Vol 2+3 K98ME

(1)When referring to this page, please quote S-Instruction Edition

MAN B&W

Warning!

It is important that all MAN Diesel A/S engines are operated within the given specifi cations and performance tolerances specifi ed in the engines Technical Files and are maintained according to the MAN 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 specifi ed in MAN Diesel A/S instructions, including, but not limited to, the instructions to that effect included in the Technical File.

WarningS900-0002

S900 0002

K98MEDS 09092965

VOLUME IIMAINTENANCE

MAN Diesel A/S

900 - Introduction

Documents in this Chapter

Table of Contents, Volume II90023 0027 Instructions for Main Engine90050 0293 Checking & Maintenance Schedule90060 0002 General - Safety Precautions

MAN Diesel A/S

Table of Contents 900Volume II - Maintenance

Page 1 (4)MAN Diesel A/S

No. Edition Title

900 - IntroductionTable of Contents

90023 0027 Instructions for Main Engine90050 0293 Checking & Maintenance Schedule90060 0002 General - Safety Precautions

901 - Cylinder Cover101-01 0076 Cylinder Cover, Data901-01 0259 Cylinder Cover90151 0214 Cylinder Cover - Panel90161 0111 Cylinder Cover - Tools90163 0003 Cylinder Cover - Support Tool90164 0002 Cylinder Cover - Hydraulic Jack Spares90165 0001 Cylinder Cover - Lifting Tools

902 - Piston with Rod & Stuffing Box102-01 0073 Piston, Data902-01 0263 Piston102-02 0055 Piston Rod Stuffing Box, Data902-02 0225 Piston Rod Stuffing Box90251 0264 Piston and Piston Rod - Panel90261 0102 Piston and Piston Rod - Tools90262 0027 Piston and Piston Rod - HydraulicTools90264 0009 Piston and Piston Rod - Tilting Tools90265 0003 Piston and Piston Rod - Support Tools90266 0003 Piston - Lifting Tools

903 - Cylinder Liner and Cylinder Lubrication103-01 0070 Cylinder Liner, Data903-01 0255 Cylinder Liner103-02 0029 Cylinder Lubricator, Data903-02 0250 Cylinder Lubricator90361 0083 Cylinder Liner - Tools90362 0006 Cylinder Liner - Milling Tools90363 0001 Cylinder Liner - Honing Tools90365 0001 Equipment For Special90366 0008 Cylinder Liner - Lifting Tools

904 - Crosshead with Connecting Rod104-01 0058 Crosshead Bearing, Data904-01 0248 Crosshead Bearing904-02 0246 Crosshead104-03 0039 Reciprocating Parts, Data904-03 0216 Reciprocating Parts104-04 0051 Crankpin Bearing, Data



No. Edition Title

904-04 0234 Crankpin Bearing104-05 0049 Connecting Rod, Data904-05 0235 Connection Rod90451 0145 Connecting Rod and Crosshead - Panel90461 0071 Connecting Rod - Hydraulic Tools90462 0035 Connecting Rod - Tools90464 0009 Crosshead - Hydraulic Tools

905 - Crankshaft, Thrust Bearing and Turning Gear105-02 0070 Main Bearing, Data905-02 0253 Main Bearing105-03 0060 Thrust Bearing, Data905-03 0279 Thrust Bearing105-04 0034 Journal Bearing, Data905-04 0224 Journal Bearing105-05 0051 Axial Vibration Damper, Data905-05 0225 Axial Vibration Damper90551 0234 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel90561 0089 Main Bearing - Hydraulic Tools90562 0121 Crankshaft - Tools90570 0001 Thrust Shaft - Tools90571 0001 Main Bearing Shell - Tools90572 0001 Main Bearing - Measuring Tools

906 - Control Gear106-01 0051 Chain, Data906-01 0237 Chain106-02 0053 Chain Tightener, Data906-02 0238 Chain Tightener10620 0002 Gear Drive90620 0203 Gear Drive10621 0005 Hydraulic Pumps90621 0207 Hydraulic Pumps10622 0006 Hydraulic System90622 0207 Hydraulic System10623 0002 Accumulators90623 0205 Accumulators10624 0005 Control Valves90624 0206 Control Valves10626 0001 Angle Encoder90626 0201 Angle Encoder10628 0008 Special Running90628 0211 Special Running10629 0001 Multi-purpose Control90629 0201 Multi-purpose Control



