-
When referring to this page, please quote S900 Edition 0001 Page
1 (1)MAN B&W Diesel A/S
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.
-
K80MC-C VOLUME IIMAINTENANCE
-
MAN B&W Diesel A/S
900 - Introduction
Documents in this Chapter
Table of Contents, Volume II
90050 0289 Checking & Maintenance Schedule90060 0002 General
- Safety Precautions
-
MAN B&W Diesel A/S
-
Table of Contents 900Volume II - Maintenance
Page 1 (4)MAN B&W Diesel A/S
No. Edition Title
900 - IntroductionTable of Contents
90050 0289 Checking & Maintenance Schedule90060 0002 General
- Safety Precautions
901 - Cylinder Cover101-01 0077 Cylinder Cover, Data901-01 0260
Cylinder Cover90151 0208 Cylinder Cover - Panel90164 0001 Cylinder
Cover - Hydraulic Jack Spares90165 0001 Cylinder Cover - Lifting
Tools
902 - Piston with Rod & Stuffing Box102-01 0090 Piston,
Data902-01 0290 Piston102-02 0064 Piston Rod Stuffing Box,
Data902-02 0231 Piston Rod Stuffing Box90251 0258 Piston and Piston
Rod - Panel90261 0102 Piston and Piston Rod - Tools90264 0006
Piston and Piston Rod - Tilting Tools90265 0001 Piston and Piston
Rod - Support Tools90266 0001 Piston - Lifting Tools
903 - Cylinder Liner and Cylinder Lubrication103-01 0075
Cylinder Liner, Data903-01 0259 Cylinder Liner103-02 0028 Cylinder
Lubricator, Data903-02 0256 Cylinder Lubricator90361 0083 Cylinder
Liner - Tools90362 0005 Cylinder Liner - Milling Tools90364 0004
Test Equipment for Lubricators90366 0003 Cylinder Liner - Lifting
Tools
904 - Crosshead with Connecting Rod104-01 0069 Crosshead
Bearing, Data904-01 0253 Crosshead Bearing104-02 0070 Crosshead,
Data904-02 0252 Crosshead104-03 0044 Reciprocating Parts,
Data904-03 0215 Reciprocating Parts104-04 0062 Crankpin Bearing,
Data904-04 0233 Crankpin Bearing104-05 0060 Connecting Rod,
Data904-05 0237 Connection Rod90451 0155 Connecting Rod and
Crosshead - Panel
-
Table of Contents 900Volume II - Maintenance
Page 2 (4)MAN B&W Diesel A/S
No. Edition Title
90462 0018 Connecting Rod - Tools
905 - Crankshaft, Thrust Bearing and Turning Gear105-02 0086
Main Bearing, Data905-02 0261 Main Bearing105-03 0075 Thrust
Bearing, Data905-03 0247 Thrust Bearing105-04 0050 Journal Bearing,
Data105-05 0061 Axial Vibration Damper, Data905-05 0230 Axial
Vibration Damper90551 0221 Crankshaft, Thrust Shaft, Main Bearing,
etc. - Panel90562 0123 Crankshaft - Tools90564 0020 Crankshaft -
Measuring Tools90570 0003 Thrust Shaft - Tools90571 0001 Main
Bearing Shell - Tools90572 0001 Main Bearing - Measuring Tools
906 - Control Gear106-01 0051 Chain, Data906-01 0246 Chain106-02
0067 Chain Tightener, Data906-02 0230 Chain Tightener106-03 0043
Camshaft, Data906-03 0218 Camshaft106-04 0045 Camshaft Bearings,
Data906-04 0219 Camshaft Bearings90651 0203 Chain Drive and
Camshaft - Panel90664 0001 Crankshaft - Pin Gauge
907 - Starting Air System107-01 0019 Starting Air Distributor,
Data907-01 0219 Starting Air Distributor107-02 0041 Start Air
Valve, Data907-02 0217 Starting Air Valve
908 - Exhaust Valve108-01 0037 High-Pressure Pipe, Data908-01
0226 High-Pressure Pipe108-02 0094 Exhaust Valve, Data908-02 0269
Exhaust Valve108-03 0057 Exhaust Valve Actuator, Data908-03 0227
Exhaust Valve Actuator108-04 0041 Exhaust Valve Roller Guide,
Data908-04 0222 Exaust Valve Roller Guide108-05 0017 Exhaust Valve
Cam, Data
-
Table of Contents 900Volume II - Maintenance
Page 3 (4)MAN B&W Diesel A/S
No. Edition Title
908-05 0219 Exhaust Valve Cam108-07 0034 Exhaust Valve - Special
Running, Data908-07 0228 Exhaust Valve90851 0177 Exhaust Valve -
Panel90861 0022 Exhaust Valve - Tools90862 0036 Exhaust Valve -
Hydraulic Tools90863 0015 Exhaust Valve - Extra Tools90864 0003
Exhaust Valve - Extractor Tool
909 - Fuel Oil System109-01 0061 Fuel Pump Settings, Data909-01
0241 Fuel Pump Settings109-02 0005 VIT System, Data909-02 0206 VIT
System109-03 0050 Fuel Pump Cam, Data909-03 0234 Fuel Pump
Cam109-04 0061 Fuel Pump, Data909-04 0224 Fuel Pump109-05 0065 Fuel
Pump Top Cover, Data909-05 0234 Fuel Pump Top Cover109-06 0052 Fuel
Pump Barrel Assembly, Data909-06 0220 Fuel Pump Barrel
Assembly109-07 0040 Fuel Pump Suction Valve, Data909-07 0214 Fuel
Pump Suction Valve109-08 0054 Fuel Pump Puncture Valve, Data909-08
0217 Fuel Pump Puncture Valve109-09 0034 Fuel Pump Shock Absorber,
Data909-09 0216 Fuel System Shock Absorber10910 0016 Lifting Gear
Roller Guide, Data90910 0218 Lifting Gear for Roller Guide10911
0065 Fuel Valve, Data90911 0249 Fuel Valve10912 0048 Spindle Guide,
Data90912 0228 Spindle Guide10913 0033 Non-Return Valve in Fuel
Valve, Data90913 0206 Non-Return Valve in Fuel Valve10914 0080 Fuel
Oil High-Pressure Pipes, Data90914 0255 Fuel Oil High-Pressure
Pipes10915 0062 Fuel Pump Roller Guide, Data90915 0236 Fuel Pump
Roller Guide90951 0446 Fuel Valve and Fuel Pump - Panel90961 0069
Fuel Valve - Tools90966 0008 Fuel Valve Nozzle - Tools90967 0001
Fuel Puncture Valve - Tools90968 0001 Fuel Valve - Inspection
Tools
-
Table of Contents 900Volume II - Maintenance
Page 4 (4)MAN B&W Diesel A/S
No. Edition Title
90974 0001 Fuel Valve Nozzle - Cleaning Tools90977 0001 Mounting
Tools - Pump Barrel Seals90979 0001 Mounting Tools - Suction Valve
Seals90980 0001 Mounting Tools - Air Piston Seals
910 - Turbocharger System110-01 0051 Air Cooler Element,
Data910-01 0243 Air Cooler Element110-02 0009 Non-Return Valve
after Air Cooler, Data910-02 0210 Non Return Valve after Air
Cooler110-03 0031 Auxilary Blower, Data910-03 0218 Auxilary
Blower110-04 0005 Butterfly Valve, Data910-04 0205 Butterfly
Valves110-05 0010 Turbocharger Turbine, Data910-05 0213
Turbocharger Turbine110-06 0032 Water Mist Catcher, Data910-06 0222
Water Mist Catcher91063 0018 Air Cooler - Tools91063 0019 Air
Cooler - Tools91063 0020 Air Cooler - Tools91064 0001 Travelling
Trolley91066 0002 Air Cooler - Lifting Tools
911 - Safety Equipment111-01 0026 Safety Valve, Data911-01 0212
Safety Valve111-02 0013 Relief Valve, Data911-02 0211 Relief
Valve111-03 0001 Scavenge Air Receiver Safety Valve, Data911-03
0001 Scavenge Air Receiver Safety Valve
912 - Assembly of Large Parts112-02 0015 Holding Down & End
Chock Bolts, Data912-02 0208 Holding Down and End Chock Bolts112-03
0027 Stay Bolts, Data912-03 0213 Stay Bolts912-05 0201 Crankcase
Oil Outlet91261 0075 Hydraulic Tools for Large Parts91265 0002
Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)913 - General
Tools913-01 0211 Hydraulic Tools913-03 0007 Working Platforms913-04
0202 Standard Tightening Torques
-
Table of Contents 900Volume II - Maintenance
Page 5 (4)MAN B&W Diesel A/S
No. Edition Title
913-05 0205 Torque Spanner913-06 0205 Tightening Gauge913-07
0207 Screws and Nuts91311 0204 Lubricating91351 0034 Accessories -
Hydraulic Tools91356 0051 Lifting Tools, etc.91357 0006 Open-Ended
Spanners91359 0003 Torque Spanners91360 0005 Pliers91361 0052
Combination Spanners91362 0060 Ring Slugging Spanners91363 0040
Spanners91364 0059 Open-Ended Spanners91366 0066 Instruments91368
0011 Working Platforms
-
When referring to this page, please quote Maintenance Schedule
A90050 Edition 0289 Page 1 of 6
Checking and Maintenance Schedule,80-108 MC/MC-C Engines
900-1MAN B&W Diesel
The Checking and Maintenance Schedules indi-cate the intervals
at which it is deemed appropri-ate to inspect the individual
components of theengine and to carry out overhauls, if
necessary,based on the engine condition or on time criteria.
