632-0003

Page 1 (2)

Plate P90632-0003 Item No. 015 027 039 052 064 076 111 135 147 160 184 196 218 243 267

Page 2 (2)

Chain Drive Guide Bars - Lower Parts

Item Description

Item No.

Item Description

Guidebar Beam f. guidebar Screw Disc Screw Locking wire Screw Beam f. guidebar Shim Screw Screw Bracket Screw Beam f. guidebar Bracket


Chain Drive Lubrication - Upper Part MAN B&W Diesel


Plate P90633-0030

Page 1 (2)

Plate P90633-0030 Item No. 010 022 034 058 071 083 095 105 129 142 166

Page 2 (2)

Chain Drive Lubrication - Upper Part MAN B&W Diesel

Item Description

Item No.

Item Description

Lubricating pipe Spray nozzle Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe Lubricating pipe


Chain Drive Lubrication - Lower Part MAN B&W Diesel


Plate P90634-0041

Page 1 (2)

Plate P90634-0041 Item No. 016 028 041 053 065 089 090 100 112 136 148 173 185 219 232

Page 2 (2)

Chain Drive Lubrication - Lower Part MAN B&W Diesel

Item Description

Item No.

Item Description

Lubricating oil pipe Lubricating oil pipe Spray pipe Spray pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Spray pipe Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Spray pipe Lubricating oil pipe


907 - Starting Air System Documents in this Chapter 90702 90703 90704

0069 0129 0053

Main Starting Valve Starting Air Distributor Starting Valve

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Main Starting Valve


Plate P90702-0069

Page 1 (2)

Plate P90702-0069 Item No. 027 039 052 064 076 088 123 135 147 160 184 196 206 218 231 255 279 280 292 314 326 338 351 363 387 399 410 422 434 458 471 495 505 517 529 530 542 554 566 591 601 625 637 650 674 698

Page 2 (2)

Main Starting Valve

Item Description Screw Name plate "Working" Screw Washer Switch Distance pipe Spindle Screw Plate Ball valve with actuator* Nut Screw Starting air pipe Gasket Intermediate piece Name plate "Blocked" Nut Washer Hand wheel Securing plate Pin Spring Screw Gasket Gasket Plug screw Adjusting screw Nut Adapter Washer Screw Screw Guide Guide pin Screw Distance pipe Screw Ball valve with actuator* Nut Plug screw Gasket Plug screw Starting air pipe Non-return valve Housing Housing

Item No. 708 900 912

Item Description Screw Repair kit, actuator* Repair kit, ball valve* Note: * When ordering spare parts for this item, please state manufacturer's Part No.


Starting Air Distributor MAN B&W Diesel


Plate P90703-0129

Page 1 (2)


Plate P90703-0129 Item No. 010 022 034 046 071 083 105 129 142 166 178 191 213 225 237 250 274 286 298 308 321 333 345

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Starting cam Lock washer Screw Cover Screw Cover Piston valve slide Liner Screw Screw Washer Screw Screw Housing Screw Pin Screw Flange Locking ring Spring guide Spring Spring guide Liner


Plate P90704-0053

Starting Valve Starting Valve 0053 P90704

U

P


Page 1 (2)

Plate P90704-0053 Item No. 016 028 053 065 077 090 100 112 148 161

Starting Valve

Item Description

Item No.

Item Description

Screw Piston Spring Bushing Valve housing Screw Cover Locking plate Sealing ring Spindle

Page 2 (2)


908 - Exhaust Valve Documents in this Chapter 90801 90803 90804 90805 90806 90810

0211 0045 0016 0122 0104 0089

Exhaust Valve - Lower Parts Exhaust Valve - Upper Parts Exhaust Valve Upper Parts - Details Exhaust Valve - Actuator Exhaust Valve - Pipe System Arrangement of Cooling Water Pipes

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Exhaust Valve - Lower Parts MAN B&W Diesel


Plate P90801-0211

Page 1 (2)

Plate P90801-0211 Item No. 013 025 037 050 062 074 086 098 121 145 169 170 182 194 204 228 253 265 277 290

Page 2 (2)

Exhaust Valve - Lower Parts MAN B&W Diesel

Item Description

Item No.