No. Edition Title

90651 0206 Chain Drive and Camshaft - Panel90653 0003 Tools For Accumulator90653 0004 Tools For Accumulator90664 0001 Crankshaft - Pin Gauge90671 0001 Hydraulic Tools - Chain Tightener90672 0001 Hydraulic Power Suppl90674 0001 Test Equipment For Ac

907 - Starting Air System107-02 0039 Start Air Valve, Data907-02 0216 Starting Air Valve

908 - Exhaust Valve108-01 0041 High-Pressure Pipe, Data908-01 0224 High-Pressure Pipe108-02 0084 Exhaust Valve, Data908-02 0257 Exhaust Valve108-03 0049 Exhaust Valve Actuator, Data908-03 0239 Exhaust Valve Actuator90851 0212 Exhaust Valve - Panel90861 0022 Exhaust Valve - Tools90862 0046 Exhaust Valve - Hydraulic Tools90862 0049 Exhaust Valve - Hydraulic Tools90864 0003 Exhaust Valve - Extractor Tool

909 - Fuel Oil System10911 0065 Fuel Valve, Data90911 0240 Fuel Valve10912 0046 Spindle Guide, Data90912 0227 Spindle Guide10913 0033 Non-Return Valve in Fuel Valve, Data90913 0206 Non-Return Valve in Fuel Valve10914 0069 Fuel Oil High-Pressure Pipes, Data90914 0242 Fuel Oil High-Pressure Pipes10920 0001 Fuel Oil Pressure Boo90920 0201 Fuel Oil Pressure Boo10921 0001 F/o Press.boost,top C90921 0201 F/o Press.boost, Top10922 0001 F/o Press Boost, Suc.90922 0201 F/o Press Boost, Suc.90961 0069 Fuel Valve - Tools90966 0008 Fuel Valve Nozzle - Tools90968 0001 Fuel Valve - Inspection Tools90974 0001 Fuel Valve Nozzle - Cleaning Tools90981 0001 Mounting Tools - Top Cover Seals



No. Edition Title

910 - Turbocharger System110-01 0060 Air Cooler Element, Data910-01 0248 Air Cooler Element110-02 0009 Non-Return Valve after Air Cooler, Data110-03 0023 Auxilary Blower, Data110-04 0005 Butterfly Valve, Data110-05 0010 Turbocharger Turbine, Data110-06 0029 Water Mist Catcher, Data910-06 0222 Water Mist Catcher91061 0070 Turbocharger System - Tools91061 0071 Turbocharger System - Tools91063 0017 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 0010 Holding Down & End Chock Bolts, Data912-02 0208 Holding Down and End Chock Bolts112-03 0021 Stay Bolts, Data912-03 0214 Stay Bolts912-05 0201 Crankcase Oil Outlet91261 0076 Hydraulic Tools for Large Parts91265 0004 Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)913 - General Tools913-01 0213 Hydraulic Tools913-03 0006 Working Platforms913-04 0201 Standard Tightening Torques913-05 0205 Torque Spanner913-06 0205 Tightening Gauge913-07 0207 Screws and Nuts91311 0204 Lubricating91351 0046 Accessories - Hydraulic Tools91356 0054 Lifting Tools, etc.



No. Edition Title

91357 0009 Open-Ended Spanners91359 0003 Torque Spanners91360 0005 Pliers91361 0052 Combination Spanners91362 0061 Ring Slugging Spanners91362 0071 Ring Slugging Spanners91363 0039 Spanners91364 0059 Open-Ended Spanners91366 0065 Instruments91366 0067 Instruments91368 0012 Working Platforms

Instructions for Main Engines

This book forms part of a set of books consisting of three volumes entitled:

Vol. I OPERATION Vol. II MAINTENANCE Vol. III COMPONENTS, DESCRIPTIONS

The purpose of these books is to provide general guidance on operation and maintenance and to describe the constructional features of a standard version of an MAN B&W main diesel engine. De-viations may be found in a specific plant. In addition, the books can be used for reference purposes, for instance in correspondence and when ordering spare parts.