The stated Normal hours of service should onlybe used as a
guide, as differences in the actualservice conditions, the quality
of the fuel oil or lu-bricating oil, the treatment of cooling
water, etc.will decisively influence the actual service results,and
thus the intervals between necessary over-hauling.
Design modifications may necessitate a revision ofthe
instructions, in which case the revised instruc-tions and changed
overhauling intervals, if any, willapply and supersede those
originally issued (seee.g our Service Letters).In addition to the
checking and overhauling inter-vals stated in this schedule, please
note that theperiodical survey requirements of the
classificationsociety may require additional checks and over-hauls
to be carried out. For further informationplease 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 compo-nents, and form the basis for estimating
whether further overhaul-ing is necessary. In a number of cases the
condition checkingprocedures refer to Volume I of the instruction
book, in whichmore detailed descriptions and working procedures can
be found.
Condition-based overhaulingprocedures
are those procedures which under the heading Normal hours
ofservice are marked with an O, and opposite which, under
theheading Overhaul to be based on procedure No. (column P),
aprocedure number is stated.
This procedure number normally refers to one of the above
condi-tion checking procedures which form the basis of the
overhaul.For this reason, the intervals stated are for guidance
only.
Time-based overhaulingprocedures
also marked with an O under the headings Normal hours of
ser-vice or Based on observations, are the procedures where
anactual basis for estimation is lacking. It is recommended,
there-fore, to carry out these procedures at the overhauling
intervalsstated 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 conditionsmay make checking or overhauling necessary beyond
the actualstandard schedules indicated.
-
When referring to this page, please quote Maintenance Schedule
A90050 Edition 0289Page 2 of 6
Checking and Maintenance Schedule,80-108 MC/MC-C Engines900-1
MAN B&W Diesel
-
MAN B&W Diesel Checking and Maintenance Schedule, 80-108
MC/MC-C Engines 900-1
V : See Volume I OperationA : Adjustment to be carried outC :
Check the condition
M : See makers instructionsO : Overhaul to be carried outH :
Check new/overhauled parts after 500-1500 hours
R : Parts to be replacedB : Based on observationsP : Refer
to
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P
Remarks
Regular Checks Service interval (x1000 hours of operation)
When referring to this page, please quote Maintenance Schedule
A90050 Edition 0289 Page 3 of 6
901 Cylinder Cover-1 Cylinder cover C* O
Indicator cock O
902 Piston with Rod and Stuffing box-1 Piston C,O O
Inspection through scavenge ports C V-2 Piston rod stuffing box
C* O
903 Cylinder Liner and Cylinder Lubrication-1 Cylinder liner
O
Inspection through scavenge ports CMeasuring wear inside liner
C
-2 Cylinder lubricators C A V,MAccumulators nitrogen pressure C
A
904 Crosshead with connecting rod-1 Crosshead bearing C C C,O
V-2 Crosshead C C C,O-3 Reciprocating parts C C,O-4 Crankpin
bearing C C C,O V-5 Connecting rod O
905 Crankshaft and Thrust Bearing-2 Main bearing C C C,O V-3
Thrust bearing C C C,O-3 Guide bearing C C C,O-4 Journal bearing C
C C,O V-5 Axial vibration damper O
* Check whenever exhaustvalve is removed
Bearings should only beopened up if bearing materialfragments
fall out.
* Check clearances withoutdismantling segments
Bearings should only beopened up if bearing materialfragments
fall out.
-
When referring to this page, please quote Maintenance Schedule
A90050 Edition 0289Page 4 of 6
Checking and Maintenance Schedule, 80-108 MC/MC-C
Engines900-1
V : See Volume I OperationA : Adjustment to be carried outC :
Check the condition
M : See makers instructionsO : Overhaul to be carried outH :
Check new/overhauled parts after 500-1500 hours
R : Parts to be replacedB : Based on observationsP : Refer
to
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P
Remarks
Regular Checks Service interval (x1000 hours of operation)
MAN B&W Diesel
Electronic axial vibration monitor CMechanical checking C
-7 Tacho pick-up C,O M-8 Angle encoder C,O M
906 Mechanical Control Gear-1 Chains C C R V-2 Chain tightener
C,A C,A A
Chain wheels, spray nozzles and guide bars C C R-3 Camshaft C C
C,A-4 Camshaft bearings C C,O
Camshaft coupling, fitted bolts C-5 Moment compensator C C
C,A
Governor O MFunctional check of overspeed device C MFunctional
check of speed-setting system C M(engine with bridge control
system)
907 Starting Air System-1 Starting air distributor C C A-2
Starting air valve C,O
908 Exhaust Valve-1 High-pressure pipe O-2 Exhaust valve O-3
Exhaust valve actuator O
Actuator safety valve C,A-4 Exhaust valve roller guide C* C* C
O-5 Exhaust valve cam C* C* O
New or overhauled chain to bechecked/retightened after 500,1500
and 4000 hours
* only inspection throughcamshaft covers
-
MAN B&W Diesel Checking and Maintenance Schedule, 80-108
MC/MC-C Engines 900-1
V : See Volume I OperationA : Adjustment to be carried outC :
Check the condition
M : See makers instructionsO : Overhaul to be carried outH :
Check new/overhauled parts after 500-1500 hours
R : Parts to be replacedB : Based on observationsP : Refer
to
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P
Remarks
Regular Checks Service interval (x1000 hours of operation)
When referring to this page, please quote Maintenance Schedule
A90050 Edition 0289 Page 5 of 6
-7 Exhaust valve special running O
909 Fuel Oil SystemFuel oil water content C
-1 Fuel pump settings A,C V-2 VIT system A V-3 Fuel pump cam A-4
Fuel pump C O O-5 Fuel pump top cover O-6 Fuel pump barrel assembly
R-7 Fuel pump suction valve C,O-8 Fuel pump puncture valve C,O-9
Fuel pump shock absorber C O-9 Fuel system shock absorber C O-10
Lifting gear for roller guide C O-11 Fuel valve C,O- Fuel nozzle
R-12 Spindle guide R-13 Non-return valve O-14 Fuel oil
high-pressure pipes O-15 Fuel pump roller guide C* C* C O-16 Fuel
pump special running O
910 Turbocharger System-1 Air cooler C O V-2 Non-return valve C
O-3 Auxiliary blower O-4 Butterfly valves C O
* Only inspection throughcamshaft covers
Check at every port inspection
Check p and tCheck at every port inspection
-
When referring to this page, please quote Maintenance Schedule
A90050 Edition 0289Page 6 of 6
Checking and Maintenance Schedule, 80-108 MC/MC-C
Engines900-1
V : See Volume I OperationA : Adjustment to be carried outC :
Check the condition
M : See makers instructionsO : Overhaul to be carried outH :
Check new/overhauled parts after 500-1500 hours
R : Parts to be replacedB : Based on observationsP : Refer
to
No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P
Remarks
Regular Checks Service interval (x1000 hours of operation)
MAN B&W Diesel
-5 Turbocharger turbine C* C C,O V,MTurbocharger air filter C
OProtective grid before turbocharger C R VTurbocharger lubricating
oil water content C* M
-6 Water mist catcher C* C,O
911 Safety Equipment-1 Overpressure indicator valve C O-2 Relief
valve C O-3 Scavenge air receiver safety valve C O
Functional test of alarm system for thrustbearing and slow down
/shut down system C C MChecking and adjustment of pressure gauge C
A MChecking and adjustment of thermometers C A MChecking and
adjustment of thermostats C A MChecking and adjustment of
pressurestats C A MChecking and adjustment of turning gear switch C
A M
912 Assembly of Large Parts-2 Holding-down and end chock bolts C
C* C-3 Stay bolts C C
Top bracings C CDiaphragm in crankcase oil outlet C RSystem
lubricating oil water content C MSystem lubricating oil bottom tank
OCooling water quality C A V,MCrankcase C*
913 General Tools-1 Hydraulic tools O M
* Check for loose nuts andbearing material fragments
Empty and clean tank
* Initial check only
* Check p* Only if separate oil system
* Dry cleaning daily
-
Page 1 (1)
SAFETY PRECAUTIONS
General Safety Precautions 900-2
When referring to this page, please quote Safety Precaution
A90060 Edition 0001MAN B&W Diesel A/S
XXXXXXXXXXXX
Stopped engineShut off starting air supply At starting air
receiverBlock the main starting valveShut off starting air
distributor/distributing system supplyShut off safety air supply
Not ME-enginesShut off control air supplyShut off air supply to
exhaust valve Only with stopped lubriating oil pumpsEngage turning
gearShut off cooling waterShut off fuel oilStop lubricating oil
supplyLock the turbocharger rotors
Before maintenance work is carried out, the engine must be
stopped and blocked according to thesafety precautions given on the
specific Data Sheet.