Item Description

Cover Screw Packing Packing Flange Screw O-ring Bottom piece Valve spindle Thread insert Spindle guide lower Exhaust valve housing Plug screw Screw Sealing ring O-ring Packing Flange Screw Sealing ring


Exhaust Valve - Upper Parts MAN B&W Diesel


Plate P90803-0045

Page 1 (2)

Plate P90803-0045 Item No. 014 026 038 063 087 099 110 134 158 205 217 229 242 254 266 291 301 325 337 349 350 362 386 398 408 433 457 469 470 482 494 504 516 528 541 553 565 589 600 612 624 636 661

Page 2 (2)

Exhaust Valve - Upper Parts MAN B&W Diesel

Item Description

Item No.

Item Description

Lifting eye bolt Screw Lifting attachment Packing Orifice plug Disc Safety handrail Piston, air cylinder O-ring Locking plate Sliding bearing Sealing ring Oil cylinder Stud Nut Sealing oil pipe Sealing oil control unit Disc Locking plate Screw O-ring Air cylinder Screw Disc Cone Piston ring Screw Pin Rotation check rod Steel pipe Union nut Screwed connection Packing ring Spring O-ring Disc Spring pin Non-return valve Piston Spring Piston Disc Piston, complete


Exhaust V alve - Upper Parts, Details Valve MAN B&W Diesel


Plate P90804-0016

Page 1 (2)

Plate P90804-0016 Item No. 021 045 905

Exhaust V alve - Upper Parts, Details Valve MAN B&W Diesel

Item Description

Item No.

Item Description

Gasket Safty valve, with o-ring O-ring* Note: * Optional extras

Page 2 (2)


Valve Gear

Plate P90805-0122

Valve Gear 0122 P90805


Page 1 (2)

Valve Gear

Plate P90805-0122 Item No. 015 027 039 040 052 064 076 088 111 123 135 147 159 160 167 196 206 218 255 267 279 280 292 314 326 338 351

Item Description

Item No.

Item Description

Nut Oil cylinder Stud Stud Piston Roller guide, complete Thrust disc Roller guide Shaft pin for roller Plug Circlip Screw Bushing Disc Bushing for roller guide Cylinder pin Screw Bushing Piston ring Disc Screw Disc Spring Cylinder pin Roller Guide block Guide pin

Page 2 (2)


Exhaust Valve - Pipe System MAN B&W Diesel


Plate P90806-0104

Page 1 (2)

Plate P90806-0104 Item No. 010 022 046 058 071 083 105 117 129 130 142 154 166 178 191 213 237 262 298 308

Page 2 (2)

Exhaust Valve - Pipe System MAN B&W Diesel

Item Description

Item No.

Item Description

Sealing ring Sealing disc Clamp Nut Screw Support Coupling Coupling Thrust bushing Screw Cooling water connection Pipe Sealing ring Packing Hose complete Drain pipe Hydraulic pipe, complete Screw Plug screw Packing ring


Arrangement of Cooling Water Pipes MAN B&W Diesel


Plate P90810-0089

Page 1 (2)

Plate P90810-0089 Item No. 012 024 036 048 061 073 085 097 119 120 132 156 181 203 215 227 239 240 264

Page 2 (2)

Arrangement of Cooling Water Pipes MAN B&W Diesel

Item Description

Item No.