It is essential that the following data is stated in spare parts orders as it is used by us to ensure the supply of the correct parts for the individual engines:

Name of vessel Engine No. built by Plate No. Part No. Quantity required (and description)

Example: M/S Nybo 7730 B&W P90201-0036 059 10 off (piston ring)

To ensure optimum efficiency, reliability and lifetime of the engine and its components, only original spare parts should be used when replacing parts on the engine.

When used in texts and illustrations, the designation D refers to the information given on the data sheets inserted in the respective books.

Reliable and economical operation of the diesel engines is conditional upon its correct operation and maintenance in accordance with MAN Diesel instructions. Emissions related maintenance of the diesel engine shall be performed as specified in MAN Diesel instructions and any additional instruc-tions to that effect included in the Technical File. Consequently, it is essential that the engine room personnel are fully acquainted with the contents of this book and, in respect of instructions on emis-sions related maintenance of the diesel engine, also the additional instructions to that effect set out in the Technical File.

This book is subject to copyright protection, and should therefore not, in whole or in part, be copied, reproduced, made public or in any other way made available to a third party without the written con-sent of this effect from MAN Diesel.

MAN Diesel A/S Teglholmsgade 41 Teleph. : +45 33 85 11 00 DK-2450 Copenhagen Telefax : +45 33 85 10 30 Denmark [email protected] www.manbw.com

CVR No. 39 66 13 14A900

23-0

028

When referring to this page, please quote Maintenance Schedule A90050 Edition 0293 Page of 7

Checking and Maintenance Schedule, ME Engines 9001MAN B&W

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

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 over-hauling.

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

In addition to the checking and overhauling inter-vals stated in this schedule, please note that the periodical survey requirements of the classifica-tion 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 compo-nents, and form the basis for estimating whether further overhaul-ing 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 condi-tion 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 ser-vice or Based on observations, are the procedures where an actual basis for estimation is lacking. It is recommended, there-fore, 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 0293Page 2 of 7

Checking and Maintenance Schedule, ME Engines9001 MAN B&W

When referring to this page, please quote Maintenance Schedule A90050 Edition 0293 Page 3 of 7

MAN B&W Checking and Maintenance Schedule, ME Engines 9001

V : SeeVolumeIOperationA : AdjustmenttobecarriedoutC : Checkthecondition

M : SeemakersinstructionsO : OverhaultobecarriedoutH : Checknew/overhauledpartsafter5001500hours

R : PartstobereplacedB : BasedonobservationsP : Referto

Remarks

RegularChecks Serviceinterval(x1000hoursofoperation)

No. Procedure H Daily Weekly Monthly 2 4 6 8 12 16 24 32 B P

901 Cylinder Cover 1 Cylindercover C* O

Indicatorcock O

902 Piston with Rod and Stuffing box1 Piston C,O

Inspectionthroughscavengeports C V2 Pistonrodstuffingbox C* O

903 Cylinder Liner and Cylinder Lubrication1 Cylinderliner O

Inspectionthroughscavengeports CMeasuringwearinsideliner C

2 Cylinderlubricators C A V,MAccumulatorsnitrogenpressure C ALubricatorlevelsensor C O V,M

904 Crosshead with connecting rod1 Crossheadbearing C C C,O2 Crosshead C C C,O3 Reciprocatingparts C C,O4 Crankpinbearing C C C,O5 Connectingrod O

905 Crankshaft and Thrust Bearing2 Mainbearing C C C,O V3 Thrustbearing C C C,O3 Guidebearing C C C,O4 Journalbearing C C C,O V

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

* Check clearances without dismantling segments

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

* Check whenever exhaust valve is removed

Vol. I Chapter 702-01

When referring to this page, please quote Maintenance Schedule A90050 Edition 0293Page of 7

9001




MAN B&WChecking and Maintenance Schedule, ME Engines

Remarks



5 Axialvibrationdamper OElectronicaxialvibrationmonitor CMechanicalchecking C

7 Tachopickup C,O M8 Angleencoder C,O M

906 Mechanical Control Gear1 Chains C C R V2 Chaintightener C,A C,A A

Chainwheels,spraynozzlesandguidebars C C R5 Momentcompensator C C C,A20 Geardrive C C21 Hydraulicpumps C R M22 Hydraulicsystem C O23 Accumulators C A24 Controlvalves C R M25 Pickuparrangement C,A M28 Specialrunning O V