The sketch gives the approximate location of the valves
concerned:
-
MAN B&W Diesel A/S
901 - Cylinder Cover
Documents in this Chapter
101-01 0077 Cylinder Cover, Data901-01 0260 Cylinder Cover90151
0208 Cylinder Cover - Panel90164 0001 Cylinder Cover - Hydraulic
Jack Spares90165 0001 Cylinder Cover - Lifting Tools
-
MAN B&W Diesel A/S
-
Page 1 (2)
MAN B&W Diesel
SAFETY PRECAUTIONS
Data
Data
For detailed sketch, see 900-2
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
Cylinder Cover
X Stopped engineX Shut off starting air supply At starting air
receiverX Block the main starting valveX Shut off starting air
distributor/distributing system supplyX Shut off safety air supply
Not ME enginesX Shut off control air supplyX Shut off air supply to
exhaust valve Only with stopped lubricating oil pumpsX Engage
turning gearX Shut off cooling waterX Shut off fuel oil
Stop lubricating oil supply
X Lock the turbocharger rotors
When referring to this page, please quote Data D10101 Edition
0077
101-1
-
Page 2 (2)
MAN B&W Diesel
The task-speci c tools used in this procedure are shown on the
plates at the end of this chapter or in the chapters indicated by
the rst three digits in the plate number, e.g. P90951 refers to
chapter 909.
Data
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
Cylinder Cover
When referring to this page, please quote Data D10101 Edition
0077
101-1
-
901-1.2MAN B&W Diesel Dismantling
Cylinder Cover
Page 1 (14)When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
D02
M90
101
0260
D01
3.
2.Shut off Oil and Water Supply
1. Check engine blocking.
Check that the engine is stopped and blocked according to the
safety precau-tions given on the data sheet.
2. Shut off the oil supply.
Close the fuel oil supply for the unit con-cerned.
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.
Shut off the water supply placed on the ex-haust side below the
exhaust gas receiver.
Open the drain next to the inlet valve.
Open the venting cock next to the outlet valve.
-
Cylinder Cover901-1.2MAN B&W DieselDismantling
Page 2 (14) When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
D06
M90
101
0260
D05
M90
101
0260
D04
4.
5.
Dismantling of Pipe Connections
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.
Remove the fuel oil high pressure pipes. See Procedure
90914.2.
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 com-pensator. Remove the insulation.
Remove the clamp ring from the ange between the intermediate
pipe and the ex-haust receiver.
6.
-
901-1.2MAN B&W Diesel Dismantling
Cylinder Cover
Page 3 (14)When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
D08
D1302
M90
101
0260
D07
7. Disconnect the starting air pipe.
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.
Remove the protective caps from the cylin-der cover nuts.
Loosen and remove the cylinder cover nuts, see Data.
For use of hydraulic tools, see Procedure 9131.
7.
8.
-
Cylinder Cover901-1.2MAN B&W DieselDismantling
Page 4 (14) When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
D10
M90
101
0260
D09
D0106
Cylinder Cover Lifting and Landing
9. Cylinder cover lifting.
Hook on the engine room crane to the lift-ing 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.
Land the cylinder cover on a couple of wooden planks.
9.
10.
-
901-1.2MAN B&W Diesel Dismantling
Cylinder Cover
Page 5 (14)When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
M12
11.11. Remove sealing ring.
Remove and discard the sealing ring be-tween the cylinder cover
and cylinder liner.
-
Cylinder Cover901-1.3MAN B&W DieselOverhaul
Page 6 (14) When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
O03
Silicone
M90
101
0260
O02
D0108
D0107
M90
101
0260
O01
D0109
Overhaul Preparations
1. 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.
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.
Lift the cylinder cover free of the cooling jacket and land it
on a couple of planks.
Remove and discard the Orings from the cover, and carefully
clean the cooling jacket and the cylinder cover.
3. Mount the cooling water jacket.
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.
1.
2.
3.
-
901-1.3MAN B&W Diesel Overhaul
Cylinder Cover
Page 7 (14)When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
O05
1 2 3
M90
101
0246
O04
Reconditioning of Bores
4. Seat reconditioning tools.
The tools for reconditioning of the valve seats are found on
tool panel 901.
5. Fuel valve bore.
The tool consists of a common spindle with a handle, a guide, a
carbon cutter, a seat-ing face cutter and a grinding mandrel.
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. Carborun-dum No. 200).
After the milling/grinding, clean the bore and seating
carefully, and check that the seating is not damaged.
4.
5.
-
Cylinder Cover901-1.3MAN B&W DieselOverhaul
Page 8 (14) When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0243
O07
M90
101
0240
O07
6. Exhaust valve bore.
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).
After the grinding, clean the bore and seat-ing carefully, and
check that the seating is not damaged.
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.
When replacing the valves on a cylinder cover while it is
mounted on the engine, recondition the valve bores/seating as
de-scribed here, however, without removing the studs.
6.
7.
-
901-1.3MAN B&W Diesel Overhaul
Cylinder Cover
Page 9 (14)When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
O09
D0102
D0101
D0103
M90
101
0260
O08
8. Indicator safety valve bore.
Clean the bores for safety valve/indicator cock.
Preparations before Mounting
9. Fitting of studs.
Lubricate the threads with Never Seize or molybdenum disulphide
(MoS2) and t the valve 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 per-matex to prevent water or oil from
entering the bores during operation of the engine.
10. Mounting of valves.
Install the valves on the cylinder cover, see Procedures 9072.4,
9082.4 and 90911.4.
8.
9.
-
Cylinder Cover901-1.4MAN B&W DieselMounting
Page 10 (14) When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
M02
M90
101
0260
M01
Landing Preparation
1. Sealing ring.
Check that the liner sealing surface is clean.
Place a new sealing ring on top of the cyl-inder liner.
2. Water connections.
Check that the water connections are clean and provided with new
Orings.
Lubricate the Orings with Vaseline and t them on the cylinder
liner.
1.
2.
-
901-1.4MAN B&W Diesel Mounting
Cylinder Cover
Page 11 (14)When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
M03
D0106
M90
101
0254
M04
D0105
Cylinder Cover Mounting
3. Cylinder cover landing.
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 en-gage correctly with the holes
in the cooling jacket.
4. Cylinder cover stud check distance.
If the cylinder cover studs have been re-moved and reinstalled,
check the distance the stud is protruding from the cylinder
cover.
If necessary, adjust to the distance D0105 by turning the
stud.
3.
4.
-
Cylinder Cover901-1.4MAN B&W DieselMounting
Page 12 (14) When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0246
M05
M90
101
0260
M05
D1301
5. Cylinder cover tightening.
Fit and tighten the cylinder cover nuts.
For operation of hydraulic jacks, see Proce-dure 9131.
Fit the protective caps on the cylinder cover studs.
Fitting Pipe Connections
6. Mount the exhaust gas compensator.
When mounting the clamp connecting the compensator and the
intermediate pipe/ex-haust valve it may, in some cases, become
necessary to use the engine room crane.
Clean the anges and the clamp ring care-fully and lubricate all
contact faces with Molycote.
Fit the insulating jacket around the interme-diate pipe.
5.
6.
-
901-1.4MAN B&W Diesel Mounting
Cylinder Cover
Page 13 (14)When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
M09
M90
101
0260
M08
M90
101
0260
M07
7. Connect the starting air pipe.
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.
9. Connect the oil pipes.
Mount the hydraulic high pressure pipe for the exhaust valve.
See Procedure 9081.4.
Connect the drain pipe for the exhaust valve.
Connect the fuel oil high pressure pipes. See Procedure
90914.4.
Connect the pipes for return fuel oil from the fuel valves.
7.
8.
9.
-
Cylinder Cover901-1.4MAN B&W DieselMounting
Page 14 (14) When referring to this page, please quote Procedure
M90101 Edition 0260
M90
101
0260
M11
M90
101
0260
M10
Open Oil and Water Supply
10. Close the drain and open the water sup-ply.
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 nished, close the venting cock. Open the two
water outlet valves on the exhaust side of the cylinder cover.