Item Description

Steel pipe Ball valve Coupling Steel pipe Gasket Freshwater pipe, outlet Screw Packing Screw Nut Packing Freshwater pipe, inlet Globe valve Packing Screw Sealing ring Screw Spring pin Freshwater pipe, inlet


909 - Fuel Oil System Documents in this Chapter 90901 90902 90903 90904 90905 90907 90910 90911 90913 90914 90915 90915 90916

0184 0150 0040 0061 0030 0011 0143 0022 0158 0078 0060 0080 0006

Fuel Pump Fuel Pump Gear Fuel Pump Gear - Details Fuel Pump - Details Reversing Mechanism Lifting Device for Fuel Pump Fuel Valve Fuel Valve Function High-Pressure Pipes Fuel Oil System Fuel Oil System - Details Fuel Oil System - Details Lifting Device for Fuel Pump - Cylinder No. 1

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Fuel Pump


Plate P90901-0184

Page 1 (2)

Plate P90901-0184 Item No. 017 042 054 078 101 113 125 137 149 150 162 174 186 198 221 233 257 269 270 282 294 341 389 390 400 412 436 448 461 473 520 532 544 568 581 603 615 627 639 640 652 664 676 688 711 723 735 747 772 784

Page 2 (2)

Fuel Pump

Item Description Gasket Gasket Plug screw Pump housing, complete Timing guide Sleeve Regulating guide Guide pin Screw Guide pin Stud Gasket Guide screw Guide pin Guide bushing, complete Guide bushing Screw Screw Top cover Lock washer Plug screw Throttle plug Nut Screw Spring guide Spring Suction value, complete Slide Thrust piece Sealing ring Sealing ring Pump barrel Pump barrel, complete Sealing ring Plunger Screw Lock washer Cover Sealing ring Sealing ring Puncture valve, complete Air piston Gasket Valve housing O-ring Slide Spring Spring guide Throttle plug Gasket

Item No. 855 867 879 880 892 902 914 926

Item Description Screw Portective cap Coupling Pipe Banjo coupling Plug screw Disc Pipe


Fuel Pump Gear


Plate P90902-0150

Page 1 (2)

Plate P90902-0150 Item No. 012 024 036 048 061 073 085 097 107 119 120 132 168 181 193 203 215 239 240 252 276 288 311 323 335 360 384 396 406 418 431 467 479 492 502 514 526 551 563 575 587 599 609 610 622 634 646 658

Page 2 (2)

Fuel Pump Gear

Item Description

Item No.

Item Description

Pin Shaft Plug Circlip Screw Fuel pump roller guide, complete Roller Bushing Disc Shaft Link f. reversing Pin Guide pin Thrust disc Roller guide Plug Bushing Nut Nut Pump base, complete Pin Guide block Screw Pin Bushing Bushing for roller guide Disc Sealing ring Cap Sealing ring Cap Locking wire Screw Gasket Gasket Cover Screw Seat disc Spring, internal Stud Spring, external Stud Seat disc Seat disc Pump base Sealing bush Retaining ring Orifice plug


Fuel Pump Gear - Details


Plate P90903-0040

Page 1 (2)

Plate P90903-0040 Item No. 018 031 043 055 067 080 092 102 114 126 138 151 175 187 199 209 210 222 246 258 271 283 295 305 317 329 330 342 354 366 391 401 413

Page 2 (2)

Fuel Pump Gear - Details

Item Description

Item No.

Item Description

Screw Support, complete Ball lock Screw O-ring Screw Coupling arm Screw Washer Pull rod head Nut Nut Flange Shaft Screw Collar pin Split pin Air cylinder Locking pin Securing pin O-ring Bearing Piston ring O-ring Screw Bracket Stud Distance piece Flange suspension Screw Disc Needle bearing Pin


Fuel Pump - Details MAN B&W Diesel


Plate P90904-0061

Page 1 (2)

Fuel Pump - Details

Plate P90904-0061 Item No. 013 025 037 049 050 062 074 086 108 121 133 157 169 170 182 194 216 228 241 253 265 277 289

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Union Screw Bracket Screw Actuator Coupling Washer Nut Guide screw Toothed bar, regulation Packing Union Pointer Toothed bar, timing Nut Forked lever Retaining ring Guide pin Forked lever Forked lever Nut Adjusting screw Nut


Reversing Mechanism

Plate P90905-0030

Reversing Mechanism 0030 P90905


Page 1 (2)

Reversing Mechanism

Plate P90905-0030 Item No. 019 020 032 044 056 068 093 103 115 127 139 152 164 176 211 223 235 247 259 272 284 296 306

Item Description

Item No.