Start-uppumps C O VHCUsafetyby-pass C O VMPCunitsshut-downsignal C O VHydraulicsystemleakagetest C O VDouble-wallpipesleakagetest C C O VBoll&Kirchfilter C O MFunctionalcheckofoverspeeddevice C MFunctionalcheckofspeedsettingsystem C M(enginewithbridgecontrolsystem)

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

Vol. I, Chapter 702-01










Remarks



907 Starting Air System2 Startingairvalve C* C,O V

Mainstartingvalvepilotvalve C* V

908 Exhaust Valve1 Highpressurepipe O2 Exhaustvalve O3 Exhaustvalveactuator O

Actuatorsafetyvalve C,A7 Exhaustvalvespecialrunning O

909 Fuel Oil SystemFueloilwatercontent C V,M

11 Fuelvalve C,O Fuelnozzle R12 Spindleguide R13 Nonreturnvalve O14 Fueloilhighpressurepipes O16 Fueloilpressureboosterspecialrunning O20 Fueloilpressurebooster O21 Fueloilpressureboostertopcover O22 Fueloilpressureboostersuctionvalve C,O

910 Turbocharger System1 Aircooler C O V2 Nonreturnvalve C O3 Auxiliaryblower O4 Butterflyvalves C O5 Turbochargerturbine C* C C,O V,M

Check at every port inspection

Check p and tCheck at every port inspection

* Dry cleaning daily

* Vol. I, Chapter 702-01After arrival in port

When referring to this page, please quote Maintenance Schedule A90050 Edition 0293Page of 7

9001




MAN B&WChecking and Maintenance Schedule, ME Engines

Remarks



Turbochargerairfilter C* OProtectivegridbeforeturbocharger C R VTurbochargerlubricatingoilwatercontent C M

6 Watermistcatcher C* C,O

911 Safety Equipment1 Overpressureindicatorvalve C O2 Reliefvalve C O3 Scavengeairreceiversafetyvalve C O

LOPlamptest C O VElectronicboxes C O VFunctionaltestofalarmsystemforthrustbearingandslowdown/shutdownsystem C C MCheckingandadjustmentofpressuregauge C A MCheckingandadjustmentofthermometers C A MCheckingandadjustmentofthermostats C A MCheckingandadjustmentofpressurestats C A MCheckingandadjustmentofturninggearswitch C A M

912 Assembly of Large Parts2 Holdingdownandendchockbolts C C3 Staybolts C C

Topbracings C CDiaphragmincrankcaseoiloutlet C RSystemlubricatingoilwatercontent C V,MSystemlubricatingoilbottomtank OCoolingwaterquality C A V,MCrankcase C*

* Check for loose nuts and bearing material fragments

Empty and clean tank

* Check p

* Check p








Remarks



913 General Tools1 Hydraulictools C O M

(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 Diesel A/S

901 - Cylinder Cover


101-01 0076 Cylinder Cover, Data901-01 0259 Cylinder Cover90151 0214 Cylinder Cover - Panel90161 0111 Cylinder Cover - Tools90163 0003 Cylinder Cover - Support Tool90164 0002 Cylinder Cover - Hydraulic Jack Spares90165 0001 Cylinder Cover - Lifting Tools

MAN Diesel A/S

(2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Data

For detailed sketch, see 900-2

Ref. Description Value Unit

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 oilX Stop lubricating oil supplyX Lock the turbocharger rotors

When referring to this page, please quote Data D10101 Edition 0076

101-1

D01-01 Exhaust valve stud, screwing-in torque 600 Nm

D01-02 Starting valve stud, screwing-in torque 110 Nm

D01-03 Fuel valve stud, screwing-in torque 140 Nm

D01-05 Cylinder cover stud, check distance 196.5 - 197.5 mm

D01-06 Cylinder cover, complete 11000 kg

D01-07 Cylinder cover without valves 7600 kg

D01-08 Cooling jacket 310 kg

D01-09 Exhaust valve stud 210 kg

D01-10 Cylinder cover stud 205 kg

D13-01 Hydraulic pressure, mounting 2200 bar

D13-02 Hydraulic pressure, dismantling 2000 -2400 bar

(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

Cylinder Cover

When referring to this page, please quote Data D10101 Edition 0076

101-1

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 142 Lifting Tool for Gas Compensator

P90161 Cylinder cover tightening tool

P90165 Cylinder Cover - Lifting Tools

P91351 10 Hydraulic pump, pneumatically operated

P91351 60 Hose with unions (5000 mm), complete

(14)

901-1.2

When referring to this page, please quote Procedure M90101 Edition 0259

MAN B&W Diesel Dismantling

Cylinder Cover

M90101-0259D03

531

M90101-0259D02

ON

OFF

00:00

Bourdon Sedeme

CC

455

420

421

M90

101

0240

D01

F

D

A

E G

C

B

2.