11. Open the oil supply.
Open the fuel oil supply for the unit con-cerned.
10.
11.
-
Plate
Page 1 (2)When referring to this page, please quote Plate
EditionMAN B&W Diesel A/S
Cylinder Cover Panel P90151-0208
P90151 0208
-
Plate
Page 2 (2) When referring to this page, please quote Plate
EditionMAN B&W Diesel A/S
P90151-0208 Cylinder Cover Panel
ItemNo. Item Description
ItemNo. Item Description
P90151 0208
010 Panel for tools022 Name plate046 Grinding tool, exhaust
valve seat058 Milling and grinding tool, fuel valve
seat060 Milling and grinding wheel, fuel valve
seat071 Dismantling tool, fuel valve083 Handle, sundry types095
Grinding ring, starting valve105 Pin spanner, starting valve117
Test equipment, combined safety
valve129 Extension studs, lifting cylinder cover
-
PlatePlatePlatePlatePlate
Page 1 (2)When referring to this page, please quote Plate
Edition
MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN
B&W DieselMAN B&W DieselCylinder Cover - Hydraulic Jack
SparesCylinder Cover - Hydraulic Jack SparesCylinder Cover -
Hydraulic Jack SparesCylinder Cover - Hydraulic Jack SparesCylinder
Cover - Hydraulic Jack Spares
P90164-0001P90164-0001P90164-0001P90164-0001P90164-0001
P90164 0001
-
PlatePlatePlatePlatePlate
Page 2 (2) When referring to this page, please quote Plate
Edition
MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN
B&W DieselMAN B&W
DieselP90164-0001P90164-0001P90164-0001P90164-0001P90164-0001
Cylinder Cover - Hydraulic Jack SparesCylinder Cover - Hydraulic
Jack SparesCylinder Cover - Hydraulic Jack SparesCylinder Cover -
Hydraulic Jack SparesCylinder Cover - Hydraulic Jack Spares
ItemItemItemItemItemNo.No.No.No.No.
Item DescriptionItem DescriptionItem DescriptionItem
DescriptionItem Description ItemItemItemItemItemNo.No.No.No.No.
Item DescriptionItem DescriptionItem DescriptionItem
DescriptionItem Description
P90164 0001
011 Wooden box023 Tommy bar035 Spanner047 Venting screw059 Quick
coupling male060 Disc072 O-ring with back-up ring084 O-ring with
back-up ring096 Stud setter118 Disc
-
PlatePlatePlatePlatePlate
Page 1 (2)When referring to this page, please quote Plate
Edition
MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN
B&W DieselMAN B&W DieselCylinder Cover - Lifting TCylinder
Cover - Lifting TCylinder Cover - Lifting TCylinder Cover - Lifting
TCylinder Cover - Lifting Toolsoolsoolsoolsools
P90165-0001P90165-0001P90165-0001P90165-0001P90165-0001
P90165 0001
-
PlatePlatePlatePlatePlate
Page 2 (2) When referring to this page, please quote Plate
Edition
MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN
B&W DieselMAN B&W
DieselP90165-0001P90165-0001P90165-0001P90165-0001P90165-0001
Cylinder Cover - Lifting TCylinder Cover - Lifting TCylinder
Cover - Lifting TCylinder Cover - Lifting TCylinder Cover - Lifting
Toolsoolsoolsoolsools
ItemItemItemItemItemNo.No.No.No.No.
Item DescriptionItem DescriptionItem DescriptionItem
DescriptionItem Description ItemItemItemItemItemNo.No.No.No.No.
Item DescriptionItem DescriptionItem DescriptionItem
DescriptionItem Description
P90165 0001
017 Lifting chains for cylinder cover
-
MAN B&W Diesel A/S
902 - Piston with Rod & Stuffing Box
Documents in this Chapter
102-01 0090 Piston, Data902-01 0290 Piston102-02 0064 Piston Rod
Stuffing Box, Data902-02 0231 Piston Rod Stuffing Box90251 0258
Piston and Piston Rod - Panel90261 0102 Piston and Piston Rod -
Tools90264 0006 Piston and Piston Rod - Tilting Tools90265 0001
Piston and Piston Rod - Support Tools90266 0001 Piston - Lifting
Tools
-
MAN B&W Diesel A/S
-
Page 1 (2)
SAFETY PRECAUTIONS
Data
PistonData
102-1
When referring to this page, please quote Data D10201 Edition
0090MAN B&W Diesel A/S
XXXXXXXXXXXX
For detailed sketch, see 900-2
Stopped engineShut off starting air supply At starting air
receiverBlock the main starting valveShut off starting air
distributor/distributing system supplyShut off safety air supply
Not ME enginesShut off control air supplyShut off air supply to
exhaust valve Only with stopped lubricating oil pumpsEngage turning
gearShut off cooling waterShut off fuel oilStop lubricating oil
supplyLock the turbocharger rotors
Ref. Description Value UnitD01-05 Cylinder cover stud, check
distance 196 - 197 mmD02-01 Test pressure 7 barD02-04 Piston
rod/crown stud, screwing-in torque 300 NmD02-05 Piston skirt,
tightening torque 380 NmD02-06 Cooling oil pipe, tightening torque
190 NmD02-08 Piston ring new, radial width 25.2 mmD02-09 Piston
ring worn, min. radial width 21.2 mmD02-10 Groove No.1, max.
vertical height 18.8 mmD02-11 Groove Nos. 2, 3 and 4, max. vertical
height 14.8 mmD02-13 Piston ring new, height of ring No. 1 17.9
mmD02-14 Piston rings new, height of ring Nos. 2, 3 and 4 13.9
mmD02-46 CPR ring CL groove, min. depth 1.8 mmD02-15 Minimum free
ring gap ( before dismantling ) 44 mmD02-16 Minimum ring gap, ring
No. 1 ( new ring in new liner ) 5.6 mmD02-17 Minimum ring gap, ring
Nos. 2, 3 and 4 ( new ring in new liner ) 4.0 mmD02-18 Vertical
clearance, new parts 0.48 mmD02-19 Vertical clearance, worn parts,
max. 0.97 mmD02-20 Piston complete 3300 kgD02-21 Piston crown 870
kgD02-22 Piston rod 2000 kgD02-23 Piston skirt 210 kgD02-24 Piston
cooling pipe 55 kgD02-25 Lifting tool, tightening torque 200
NmD02-47 Piston top centre, max. permissible burn-away 9 mmD02-48
Piston top centre diameter 375 mmD02-49 Piston top outer ring area,
max. permissible burn-away 6 mmD13-01 Hydraulic pressure, mounting
900 barD13-02 Hydraulic pressure, dismantling 800 - 990 bar
-
Page 2 (2)
The task-specific tools used in this procedure are shown on the
plates at the end of this chapter or in thechapters indicated by
the first three digits in the plate number, e.g. P90951 refers to
chapter 909.
PistonData
102-1
When referring to this page, please quote Data D10201 Edition
0090MAN B&W Diesel A/S
P90251 40 Lifting tool for piston rod footP90251 75 Template for
piston topP90251 87 Distance piece for stuffing boxP90251 99 Cover
for stuffing box holeP90251 110 Pressure test tool for pistonP90251
134 Piston ring expanderP90251 158 Guide screw for piston
crownP90251 171 Dismantling screw piston skirtP90261 Guide ring for
pistonP90262 Hydraulic jack for piston rodP90264 Tools for tilted
liftP90265 Support for pistonP90266 Piston - Lifting ToolsP90366
Cylinder Liner - Lifting ToolsP90451 120 Rubber cover for
crossheadP91351 10 Hydraulic pump, pneumatically operatedP91351 34
Hose with unions (1000 mm), completeP91351 60 Hose with unions
(5000 mm), completeP91351 117 5-way distributor block, complete
Plate Item No. Description
-
Page 1 (23)
902-1.1
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Checking
Piston
M90
201
0280
C03
M90
201
0280
C02
M90
201
0280
C01
2.
3.
1.Scavenge Port Inspection
To detect possible leakages from the piston or cylinder cover,
keep the cooling water and cooling oil circulating during the
scav-enge port inspection.
1. The scavenge port inspection is carried out from the scavenge
air receiver. An addition-al view of the rings is possible through
the cleaning cover on the manoeuvring side.
Turn the engine at least 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 cylin-der wall.
While the piston is passing downwards, inspect the piston skirt,
all the piston rings, the ring lands and the piston top.
2. Ring inspection:Inspect the rings, one at a time, and note
down the results. See Volume I, Operation, Chapter 707.
3. Ring tension:Check the tension of the piston rings, by
pressing against them with a wooden stick.
-
Piston
Page 2 (23)
902-1.1
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselCheckingM
9020
102
80C
06M
9020
102
80C
04
D0218
Max. 2mm
E
F
D0219
M90
201
0280
C05
D02465.