Item Description

Shaft Guide for reversing Distance pipe Nut Guard Screw Cover Screw Bolt Flange for air cylinder Reversing mechanism, complete Screw Bush Air cylinder Ball valve Tee-screwed connection Nut Packing Union Orifice plate Non-return valve Nut Safety valve

Page 2 (2)


Lifting Device for Fuel Pump


Plate P90907-0011

Page 1 (2)

Plate P90907-0011 Item No. 021 033 057 069 070 082 094 104 116 141 153 177 189 200 212 224

Page 2 (2)

Lifting Device for Fuel Pump

Item Description

Item No.

Item Description

4/2 way valve Screw Pipe Coupling Coupling Coupling Coupling Coupling Non-return valve Pressure switch Screw Coupling Pipe Coupling Pipe Hose


Plate P90910-0143

Fuel Valve P90910 Fuel Valve 0143

016

197 207

028

065

219

089

090 220

100

232

124 244

256

136

268

148 950

281

161

173


Page 1 (2)

Plate P90910-0143 Item No. 016 028 065 089 090 100 124 136 148 161 173 197 207 219 220 232 244 256 268 281 950

Fuel Valve

Item Description

Item No.

Item Description

Thrust piece Cut-off shaft Spindle guide, complete Spindle guide Spring pin Nozzle O-ring Holder Guide pin Union nut O-ring O-ring Valve head Guide pin Spring Non-return valve Disc Thrust spindle Spring Thrust foot Disc (optional extras)

Page 2 (2)


Fuel Valve Function


Plate P90911-0022

Page 1 (2)

Plate P90911-0022 Item No.

Fuel Valve Function

Item Description

Item No.

Item Description

Note: D1 = Predetermined closing value for non-return valve D2 = Predetermined opening value for cut-off spindle

Page 2 (2)


High-Pressure Pipes


Plate P90913-0158

Page 1 (2)

Plate P90913-0158 Item No. 012 024 036 048 073 085 097 107 120 132 156 181 193 203 215 227 252 264 276 288 323 335 372

High-Pressure Pipes

Item Description

Item No.

Item Description

Sleeve Retaining ring High-pressure pipe Union nut Sealing ring Union nut Housing O-ring Union nut O-ring High-pressure pipe, complete Coupling Steel pipe Screw Flange Housing Coupling Guide pin High-pressure pipe, complete High-pressure pipe High-pressure pipe, complete High-pressure pipe Insulation* Note: *Pipe end insulation sleeve and tape can be sold seperatly

Page 2 (2)


Fuel Oil System

Plate P90914-0078

Fuel Oil System 0078 P90914


Page 1 (2)

Plate P90914-0078 Item No. 018 031 055 067 079 092 102 126 138 187 199

Fuel Oil System

Item Description

Item No.

Item Description

Pipe Pipe Pipe Coupling Coupling Distributor piece Screw Pipe Coupling Coupling Gasket

Page 2 (2)


Fuel Oil System - Details


Plate P90915-0060

Page 1 (2)

Plate P90915-0060 Item No. 013 025 037 049 050 074 086 098 121 133 145

Page 2 (2)

Fuel Oil System - Details

Item Description

Item No.

Item Description

By-pass valve, complete Valve housing Valve housing Sealing ring Spring guide Screw Union nut Nut Sealing ring Piston Spring


Fuel Oil System - Details MAN B&W Diesel


Plate P90915-0080

Page 1 (2)

Plate P90915-0080 Item No. 013 025 037 049 050 062 074 086 098 108 121 133 157 169 170 194 204 216 228 241

Page 2 (2)

Fuel Oil System - Details MAN B&W Diesel

Item Description

Item No.