3.

1.1. Set blocking device A on the main starting

valve in the BLOCKED position.

Engage turning gear B.

Close fuel oil inlet valve C.

Close cooling water inlet valve D.

Close cooling water outlet valve E.

Open cooling water drain cocks F and G.

Shut off the air supply for the pneumatic exhaust valve spring, and vent the system.

2. Connect a pressure gauge at minimess point 455.

Check the pressure.

Close valve 420 and open valve 421 on the hydraulic block.

Check that the system is pressure free.

3. Close valve 531 for hydraulic operation of the exhaust valve.

Cylinder Cover

Page 2 (14)

901-1.2


MAN B&W DieselDismantlingM90101-0259D04

M90101-0259D05

5.

4.4. Remove the cooling water outlet pipe from

the exhaust valve.

Remove the screws which fasten the cool-ing water outlet pipe to the cylinder cover.

Dismount the fuel oil highpressure pipes. See Procedure 90914.2.

Dismount the control air pipe from the starting valve.

Remove the starting air pipe.

5. Dismount the hydraulic highpressure pipe to the exhaust valve, see Procedure 9081.2.

Remove the oil supply pipe for the hydrau-lic damper in the exhaust valve.

Dismount the drain oil pipe between the exhaust valve and the hydraulic actuator, and the air pipe for the pneumatic exhaust valve spring.

Disconnect the plug for the electrical con-nection to the exhaust valve spindle posi-tion sensor.

(14)

901-1.2



Cylinder Cover

6. Remove the protective jacket enclosing the insulation for the intermediate pipe or com-pensator. Remove the insulation.

Loosen the screws in the ange between the compensator and the exhaust gas bend and let the compensator contract.

Fit the lifting tool as shown in the sketch.

Suspend the compensator in the en-gine room crane. Loosen and remove the screws in both the uppermost and lower-most ange.

Move the compensator forward and clear of the exhaust valve and the exhaust com-pensator.

Lift the compensator away.M

9010

102

56D

06

6.

Cylinder Cover

Page 4 (14)

901-1.2


MAN B&W DieselDismantlingM

9010

102

40D

07

D1302

M90

101

0240

D08

8.

7.7. Remove the protective caps from the cylin-

der cover nuts.

Position the cylinder cover tightening tool over the cylinder cover.

Pull down the spacer rings and the hydrau-lic jacks over the nuts.

For operation of the hydraulic tools, see Chapter 913.

If the cylinder cover is not to be overhauled, the cylinder cover tightening tool may re-main placed on the cylinder cover while the cylinder cover is removed from the engine.

If the cylinder cover is to be overhauled, re-move the cylinder cover tightening tool from the cylinder cover.

8. Mount the cylinder cover support tool on the uppermost platform in the purposed holes.

9. Hook the engine room crane on to the lift-ing attachment on top of the exhaust valve.

Lift away the cylinder cover complete.

(14)

901-1.2



Cylinder Cover

M90101-0259D10

D01-06

M90101-0259D11

M90101-0259D12

11.

12.

10.10. Land the cylinder cover on the support

tool.

11. If the cylinder cover is to be overhauled it is recommended instead to land the cylin-der cover on a couple of wooden planks.

12. Remove and discard the sealing ring be-tween cylinder cover and cylinder liner.

Note!

The cylinder cover support tool should only be used when the ship is in port.

Cylinder Cover

Page 6 (14)

901-1.3


MAN B&W DieselOverhaulM

9010

102

40O

01

D0109

M90

101

0240

O02

D0107

D01-08

M90

101

0240

O03

2.

3.

1.

4.

1. Dismount all valves and pipes on the cylin-der cover. See Procedure 9072.2, 9082.2 and 90911.2.

Dismount all studs on the top of the cylin-der cover.

2. Unscrew 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.

If the cooling jacket sticks, use dismantling screws to force the jacket/cover apart.