6.
4.4. 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.
Measure the clearance at the top (E) and bottom (F) of the
piston ring groove. Total clearance = E + F.
5. Uppermost piston ring:If possible, measure the depth of the
pres-sure 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
6. Piston support:Remove the piston from the cylinder and place
it on the piston support. See Proce-dure 9021.2. For evaluation of
the rings, see Volume I, Chapter 707.
Note!
It is recommended to replace all the pis-ton rings whenever a
piston is removed from the engine.
-
Page 3 (23)
902-1.1
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Checking
Piston
M90
201
0280
C09
D02-10D02-11
Max 2mm
M90
201
0280
C08
New
Worn
D0208
D0209
M90
201
0280
C07
D0215
8.
9.
7.7. Free ring gap:
Before dismantling the piston rings, mea-sure the free ring gap
of all the piston rings.
For dismantling the piston rings, see Proce-dure 9021.3.
8. Radial ring width:Measure the radial width of the rings. Note
down the results See Volume I, Operation, Chapter 707.
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.
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.
If the ring grooves are worn out, the piston crown must be
reconditioned, contact MAN B&W Diesel A/S for advice.
-
Piston
Page 4 (23)
902-1.1
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselCheckingM
9020
102
80C
11
D0249D0247
M90
201
0280
C10
D0248
RC
10. Piston top template:Check that the piston top template is
per-manently marked with the piston top centre diameter D0248.
Check that the centre area C has been marked off, and write the
maximum per-missible burnaway rate on the template. See data
D0247.
Mark the outer part of the template R for ring area, and write
the maximum permis-sible 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.
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 circum-ference of the piston
crown top.
If the burnaway exceeds the values given in Data, contact MAN
B&W for advice.
Note down the results for later reference.
11.
10.
-
Page 5 (23)
902-1.2
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Dismantling
Piston
M90
201
280D
01
Preparations in the crankcase
1. Access: Open the crankcase door to the cylinder
concerned.
Turn the crosshead down far enough to give access to the piston
rod stuf ng box and the piston rod/crosshead connection.
1.
-
Piston
Page 6 (23)
902-1.2
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselDismantlingM
9020
102
80D
02
2. Telescopic pipe:Loosen and remove the screws which tight-en
the telescopic pipe to the bend. Remove one screw from the
telescopic stuf ng box housing and mount the special tool for
suspending the telescopic pipe or use the thread in the telescopic
pipe stuf ng 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.
2.
Note!
When a piston is dismantled, never turn the engine without rst
dismantling the telescopic pipe from the crosshead.
-
Page 7 (23)
902-1.2
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Dismantling
Piston
M90
201
0280
D04
D1302M
9020
102
80D
03
3. Stuf ng box:Release the stuf ng box by removing the innermost
screws from the stuf ng box ange.
On engine models where the drain pipe is connected directly to
the stuf ng box:
Disconnect the stuf ng box drain pipe.
4. Loosen the piston rodcrosshead connec-tion:Loosen and remove
the hydraulic nuts, see Data. See Procedure 9131. 4.
3.
Note!
Do NOT remove the outermost screws from the ange.
-
Piston
Page 8 (23)
902-1.2
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselDismantlingM
9020
102
80D
05
5. Stuf ng box distance pieces:Mount the two distance pieces on
the pis-ton rod foot to protect the lower scraper ring and to guide
the stuf ng box.
Preparations on the cylinder top
6. Cylinder cover: Remove the cylinder cover. See Procedure
9011.2.
Make a scratch mark in liner and pis-ton cleaning ring to ensure
correct remounting. Remove the piston cleaning ring.
Carefully remove any wear ridges at the top of the cylinder
liner. See Procedure 9031.3.
5.
M90
201
0280
D06
6.
-
Page 9 (23)
902-1.2
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Dismantling
Piston
M90
201
0280
D07
D0225
7. Piston lifting tool:Turn the piston to TDC. The top of the
pis-ton is now free of the cylinder liner.
Clean the lifting groove of the piston crown and mount the
lifting tool.
Limited lifting high:If the engine is not equipped with long
dis-tance pieces, remove one or two cylinder cover studs, using a
stud setter.
7.
Note!
Make sure to mount the lifting tool cor-rectly, so that the
claws of the lifting tool enter the lifting grooves of the piston
crown.
-
Piston
Page 10 (23)
902-1.2
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselDismantlingM
9020
102
80D
08
D0220
Piston lift
8. Lift the piston out of the cylinder liner and guide the
piston rod foot through the stuff-ing box ange.
If the engine is equipped with long distance pieces for the stuf
ng 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. Low-er the piston rod foot and stuf ng 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 ange.
8.
-
Page 11 (23)
902-1.2
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Dismantling
Piston
M90
201
0280
D09
9. Protect the crosshead bearing:Place a cover over the opening
for the pis-ton rod stuf ng box at the bottom of the cylinder
unit.
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 impuri-ties until the piston is remounted.
Clean, measure and recondition the cylin-der liner. See
Procedure 9031.
9.
-
Piston
Page 12 (23)
902-1.3
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselOverhaulM
9020
102
80O
03
D0221+D0223
D1302
M90
201
0280
O02
M90
201
0280
O01
D02201. 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 stuf ng box. See Procedure 9022.3.
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 ex-pander is for the uppermost ring.
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
be-tween the rod and the piston crown. See Data.
For operation of hydraulic tools, see Proce-dure 9131.
Lift the piston crown and skirt clear of the piston rod.
2.
1.
3.
-
Page 13 (23)
902-1.3
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Overhaul
Piston
M90
201
0280
O04
D0206
D0224
D0222
4. Piston rod and cooling pipe:Remove the screws from the
cooling oil pipe ange.
Mount the eye bolts and lift out the cooling oil pipe.
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.
Mount a new Oring on the piston rod ange.
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.
Fit two eyebolts in the piston skirt and a wire rope between the
bolts as shown in the sketch.
Install a tackle in a suitable place with suf- cient 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.
Land the piston lifting tool and the piston crown on a suf cient
support of wood pieces. Loosen the piston lifting tool and lift the
piston crown clear of the tool.
5.
4.
M90
201
0290
O05
-
Piston
Page 14 (23)
902-1.3
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselOverhaul
6. Piston crown dismantling and cleaning:Place the piston crown
with skirt on a wooden support as shown.
Remove the locking wire and the screws in the skirt. If
necessary, use two disman-tling 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.
Thoroughly clean and inspect all parts of the crown and skirt.
If coke deposits are found in the cooling spaces of the pis-ton
crown, the coke deposits should be washed out with Carbon Remover
or a sim-ilar cleaning uid. When all coke deposits have been
dissolved, clean and inspect the piston crown again.
If the piston crown is renewed, remove the piston crown studs
using a stud setter.
7. Piston crown assembly:Mount the piston crown studs in a new
or overhauled piston crown, lubricate the threads on the studs with
molybdenum di-sulphide (MoS2).
Tighten the studs to the speci ed 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 speci ed torque, see Data D0205. Lock
the screws with locking wire. See Procedure 9137.
7.
6.
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 over-hauled.
M90
201
0280
O05
D0223
M90
201
0280
O06
D0205
D0204
-
Page 15 (23)
902-1.3
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Overhaul
Piston
45
6
12 3
12
3
12
31
23
4
56 4
5
6
4
56
M90
201
0280
O07
D1301
M90
201
0277
O16
8. Piston crown and skirt mounting:Lubricate the Oring on the
piston rod ange with lubricating oil.
Land the overhauled piston crown and skirt on the piston
rod.
Mount and tighten the hydraulic nuts on the piston crown
studs.
When tightening the hydraulic nuts follow the tightening
sequence. All the nuts must be tightened twice to full tightening
pres-sure, see Data.
Sealing ring and pressure test
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 lling the piston with oil.
The sealing ring test can also be carried out when the piston is
rest-ing in the support tool.
9. Sealing ring test:Mount the pressuretesting tool on the
piston rod foot. Connect compressed air to the testing tool and ll
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.
Spray a little soap water on to the surface joints between
piston rod/crown/skirt and around the hydraulic nuts to detect
leaks.
Dry off all soap water.
9.
8.
-
Piston
Page 16 (23)
902-1.3
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselOverhaulM
9020
102
77O
17
oil
D0201
10. Pressure test:For this test, the piston must be turned
upside down (see next step to turn a com-plete piston).
Fill the piston and piston rod with lubricat-ing 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 pis-ton crown.
Turn the piston upside up and drain out the piston oil.
10.
-
Page 17 (23)
902-1.3
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Overhaul
Piston
11.
Note!
During the lift, follow with the crane to keep the crane
positioned vertically above the lifting point. The stuf ng box must
be removed.
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.
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 lift-ing 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.
M90
201
0280
O10
-
Piston
Page 18 (23)
902-1.3
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselOverhaul
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.