Item Description

Nut Locking plate Flange Stud Spring guide Disc Slide Pressure spring Piston Sealing ring Wearing ring Packing Plug screw Packing ring Stud Pressure spring Packing Housing Screw Shock absorber, complete


Lifting Device for Fuel Pump Cyl. No. 1


Plate P90916-0006

Page 1 (2)

Plate P90916-0006 Item No. 020 032 056 068 081 093 103 115 140 152 164 176

Page 2 (2)

Lifting Device for Fuel Pump Cyl. No. 1

Item Description

Item No.

Item Description

4/2-Way valve Pipe holder Screw Pressure switch Screw Coupling Coupling Steel pipe Coupling Steel pipe Hose Copper pipes


910 - Turbocharger System Documents in this Chapter 91000 91001 91002 91003 91004 91005 91006 91007 91009 91011 91014

0017 0166 0142 0225 0036 0140 0029 0018 0020 0026 0029

Gas and Air System Scavenge Air Receiver Arrangement of Charging Air Pipe Exhaust Pipes and Receiver Exhaust Receiver - Details Air Cooler Arrangement of Auxiliary Blower Butterfly Valve Air Cooler System - Cleaning Arrangement of Non-Return Valve Arrangement of Suction Pipe

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Gas and Air System


Plate P91000-0017

Page 1 (1)

Scavenge Air Receiver MAN B&W Diesel


Plate P91001-0166

Page 1 (2)

Plate P91001-0166 Item No. 017 029 030 042 054 066 078 091 101 113 125 137 149 150 162 174 186 198 221 233 257 269 270 282 294 304 316 328 341 353 365 377 389 390 400 412 424 436 448 461 473 485 497 507 519 532 544 556 568

Page 2 (2)

Scavenge Air Receiver MAN B&W Diesel

Item Description

Item No.

Item Description

Scavenge air receiver, aft Screw Distance pipe Air cooler housing sealing Screw Support Spring pin O-ring Flange Screw Stud Nut Washer Washer Locking plate Hinge Cover Cross member Distance piece O-ring Screw Nut O-ring Screw Cover Distance pipe Screw Locking plate Distance pipe Screw Nut Screw Cover Scavenge air receiver, fore Airflow reversing chamber Safety catch Round iron Stud Nut Screw Distance pipe O-ring O-ring Screw Cover Plate Plate Stud Packing


Arrangement of Charging Air Pipe MAN B&W Diesel


Plate P91002-0142

Page 1 (2)

Arrangement of Charging Air Pipe

Plate P91002-0142 Item No. 012 024 036 061 085 119 132

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Screw Washer Nut Plug screw Screw Compensator Charging air pipe


Exhaust Pipes and Receiver MAN B&W Diesel


Plate P91003-0225

Page 1 (2)

Exhaust Pipes and Receiver

Plate P91003-0225 Item No. 031 055 067 079 080 092 102 114 138 151 163 175 199 209 234 246 258 271 283 305 317 330 342 354 366 378 391 401 437 449 450 474 486 521 533 545 557 569


Item Description

Item Description

Grid, complete Packing Compensator Nut Screw* Pipe bend Nut Screw* Wire gauze Clamp Pin Disc Screw* Nut Special nut Locking device Locking device Nut Screw Packing Compensator Packing Gas compensator Nut Screw* Gas inlet Screw* Nut Packing Pipe Screw* Packing ring Plug O-ring Stud Plate Plate Wing nut Note: * These screws are special screws for hot joints, they are marked with a »T«, and MUST NOT BE USED ELSEWHERE!

Page 2 (2)


Exhaust Receiver - Details MAN B&W


Plate P91004-0036

Page 1 (2)

Exhaust Receiver - Details

Plate P91004-0036 Item No. 013 025 037 049 050 062 074 086 098 108 121 133 157 169 182 194 204 216 228 241 265 277 300 312 324

MAN B&W Item No.