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

Provide the cylinder cover with new Orings, well lubricated with vaseline.

4. Lift the cylinder cover and guide the jacket/cover into position, using the guide pin as reference (manoeuvre side).

Mount and tighten the screws for the cool-ing jacket.

(14)

901-1.3


MAN B&W Diesel Overhaul

Cylinder Cover

M90

101

0240

O05

M90

101

0240

O06

M90

101

0240

O07

6.

7.

5.5. Recondition the valve bores as follows:

Fuel valve bore

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

Clean the fuel valve bores, using the car-bon cutter. If required, recondition the fuel valve seating with the appropriate cutter.

Grind the seating with the grinding man-drel and a grinding compound (e.g. Carborundum No. 200).

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

Exhaust valve bore

7. The tool consists of a spindle with 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.

Cylinder Cover

Page 8 (14)

901-1.3


MAN B&W DieselOverhaulM

9010

102

40O

09M

9010

102

40O

08

9.

8.Starting valve bore

8. 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 valves on a cylinder cover that is mounted on the engine, recondition the valve bores/seating in the same way as described here, but without dismounting the studs.

9. Clean the bores for safety valve/indicator cock.

(14)

901-1.3


MAN B&W Diesel Overhaul

Cylinder Cover

M90

101

0240

O10

D0101

D0102

D0103

M90

101

0240

O11

10.

11.

10. Lubricate the threads with Never Seize or Molybdenum Disulphide (MoS2) and mount 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.

Provide the water connection ange with a new gasket, and keep the cylinder cover ready for replacement.

Always t new or overhauled valves before a cylinder cover is mounted on the engine.

11. For examination/cleaning of the underside or the inside of the cylinder cover the cylin-der cover support tool must be used.

Cylinder Cover

Page 10 (14)

901-1.4


MAN B&W DieselMountingM90101-0259M01

D01-06

M90101-0259M03

3.

1.

M90101-0259M04

D01-05

4.

1. Place a new sealing ring on top of the cyl-inder liner.

2. With the cylinder cover still placed on the cylinder cover support tool, carefully wipe the contact surface which faces the cylin-der liner.

3. Provide the cooling water connecting pipes with new Orings and lubricate them with grease or soft soap.

Mount a new sealing ring in the groove of the ange of the intermediate pipe.

Lower the cover carefully into position.

During the landing, carefully check that the cooling water connecting pipes engage cor-rectly with the holes in the cooling jacket.

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

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

(14)

901-1.4


MAN B&W Diesel Mounting

Cylinder Cover

M90

101

0240

M05

D1301

5.5. Mount all eight nuts on the studs and

screw them down to the cylinder cover.

Position the cylinder cover tightening tool over the cylinder cover.

Pull down the spacer rings and hydraulic jacks of the tightening tool and screw the jacks on to the studs.

For operation of hydraulic jacks, see Proce-dure 9131.

Connect the hydraulic hoses to the jacks and raise the pressure to the level stated in Data. Tighten the nuts with a tommy bar.

Release the pressure. Remove the hydrau-lic jacks.

Cylinder Cover

Page 12 (14)

901-1.4


MAN B&W DieselMountingM

9010

102

56M

06

6. 6. Mount the exhaust gas compensator.

Lift the compensator in between the ang-es, from fore to aft.

Fit the screws in the uppermost ange.

Fit the screws in the lowermost ange.

Remove the lifting tool. Tighten the screws in the anges.

Fit the insulating jacket around the interme-diate pipe.

Lubricate the screws with Never Seize or molybdenum disulphide (MoS2) before tting.

Note!

(14)

901-1.4


MAN B&W Diesel Mounting

Cylinder Cover

M90101-0259M07

7.

M90101-0259M08

8.

7. Mount the return oil pipe and the air pipe for pneumatic closing of the exhaust valve.

Mount the oil supply pipe for the hydraulic damper in the exhaust valve.

Mount the highpressure pipe for the hy-draulic valve gear. See Procedure 9081.4.

Mount the plug for the elctrical sensor for the exhaust valve.

8. Mount the starting air pipe and control air pipe for the starting valve.

Mount the cooling water outlet pipe on the exhaust valve.

Mount the drain pipe on the intermediate pipe between the exhaust valve and the cylinder cover.