When mounting the piston rings, use the ring expanders to
prevent unintended de-formation of the rings.
Do not expand the rings more than neces-sary. The uppermost ring
(CPRring) must be mounted with the short ring expander.
Mount the piston rod stuf ng box. See Procedure 9022.3.
12.
M90
201
0280
O11
TOP
A
B
C
D
A
B
C
D
-
Page 19 (23)
902-1.4
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Mounting
Piston
Preparation of piston
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. Stuf ng box position:Ensure that the stuf ng box is correctly
po-sitioned over the distance pieces mounted on the piston rod
foot. Both the holes for the ange and the drain hole for the drain
pipe must be positioned correctly.
M90
201
0277
M02
M90
201
0280
M01
D0225
2.
1.
-
Piston
Page 20 (23)
902-1.4
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselMountingM
9020
102
77M
06
45
M90
201
0277
M05
M90
201
0280
M03
Preparation of cylinder liner
3. Mount the guide ring:Mount the guide ring in the top of the
cyl-inder liner. The cut outs for the lifting tool must be turned
to foreaft position.
4. Stuf ng box cover:Remove the cover from the piston rod stuf
ng box opening in the bottom of the cylinder unit.
Clean the stuf ng box ange.
5. Crosshead position:Turn the crosshead to a position 45 from
TDC (crank web pointing towards exhaust side).
3.
5.
4.
-
Page 21 (23)
902-1.4
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Mounting
Piston
Mounting of piston
6. Coat the Orings of the stuf ng box and the piston rod with
oil. Coat the piston rings and cylinder liner with cylinder
lubri-cating oil.
Lower the piston into the cylinder liner while guiding the
piston rod foot through the cutout in the stuf ng box ange until
the piston rings are inside the liner.
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 ush with the top of the studs.
Turn the crosshead upwards until the pis-ton rod foot lands on
the nuts, thereby turning the crosshead until the face is par-allel
to the piston rod foot.
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 ts correctly in the
centre hole of the piston rod.
Unscrew the lifting tool and remove the lift-ing tool and the
guide ring for piston rings.
M90
201
0280
M08
M90
201
0277
D10
M90
201
0280
M06
D02206.
7.
8.
-
Piston
Page 22 (23)
902-1.4
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W DieselMounting
9. Stuf ng box:Turn down and land the stuf ng box on the stuf ng
box ange. Check that the holes in the stuf ng box and stuf ng box
ange are correctly centered.
Tighten the piston rod stuf ng box by means of the screws
through the inner holes in the stuf ng box ange. For Data, see
Procedure 9022.
On engine models where the drain pipe is connected directly to
the stuf ng box:
Mount the stuf ng box drain pipe.
Remove the distance pieces from the piston rod foot.
10. Tightening of the piston rodcrossheadconnection: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.
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.
M90
201
0280
M09
M90
201
0280
M10
D1301
M90
201
0280
M11
10.
9.
11.
-
Page 23 (23)
902-1.4
When referring to this page, please quote Procedure M90201
Edition 0290
MAN B&W Diesel Mounting
Piston
M90
201
0277
M14
M90
201
0277
M15
M90
201
0280
M14
D0105
12.
13.
14.
12. Piston cleaning ring:Mount the piston cleaning ring in
accor-dance with the scratch mark. If the PCring is damaged (broken
or cracked), it must be replaced by another ring. See Procedure
9031.
13. Cylinder cover studs:If the cylinder cover studs have been
re-moved, remount them. Carefully clean the surfaces around the
base of the studs and check the Orings on the studs.
Mount the cylinder cover studs with the stud setter. Screw the
stud down to con-tact and half a revolution back.
14. Cylinder cover:Land the cylinder cover on the liner and
check the distance that the stud is protrud-ing from the cylinder
cover. If necessary, adjust the distance D0105 by turning the
stud.
Tighten the cylinder cover nuts and mount the necessary pipes.
See Procedure 9011.4.
15. Runningin:Smear the piston rod with molybdenum di-sulphide,
and turn the crankshaft a couple of revolutions.
At the rst opportunity, start the engine and keep it running for
about 15 minutes at a speed corresponding to Dead Slow Ahead.
Then stop the engine and inspect the pis-ton rod and stuf ng
box.
-
Page 1 (2)
MAN B&W Diesel
SAFETY PRECAUTIONS
Data
D02-26 Stuffing box flange, outer screws tightening torque 180
NmD02-27 Stuffing box flange, inner screws tightening torque 200
NmD02-28 Stuffing box halves, tightening torque 80 NmD02-29
Uppermost rings, ring-end clearance 4x6 mmD02-30 Lowermost rings,
ring-end clearance 3x3 mmD02-34 Sealing ring springs new, free
length 831 mmD02-38 Scraper ring springs new, free length 782
mmD02-44 Stuffing box complete 190 kgD02-45 Stuffing box half 65
kgD02-50 Stuffing box halves fitted bolts, tightening torque 80
Nm
Piston Rod Stuffing BoxData
102-2
When referring to this page, please quote Data D10202 Edition
0064
X
For detailed sketch, see 900-2
Stopped engineShut off starting air supply At starting air
receiverBlock the main starting valveShut off starting air
distributor/distributing system supplyShut off safety air supply
Not ME enginesShut off control air supplyShut off air supply to
exhaust valve Only with stopped lubricating oil pumpsEngage turning
gearShut off cooling waterShut off fuel oilStop lubricating oil
supplyLock the turbocharger rotors
Ref. Description Value Unit
XXXXXXXXXX
-
Page 2 (2)
MAN B&W Diesel
The task-specific tools used in this procedure are shown on the
plates at the end of this chapter or in thechapters indicated by
the first three digits in the plate number, e.g. P90951 refers to
chapter 909.
Piston Rod Stuffing BoxData
102-2
When referring to this page, please quote Data D10202 Edition
0064
P90251 109 Mounting tool for stuffing box springP90251 122
Worktable for stuffing box
P90451 120 Rubber cover for crosshead
Plate Item No. Description
-
Page 1 (10)
902-2.1
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W Diesel CheckingPiston Rod Stuffing Box
M90
202
0230
C01
D0229
D0230D0229
D0230
A B
A
B
M90
202
0227
C02
D0234
D0238
2.
1.1. After the piston rod stuffing box has beendismantled, check
the following clearances:See Procedure 902-2.2.
Uppermost scraper ring and sealing rings
Clearance at ring ends (scraper ring).Total clearance (scraper
ring). (D02-29)
Clearance at ring ends (sealing rings).Total clearance (sealing
rings). (D02-29)
Lowermost scraper rings
Clearance at ring ends.Total clearance. (D02-30)
The ring clearances stated in Data apply tonew rings.
As a general guide, it is recommended depending on the
overhauling intervals andones own experience to replace
sealingrings and scraper rings when the specifiedclearance values
D02-29 and D02-30 havebeen halved.
2. Garter springs:
Generally, it is recommended to renew thesprings when the
sealing rings and scraperrings are renewed.
The springs can be checked as follows:Place the springs on the
table, measure Lo(free length), and compare with Data. If aspring
is extended more than 8% from thevalue given in data, it must be
discarded.
-
Piston Rod Stuffing Box
Page 2 (10)
902-2.2
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W DieselDismantlingM
9020
202
31D
02M
9020
202
31D
01M
9020
202
30D
03
2.
3.
1.In connection with dismantling of the piston,only the
innermost screws in the stuffing boxflange and the screws for the
drain oil pipeshould be removed.
If, in the period between piston overhauls, itbecomes necessary
to inspect the piston rodstuffing box, proceed as follows:
1. Turn the crosshead to about 90 from TDC.
Mount the rubber cover around the pistonrod to protect the
crosshead bearing fromimpurities.
2. Remove the drain oil pipe and all innermostscrews and all
outer screws except for twoscrews placed diametrically opposite in
thestuffing box flange, longitudinally to the en-gine.
3. Mount the worktable around the piston rodso that the two
remaining screws in thestuffing box flange can be loosenedthrough
the holes.
-
Page 3 (10)
902-2.2
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W Diesel DismantlingPiston Rod Stuffing Box
M90
202
0230
D05
M90
202
0230
D04
M90
202
0229
D05
5.
6.
4.4. Remove the two long dismantling screws
from the worktable.
Mount them in the stuffing box through theholes in the
worktable.
Remove the remaining two screws from thestuffing box.
5. Turn the piston to BDC, thereby withdraw-ing the stuffing box
from the cylinder framebottom.
6. Remove the two long dismantling screwsfrom the stuffing box
and mount them inthe worktable.
By means of the four short screws in theworktable, press the
stuffing box out of theflange.For overhauling the stuffing box, see
Pro-cedure 902-2.3.