Item Description

Item Description

Support Support Spring pin Distance pipe Screw Supprt Nut Distance pipe Nut Spring pin Washer Screw Exhaust reciever, aft Shim Clamp Support Support Distance pipe Distance pipe Spring pin Exhaust reciever, fore Support Support Spring pin Clamp Note: * These screws are special screws for hot joints, they are marked with a ‘‘T’’ and MUST NOT be used elsewhere !

Page 2 (2)


Air Cooler MAN B&W Diesel


Plate P91005-0140

Page 1 (2)

Air Cooler

Plate P91005-0140 Item No. 019 020 044 056 068 081 093 103 127 139 140 152


Item Description

Item Description

Air cooler insert* Water mist catcher* O-ring Frame for air cooler Screw Frame for air cooler Support Support Screw Stud Nut Screw Note: * When ordering spare parts for this item, please state manufacturer’s part no.

Page 2 (2)


Arrangement of Auxiliary Blower


Plate P91006-0029

Page 1 (2)

Plate P91006-0029 Item No. 014 026 038 051 075

Page 2 (2)

Arrangement of Auxiliary Blower

Item Description

Item No.

Item Description

Packing Distance pipe Screw Nut Auxiliary blower


Butterfly Valve


Plate P91007-0018

Page 1 (2)

Plate P91007-0018 Item No. 021 033 045 057 069 070 082 116 128

Page 2 (2)

Butterfly Valve

Item Description

Item No.

Item Description

Cover Packing Locking wire Screw Locking plate Housing Screw Shaft Flap


Air Cooler System - Cleaning


Plate P91009-0020

Page 1 (2)

Plate P91009-0020 Item No. 010 022 034 046 058 071 083 095 117 129 130 142 154 166 191 201 213 225 237 249 250 262 274 298 321 345 357 370 382 394 404 428 441 453 465 477 489 490 500 512 536 548 561 573 585 597 607 619 620 644

Page 2 (2)

Air Cooler System - Cleaning

Item Description Main pipe Support cleaning Flow controller Drain box Drain pipe Main pipe Packing ring Screw Nut Cleaning pipe Flange Packing ring Screw Steel pipe Valve Screw Drain pipe Packing ring Screw Main pipe Main pipe Main pipe Orifice plate Valve Screw Screw Nut Packing ring Packing ring Valve Drain pipe Drain pipe Drain pipe Packing Stud Coupling Guide Cleaning pipe Guide Steel pipe Coupling Stud Stud Nut Steel pipe Cleaning pipe Coupling Steel pipe Cleaning pipe Cleaning pipe

Item No. 656 668

Item Description Packing ring Screw


Arrangement of Non-return Valve MAN B&W Diesel


Plate P91011-0026

Page 1 (2)

Plate P91011-0026 Item No. 023 035 059 072 084 096 106 131 143 167 180 202 214 238 263 287 299 309 322 334 346 371 395 417

Page 2 (2)

Arrangement of Non-return Valve MAN B&W Diesel

Item Description

Item No.

Item Description

Screw Distance pipe Screw Support Clamp Support Valve flap Valve mounting plate Valve mounting plate Locking wire Screw Spring pin Screw Shaft Locking wire Screw Support Clamp Spring pin Support Shaft Valve flap Non-return valve, complete Non-return valve, complete


Arrangement of Suction Pipe MAN B&W Diesel


Plate P91014-0029

Page 1 (2)

Arrangement of Suction Pipe

Plate P91014-0029 Item No. 018 031 043 055 067 079 080 092 114 126 151 163 175 187 209 222 234

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Screw Distance pipe Screw Packing Disc O-ring Nut Suction pipe Pipe Plate Nut Screw Disc special Screw Suction pipe Clamp Nut


911 - Safety Equipment Documents in this Chapter 91101 91102 91102 91103 91104

0037 0029 0035 0018 0099

Safety Valve - Cylinder Relief Valve Relief Valve Safety Valve - Scavenge Air System Arrangement of Safety Cap

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Safety V alve - Cylinder Valve MAN B&W Diesel


Plate P91101-0037

Page 1 (2)

Safety V alve - Cylinder Valve

Plate P91101-0037 Item No. 010 022 034 046 058 071 083 095 105 117

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Spindle Spring retainer Lock nut Spring Valve housing Stop ring Valve flap Valve guide Gasket Safety valve, complete


Relief Valve


Plate P91102-0029

Page 1 (2)

Plate P91102-0029 Item No. 016 028 030 041

Relief Valve

Item Description

Item No.