Using a crowfoot wrench and torque span-ner, mount the fuel oil highpressure pipes. See Procedure 90914.4.

Connect the outlet pipe from the return oil pipe on the fuel valves.

Shut the drain valves and open the cool-ing water inlet. After venting the cylinder section, shut the vent cocks and open the cooling water outlet valve.

Open the air supply to the exhaust valves, open the fuel oil and start the lubricating oil pump.

Caution !

The air supply to the exhaust valve must always be connected and pres-surised before starting the oil pumps to the exhaust valve actuator.

Cylinder Cover

Page 14 (14)

901-1.4


MAN B&W DieselMountingM90101-0259M10

531

M90101-0259M11

420

421

10.

11.

9. If the lubricating oil pumps have been started before the exhaust valve pneumatic springs are pressurised:

Wait 510 minutes and check on the MOP panel that all exhaust valves are closed.

Closing of the exhaust valves is eased if the lubricating oil pumps are stopped and the actuators drained at the drain screw.

10. Open valve 531 for hydraulic operation of the exhaust valve.

11. Close valve 421 and open valve 420 on the hydraulic block.

Plate

Page 1 (2)When referring to this page, please quote Plate EditionMAN B&W Diesel A/S

Cylinder Cover Panel P90151-0214

P90151 0214

Plate

Page 2 (2) When referring to this page, please quote Plate EditionMAN B&W Diesel A/S

P90151-0214 Cylinder Cover Panel

ItemNo. Item Description


P90151 0214

010 Panel for tools022 Name plate046 Grinding tool, exhaust valve seat058 Milling and grinding wheel, fuel valve060 Milling and grinding wheel, starting

valve071 Dismantling lever, fuel valve083 Handle, grinding tools095 Grinding ring, starting valve105 Pin spanner, starting valve117 Test equipment, combined safety

valve142 Lifting tool for compensator

Plate

Page 1 (2)When referring to this page, please quote Plate Edition

MAN B&W DieselCylinder Cover - Tools

P90161-0111

P90161 0111

Plate

Page 2 (2) When referring to this page, please quote Plate Edition

MAN B&W DieselP90161-0111Cylinder Cover - Tools



P90161 0111

015 Balancing ring assembly, upper027 Balancing ring assembly, lower039 Spring balance052 Coupling064 Hose, 1,5 m076 Hose, 3,0 m088 Hose, 5,0 m090 Screw100 Nut111 Coupling123 Nipple135 Pipe clamp147 Screw159 Nut302 Jack-hydraulic, complete314 Jack-hydraulic, support326 Screw900 Cylinder cover tightening tool, complete

PlatePlatePlatePlatePlate


MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN B&W DieselMAN B&W DieselCylinder Cover - Support TCylinder Cover - Support TCylinder Cover - Support TCylinder Cover - Support TCylinder Cover - Support Tooloolooloolool

P90163-0003P90163-0003P90163-0003P90163-0003P90163-0003

P90163 0003



MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN B&W DieselMAN B&W DieselP90163-0003P90163-0003P90163-0003P90163-0003P90163-0003

Cylinder Cover - Support TCylinder Cover - Support TCylinder Cover - Support TCylinder Cover - Support TCylinder Cover - Support Tooloolooloolool

ItemItemItemItemItemNo.No.No.No.No.

Item DescriptionItem DescriptionItem DescriptionItem DescriptionItem Description ItemItemItemItemItemNo.No.No.No.No.

Item DescriptionItem DescriptionItem DescriptionItem DescriptionItem Description

P90163 0003

016 Cylinder cover rack

Plate


MAN B&W DieselCylinder Cover - Hydraulic Jack Spares

P90164-0002

P90164 0002

Plate


MAN B&W DieselP90164-0002Cylinder Cover - Hydraulic Jack Spares



P90164 0002

023 O-ring with back-up ring035 O-ring with back-up ring047 Key, hexagon socket screw059 Tommy bar072 Venting screw084 Steel ball096 Stud setter106 Quick coupling, male202 Spare part kit, complete



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




Cylinder Cover - Lifting TCylinder Cover - Lifting TCylinder Cover - Lifting TCylinder Cover - Lifting TCylinder Cover - Lifting Toolsoolsoolsoolsools