-
Piston Rod Stuffing Box
Page 4 (10)
902-2.3
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W DieselOverhaulM
9020
202
30O
02M
9020
202
30O
01
D0244
Normally, overhaul of the piston rod stuffingbox is carried out
by routine methods in con-nection with the dismantling (pulling) of
the pis-tons.
During such overhauls, the piston rests on asupport placed over
one of the cut-outs in thetop platform.
Work on the stuffing box is then carried outfrom the platform
below.
Overhaul inside the engine is carried out in thesame way as
outside the engine.
1. Mount two eye bolts in the stuffing boxflange, and hook on
two tackles.
Lift the stuffing box a little up the pistonrod, and mount the
worktable round thepiston rod at a suitable working height.
Land the stuffing box on the worktable,and remove the tackles
and eye bolts.
2. Remove the O-ring of the stuffing box. Ifthe O-ring is intact
and is to be used again,move it up the piston rod and secure it
inthis position, for example with tape.
Remove the nuts from the stuffing box as-sembling bolts.
1.
2.
M90
202
0230
O04
-
Page 5 (10)
902-2.3
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W Diesel OverhaulPiston Rod Stuffing Box
M90
202
0230
O08
M90
202
0230
O03
D0245
M90
202
0227
C02
D0234
D0238
3. Take out the six bolts, and pull away onestuffing box
half.
Mount two eye bolts on the stuffing boxhalf and remove it from
the worktable.
4. Using a feeler gauge, measure the verticalclearance of the
rings.See Procedure 902-2.1.
5. Remove the remaining stuffing box half andpress all sealing
rings and scraper ringsdown against the worktable.
6. Measure the clearance between the ringsegments to determine
whether replace-ment is necessary.See Procedure 902-2.1.
Dismantle and stack the rings in the sameorder as when fitted in
the stuffing box.
Carefully clean all the ring segments.
Inspect and assess the surface quality ofthe sealing rings. If
their sliding surfaceshave scratches or marks, replace the
rings.
7. Check the lengths of the springs.See Procedure 902-2.1.
8. Inspect the surface of the piston rod. Ifsmall longitudinal
scratches have occurred(caused by poorly adapted stuffing
boxrings), smooth the piston rod surface care-fully with a fine
grained carborundumstone. In the case of coarse scratches, itmay
prove necessary to machine-grind thesurface in a workshop.
9. Clean the halves of the stuffing box hous-ing.
3.
7.
8.
-
Piston Rod Stuffing Box
Page 6 (10)
902-2.3
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W DieselOverhaulM
9020
202
30O
10
A
B
C
Scraperring
Scraperring
Sealingring
No reliefgroove
Reliefgroove
A
B
C
10. Lubricate the piston rod (in the area whereall the ring
units in the stuffing box will bepositioned) with molybdenum
disulphide(MoS2).
For correct mounting of the sealing andscraper rings see the
sketch. The scraperring in groove no. 4 must be without
reliefgrooves on the underside.
10.
-
Page 7 (10)
902-2.3
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W Diesel OverhaulPiston Rod Stuffing Box
M90
202
0230
O12
M90
202
0229
O11
11. Assemble all the stuffing box ring unitsround the piston
rod, on the worktable, inthe following way:
Place the lowermost scraper ring seg-ments on the worktable.
Place the spring round the segments,and hook the spring ends
together.
Repeat this procedure for the remainingscraper rings.
On top of the scraper rings, assemble thetwo sealing ring units
(each consisting of a4-part and an 8-part ring).
Assemble the 8-part sealing ring so thatthe two guide pins face
upwards, place thespring round the segments and, hook thespring
ends together.
Assemble the 4-part sealing ring above the8-part sealing ring.
Push the two rings to-gether in such a manner that the guidepins in
the lower sealing ring engage withthe two holes in the upper
sealing ring.
Finally, assemble the uppermost ring unit(consisting of a 4-part
scraper ring and an8-part sealing ring).
12. Use the stuffing box half on the worktableto adjust the
height of all the assembledring units on the piston rod until the
ringunits are opposite the correspondinggrooves in the stuffing box
housing. Subse-quently, push the stuffing box half into con-tact
with the piston rod, round the ringunits.
Note!
If the stuffing box is assembled insidethe engine, place two
pieces of plywoodof the same thickness as the flange onthe
worktable, to ease the assembling.
11.
12.
-
Piston Rod Stuffing Box
Page 8 (10)
902-2.3
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W DieselOverhaulM
9020
202
30O
14
D0244
M90
202
0230
O13
D0228
D0250
13. Check the ring clearance again.
Then place the other half of the stuffingbox housing on the
worktable, pushing itinto place round the rings.
In the middle holes mount and tighten upthe fitted bolts to the
torque specified onthe Data Sheet, See Data D02-50
Mount the O-ring in the stuffing boxgroove.
14. Mount eye bolts and wire ropes, and liftthe stuffing box a
little.
Remove the worktable and lower the stuff-ing box until it rests
against the distancepieces on the piston rod foot.
Remove wire ropes and screws.
Mount and tighten the standard bolts tospecified torque, See
Data D02-28
13.
14.
-
Page 9 (10)
902-2.4
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W Diesel MountingPiston Rod Stuffing Box
M90
202
0230
M03
M90
202
0230
M02
M90
202
0230
M01
1. In connection with mounting of the piston,only the innermost
flange screws are to bemounted and tightened, see data.
After overhauling the stuffing box inside theengine, assemble
the stuffing box halveson top of the four screws.
Mount the two long screws from the work-table in the stuffing
box.
Turn down the short screws so that thestuffing box lands on the
flange.
2. Turn the piston upwards until the stuffingbox is in place in
the cylinder frame.
3. Mount two screws in the flange through theholes in the
worktable.
Note!
Make sure that the two guide pins in theflange enter the guide
holes in the bot-tom of the cylinder frame.
1.
2.
3.
-
Piston Rod Stuffing Box
Page 10 (10)
902-2.4
When referring to this page, please quote Procedure M90202
Edition 0231
MAN B&W DieselMountinglM
9020
202
31O
05
D0226D0227
M90
202
0230
M04
4.
5.
6.
4. Remove the long screws from the stuffingbox and mount them in
the worktable.
Remove the worktable from the piston rod.
5. Mount the drain oil pipe.
Mount and tighten all the inner and outerscrews for the stuffing
box. See Data.
6. Remove the protecting rubber cover fromthe piston
rod/crosshead.
Smear the piston rod with molybdenumdisulphide.
Then turn the crankshaft a couple of revo-lutions.
If possible: Start up the engine and keep itrunning for about
fifteen minutes at a num-ber of revolutions corresponding to
veryslow or idle speed.
Then stop the engine and inspect the pis-ton rod and stuffing
box.
M90
202
0231
O06
-
Plate
Page 1 (2)When referring to this page, please quote Plate
EditionMAN B&W Diesel A/S
Piston and Piston Rod Panel P90251-0258
P90251 0258
-
Plate
Page 2 (2) When referring to this page, please quote Plate
EditionMAN B&W Diesel A/S
P90251-0258 Piston and Piston Rod Panel
ItemNo. Item Description
ItemNo. Item Description
P90251 0258
014 Panel for tools026 Name plate040 Lifting tool for piston
rod063 Lifting tool for cylinder liner075 Template for piston
top087 Distance piece for stuffing box099 Cover for stuffing box
hole109 Hook for mounting of spring110 Pressure tester122
Worktable134 Piston ring expander160 Dismantling screw
-
PlatePlatePlatePlatePlate
Page 1 (2)When referring to this page, please quote Plate
Edition
MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN
B&W DieselMAN B&W DieselPiston and Piston Rod - TPiston and
Piston Rod - TPiston and Piston Rod - TPiston and Piston Rod -
TPiston and Piston Rod - Toolsoolsoolsoolsools
P90261-0102P90261-0102P90261-0102P90261-0102P90261-0102
P90261 0102
-
PlatePlatePlatePlatePlate
Page 2 (2) When referring to this page, please quote Plate
Edition
MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN
B&W DieselMAN B&W
DieselP90261-0102P90261-0102P90261-0102P90261-0102P90261-0102
Piston and Piston Rod - TPiston and Piston Rod - TPiston and
Piston Rod - TPiston and Piston Rod - TPiston and Piston Rod -
Toolsoolsoolsoolsools
ItemItemItemItemItemNo.No.No.No.No.
Item DescriptionItem DescriptionItem DescriptionItem
DescriptionItem Description ItemItemItemItemItemNo.No.No.No.No.