Item Description

Relief valve (P.C.D. 530mm) * Screw* Packing* O-ring* Note: *When ordering, please state manufacturer of Relief Valve and P.C.D. xxx mm

Page 2 (2)


Relief Valve


Plate P91102-0035

Page 1 (2)

Plate P91102-0035 Item No. 016 028 030 041

Relief Valve

Item Description

Item No.

Item Description

Relief valve (P.C.D. 795mm) * Screw * Packing * O-ring * Note: *When ordering, please state manufacturer of Relief Valve and P.C.D. xxx mm

Page 2 (2)


Safety Valve - Scavenge Air System MAN B&W Diesel


Plate P91103-0018

Page 1 (2)

Plate P91103-0018 Item No. 011 035 047 059 060 072 096 106 118 131 143 155

Page 2 (2)

Safety Valve - Scavenge Air System MAN B&W Diesel

Item Description

Item No.

Item Description

Safety valve, complete Spindle Washer Spring retainer Castle nut Split pin Screw Nut Valve flap Seal Valve seat Spring


Arrangement of Safety Cap

Plate P91104-0099

Arrangement of Safety Cap 0099 P91104

Only cyl. No. 1


Page 1 (2)

Plate P91104-0099 Item No. 017 029 030 042 054 066 078 091 101 125 137 149 150 162 174 186 198 208 233 257 269 270 282

Arrangement of Safety Cap

Item Description

Item No.

Item Description

Fitted bolt Bursting cap cover Check plate Screw Perforated cylinder Screw Washer Starting air pipe Packing ring Screw Bursting cap protector Wing nut Washer Stud Bursting disc Nut Screw Nut Bursting cap complete Packing ring Steel pipe Coupling Coupling

Page 2 (2)


912 - Assembly of Large Parts Documents in this Chapter 91201 91203 91205 91206 91207 91208 91210 91211 91216

0096 0005 0201 0097 0093 0009 0188 0072 0008

Arrangement of Stay Bolts Frame Box - Details Frame Box End Shields Arrangement of Piston Cooling Chain Wheel Frame - Upper Bedplate Axial Vibration Damper Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks)

MAN B&W Diesel A/S

MAN B&W Diesel A/S

Arrangment of Stay Bolt


Plate P91201-0096

Page 1 (2)

Plate P91201-0096 Item No. 014 026 038 051 063 075

Page 2 (2)

Arrangment of Stay Bolt

Item Description

Item No.

Item Description

Screw Screw Protective cap Nut Stay bolt Neck ring in 2/2


Frame Box - Details


Plate P91203-0005

Page 1 (2)

Plate P91203-0005 Item No. 015 027 039 040 052 076 088 123 135 147

Page 2 (2)

Frame Box - Details

Item Description

Item No.

Item Description

Stud Nut Distance pipe Fitted stud Distance pipe Distance pipe Screw Distance pipe Distance pipe Fitted stud


Frame Box MAN B&W Diesel


Plate P91205-0201

Page 1 (2)

Frame Box

Plate P91205-0201 Item No. 016 028 041 077 089 100 112 124 136 148 173 197 207 219 220 244 256 281 293 315 339 340 352 376 388

MAN B&W Diesel

Item Description

Item No.

Item Description

Lubricating oil pipe Screw Locking wire Cover Screw Locking pin Spring Key ring Frame box door Packing Drain pipe Wing nut Stud Spring Door fastener Frame box door Packing Bush Washer Frame box Flange Packing Screw Cover Screw Note: *

Page 2 (2)


End Shields MAN B&W Diesel


Plate P91206-0097

Page 1 (2)

End Shields

Plate P91206-0097 Item No. 011 023 035 047 060 096 106 118 131 155 167 179 192 202 214 238 251 263

Page 2 (2)

MAN B&W Diesel

Item Description

Item No.