Item DescriptionItem DescriptionItem DescriptionItem
DescriptionItem Description
P90261 0102
019 Guide ring for piston
-
When referring to this page, please quote Plate P90264 Edition
0006 Page 1 (2)MAN B&W Diesel A/S
Piston and Piston Rod - Extra Tools PlateP90264-0006
0006Piston and Piston Rod - Extra ToolsP90264
-
Page 2 (2) When referring to this page, please quote Plate
P90264 Edition 0006MAN B&W Diesel A/S
Piston and Piston Rod - Extra ToolsPlateP90264-0006
Item No. Item Description
015 Collar ring for piston027 Support for tilting tool039
Support for tilting tool
Item No. Item Description
-
Plate
Page 1 (2)When referring to this page, please quote Plate
EditionMAN B&W Diesel A/S
Piston and Piston Rod - Support Tools P90265-0001
P90265 0001
-
Plate
Page 2 (2) When referring to this page, please quote Plate
EditionMAN B&W Diesel A/S
P90265-0001 Piston and Piston Rod - Support Tools
ItemNo. Item Description
ItemNo. Item Description
P90265 0001
010 Support iron for piston
-
When referring to this page, please quote Plate P90266 Edition
0001 Page 1 (2)MAN B&W Diesel A/S
Piston - Lifting Tools PlateP90266-0001
0001Piston - Lifting ToolsP90266
-
Page 2 (2) When referring to this page, please quote Plate
P90266 Edition 0001MAN B&W Diesel A/S
Piston - Lifting ToolsPlateP90266-0001
Item No. Item Description
016 Lifting tool for piston
Item No. Item Description
-
MAN B&W Diesel A/S
903 - Cylinder Liner and Cylinder Lubrication
Documents in this Chapter
103-01 0075 Cylinder Liner, Data903-01 0259 Cylinder Liner103-02
0028 Cylinder Lubricator, Data903-02 0256 Cylinder Lubricator90361
0083 Cylinder Liner - Tools90362 0005 Cylinder Liner - Milling
Tools90364 0004 Test Equipment for Lubricators90366 0003 Cylinder
Liner - Lifting Tools
-
MAN B&W Diesel A/S
-
Page 1 (2)
MAN B&W Diesel
SAFETY PRECAUTIONS
Data
D03-02 Lifting tool bolts, screwing-in torque 200 NmD03-03
Cylinder diameter, new 800 mmD03-04 Piston cleaning ring diameter,
new 798.3 mmD03-16 Piston cleaning ring radial width, new 15.8
mmD03-17 PC-ring/Liner max. wear deviation 0.8 mmD03-05 Cylinder
liner, complete 4700 kgD03-06 Cooling jacket 130 kgD03-18 PC-rings
replacement criteria:
Cylinder LinerData
103-1
When referring to this page, please quote Data D10301 Edition
0075
X
For detailed sketch, see 900-2
Stopped engineShut off starting air supply At starting air
receiverBlock the main starting valveShut off starting air
distributor/distributing system supplyShut off safety air supply
Not ME enginesShut off control air supplyShut off air supply to
exhaust valve Only with stopped lubricating oil pumpsEngage turning
gearShut off cooling waterShut off fuel oilStop lubricating oil
supplyLock the turbocharger rotors
Ref. Description Value Unit
XXXXXXXXXX
Liner diameter: 800 mmLiner wear: Install:
Standard PC-ring0 0.80 mm (new or max. diameter wear of 0.80
mm0.80 1.6 mm Oversize PC-ring
> 1.6 mm No PC-ring
-
Page 2 (2)
MAN B&W Diesel
The task-specific tools used in this procedure are shown on the
plates at the end of this chapter or in thechapters indicated by
the first three digits in the plate number, e.g. P90951 refers to
chapter 909.
Cylinder LinerData
103-1
When referring to this page, please quote Data D10301 Edition
0075
P90251 051 Lifting tool for cylinder liner
P90361 Measuring tool for cylinder linerP90366 Cylinder Liner -
Lifting Tools
Plate Item No. Description
-
Page 1 (11)
903-1.1
When referring to this page, please quote Procedure M90301
Edition 0259
MAN B&W Diesel CheckingCylinder Liner
M90
301
0259
C04
M90
301
0259
C02
D0303
2.
1.1. Dismount the cylinder cover, the pistoncleaning ring and
the piston.See Procedures 901-1.2 and 902-1.2.
Clean the cylinder liner and scavenge airports.
2. Position the cylinder liner measuring tool.
Measure the cylinder liner with an insidemicrometer at the
positions indicated onthe measuring tool.
Take measurements in the fore-and-aft andathwartship
directions.
Check and assess the condition of the cyl-inder liner according
to the descriptiongiven in Volume I, Chapter 707.
3. Carefully scratch over any scores or marksand grind away the
wear ridges.See Procedure 903-1.3.
4. Check the lubricating points of the cylinderby pumping
cylinder oil to each lubricatingpoint with the cylinder
lubricator.
Clean any blocked lubricating duct.
Mount the piston and cylinder cover.See Procedures 902-1.4 and
901-1.4.
-
Cylinder Liner
Page 2 (11)
903-1.1
When referring to this page, please quote Procedure M90301
Edition 0259
MAN B&W DieselChecking
5. Piston cleaning (PC) ring:
The PC-ring is to be regarded as an inte-grated part of the
liner and it is intended tofollow the service life of the
liner.
During inspection of the piston and theliner, the PC-ring must
also be inspected.
6. Measure the PC-ring radial width B, andfind the most worn
place. Compare withData D03-16 and calculate the wear of
thePC-ring, multiply the wear by 2 to get thePC-ring diameter
wear.
Measure the liner in the fore-aft andathwart-ship directions at
piston skirt TDCposition, corresponding to measuring pointNo. 5 on
the liner-measuring tool. Comparethe measurements with the diameter
of anew liner as stated in Data. Calculate thewear of the
liner.
7. Compare the PC-ring diameter wear withthe wear of the liner.
If wear of the twocomponents does not deviate more thanD03-17 then
reinstall the PC-ring.
If deviation between PC-ring wear and linerwear is more than
D03-17 or if the PC-ringis broken or cracked, replace the ring
witha new PC-ring, an oversize ring or no ringaccording to Table
D03-18 on the Datasheet.
If it is necessary to install an oversize PC-ring, contact MAN
B&W Diesel for advice.
When a new liner is installed, also a newPC-ring must be
installed. When a newliner is ordered, also a new PC-ring mustbe
ordered.
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5.
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903-1.2MAN B&W Diesel Dismantling
Cylinder Liner
Page 3 (11)When referring to this page, please quote Procedure
M90301 Edition 0259
1. Dismount the cylinder cover.See Procedure 901-1.2.
Discard the sealing ring from the top of thecylinder liner.
Turn the piston down far enough to make itpossible to remove the
wear ridges at thetop of the liner.See Procedure 903-1.3.
Dismount the piston cleaning ring and thepiston.See Procedure
902-1.2.
2. Screw the two lifting tools on to the cylin-der liner. Check
with a feeler gauge thatthere is no clearance between lifting
tooland cylinder liner. For tightening torque,see Data.
3. Disconnect the oil pipes leading from thecylinder lubricator
to the cylinder liner.
M90
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D02
M90
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1.
3.
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Cylinder Liner903-1.2MAN B&W DieselDismantling
Page 4 (11) When referring to this page, please quote Procedure
M90301 Edition 0259
M90
301
0259
D04
D0305
4. Dismount the four cooling water pipes between the cooling
jacket and cylindercover and discard the O-rings from thepipes and
clean them carefully.
Attach the crane to the lifting crossbar.
Hook the lifting tools on to the crossbar onboth sides of the
cylinder liner.
Lift the liner with the cooling jacket out ofthe cylinder
frame.
Land the cylinder liner vertically on, for in-stance, a couple
of planks.
Remove the cooling water pipes and dis-card the O-rings.
5. Clean the cylinder frame internally, takingspecial care with
the contact surfaces forthe cylinder liner at the top of the
cylinderframe.
6. The lifting tools are also used for transport-ing the
cylinder liner.
Note!
Low lifting height in the engine roommay require the removal of
one or morecylinder cover studs before dismantlingthe cylinder
liner.
4.
M90
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6.
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903-1.3MAN B&W Diesel Overhaul
Cylinder Liner
Page 5 (11)When referring to this page, please quote Procedure
M90301 Edition 0259
M90
301
0259
O02 D0306
1. Unscrew the non-return valves from thecylinder liner.
Clean and inspect the non-return valves.
2. Attach two tackles to the crossbar, asshown.
Mount two lifting eye bolts in the coolingjacket.
Hook the tackles on to the lifting eye boltson the cooling
jacket and haul tight.
Loosen the screws on the clamps which fixthe cooling jacket to
the cylinder liner. Turnthe clamps away from the liner.
M90
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O01
1.
2.
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Cylinder Liner903-1.3MAN B&W DieselOverhaul
Page 6 (11) When referring to this page, please quote Procedure
M90301 Edition 0259
M90
301
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O03
3. Lower the cooling jacket by means of thetackles and the
crane, and land it on thewooden planks.
Check tha