Item Description

Shield, upper Screw Gasket Cover Screw Screw Locking wire Damper-oil pipe Screw Damper-oil pipe Gasket Screw Shield, lower Screw Drain pipe Screw Screw Shield, fore


Arrangement of Piston Cooling

Plate P91207-0093

Arrangement of Piston Cooling 0093 P91207

B

B B-B

A

A

A-A


Page 1 (2)

Arrangement of Piston Cooling

Plate P91207-0093 Item No. 017 029 042 054 066 091 101 125 137 149 162 174 198

Item Description

Item No.

Item Description

Fitted bolt Nut - special Screw Washer Locking wire Plate Fitted bolt Drain pipe Drain pipe Sight glass, complete Screw Bracket Fitted bolt

Page 2 (2)


Chain Wheel Frame - Upper

Plate P91208-0009

Chain Wheel Frame - Upper 0009 P91208

C

A-A A

A C

B B


B-B

Page 1 (2)

Chain Wheel Frame - Upper

Plate P91208-0009 Item No. 012 024 048 061 085 097 119 120 132 156 168 193 215 239 240 252 276 311 323 347 359 360 372 384 396 418 431 455 467 479 492 502 514

Item Description

Item No.

Item Description

Nut Stud Screw Screw Screw Inspection cover Chainwheel frame Screw Cover Screw Pipe Plug Cover Nut Pipe Stud Top guard Packing ring Screw Pipe Spring pin Cover Nut Disc Fitted stud Screw Pipe Nut Pipe Stud Inspection cover Spring Stud

Page 2 (2)


Bedplate MAN B&W Diesel


Plate P91210-0188

Page 1 (2)

Bedplate

Plate P91210-0188 Item No. 013 025 037 050 062 074 086 098 121 133 145 169 170 194 204 216 241 253 277 290 312 324 336 348 373 397 407 420 432 456 468 493

MAN B&W Diesel

Item Description

Item No.

Item Description

Lubricating oil pipe Screw Locking wire Screw Screw Locking plate Grate Cover Bedplate Guide pin Screw Screw Nut Pipe holder Screw Lubricating oil pipe Lubricating oil pipe Lubricating oil pipe Screw Stud Lubricating oil pipe Lubricating oil pipe Nut Main bearing stud Main bearing cap Bearing shell, upper Bearing shell, lower Cover Screw Cover Screw Main bearing, complete Note: *

Page 2 (2)



Plate P91211-0072

Axial Vibration Damper 0072 P91211


Page 1 (2)

Plate P91211-0072 Item No. 019 020 081 093 103 115 127 139 140 152 164 223 235 247 259 260 284 296 306 318


Item Description

Item No.

Item Description

Spring Spring Screw Locking wire Restriction for damper Restriction for damper Restriction for damper Screw Guide pin Oil seal in 2/2 Oil seal in 2/2 Nut Nut Stud Stud Axial vibration damper, complete Damper, upper part Special locking Guide pin Damper, lower part

Page 2 (2)


MAN B&W Diesel

HoldingDown Bolts and End Chock Bolts (Epoxy Chocks)


Plate P91216-0008

Page 1 (2)

Plate P91216-0008 Item No. 016 028 041 053 077 090 100 112 148 161 173 197 207 219 232 244 256 281

Page 2 (2)

HoldingDown Bolts and End Chock Bolts (Epoxy Chocks) Item No.

Item Description

MAN B&W Diesel

Item Description

Screw Washer Lock plate Liner for sidechock, port side Liner for sidechock, starboard side Protecting cap Nut Distance tube Spherical washer Spherical nut Holding down bolt Nut Protecting cap End chock bolt Liner for end chock Spherical washer Spherical washer Nut


Main Engine MAN B&W K 80 MC-C

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