P90165 0001

017 Lifting chains for cylinder cover

MAN Diesel A/S

902 - Piston with Rod & Stuffing Box


102-01 0073 Piston, Data902-01 0263 Piston102-02 0055 Piston Rod Stuffing Box, Data902-02 0225 Piston Rod Stuffing Box90251 0264 Piston and Piston Rod - Panel90261 0102 Piston and Piston Rod - Tools90262 0027 Piston and Piston Rod - HydraulicTools90264 0009 Piston and Piston Rod - Tilting Tools90265 0003 Piston and Piston Rod - Support Tools90266 0003 Piston - Lifting Tools

MAN Diesel A/S

When referring to this page, please quote Data D10201 Edition 0073 Page 1 (2)MAN B&W Diesel A/S

SAFETY PRECAUTIONS

Data

102-1PistonData

Special DataD10201 Edition 0073K98MC Piston102-1

X Stopped engineX Block the starting mechanismX Shut off starting air supplyX Engage turning gearX Shut off cooling waterX Shut off fuel oilX Shut off lubricating oil

Lock turbocharger rotors


D01-05 Cylinder cover stud, check distance 196.5-197.5 mmD02-01 Test pressure 7 barD02-04 Piston rod/crown stud, screwing-in torque 450 NmD02-05 Piston skirt, tightening torque 650 NmD02-06 Cooling oil pipe, tightening torque 190 NmD02-08 Piston ring new, radial width 30.5 mmD02-09 Piston ring worn, min. radial width 26 mmD02-10 Groove No.1, max. vertical height 22.8 mmD02-11 Groove Nos. 2, 3 and 4, max. vertical height 16.8 mmD02-12 Piston top, max. permissible burn-away 10 mmD02-15 Minimum free ring gap ( before dismantling ) 60 mmD02-16 Minimum ring gap, ring No. 1 ( new ring in new liner ) 6.9 mmD02-17 Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) 4.9 mmD02-18 Vertical clearance, new parts 0.6 mmD02-19 Vertical clearance, worn parts, max. 1.0 mmD02-20 Piston complete 5550 kgD02-21 Piston crown 1600 kgD02-22 Piston rod 3100 kgD02-23 Piston skirt 380 kgD02-24 Piston cooling pipe 70 kgD02-25 Lifting tool, tightening torque 150 NmD02-27 Stuffing box flange, inner screws tightening torque 350 NmD02-46 CPR ring CL groove, min. depth 2.2 mmD13-01 Hydraulic pressure, mounting 1500 barD13-02 Hydraulic pressure, dismantling 1400-1650 bar

(2) When referring to this page, please quote Data D10201 Edition 0073MAN B&W Diesel A/S

Piston102-1Data

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.


P90251 40 Lifting tool for piston rod footP90251 51 Lifting tool for cylinder linerP90251 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 expanderP90261 Guide ring for pistonP90262 Hydraulic jack for piston rodP90264 Tools for tilted liftP90265 Support for pistonP90266 Piston - Lifting ToolsP90451 118 Rubber cover for crossheadP90451 120 Rubber cover for crossheadP91356 Lifting Tools, Etc.P91351 10 Hydraulic pump, pneumatically operatedP91351 46 Hose with unions (1500 mm), completeP91351 58 Hose with unions (3000 mm), completeP91351 117 5-way distributor block, complete

When referring to this page, please quote Procedure M90201 Edition 0263 Page 1 (20)MAN B&W Diesel A/S

Piston 902-1.1Checking

0263K98MCPiston902-1.1Checking

Scavenge port inspection

To detect possible leakages from the piston orcylinder cover, keep the cooling water and cool-ing oil circulating during the scavenge port in-spection.

1. The scavenge port inspection is carried outfrom the scavenge air receiver. An addition-al view of the rings is possible through thecleaning cover on the manoeuvring side.

Turn the engine at least a revolution andstart with a unit arriving downwards, justabove the scavenge air ports.

Inspect the piston rod and the lower part ofthe cylinder wall. While the piston is pass-ing downwards, inspect the piston skirt, allthe piston rings, the ringlands and the pis-ton top.

2. Inspect the rings, one at a time, and notedown the results. See Volume I, Operation,Chapter 707.

3. Check the movability and the tension of thepiston rings, by pressing against them witha wooden stick.

1.

HN

902-

1.1

256

01H

N90

2-1.

1 25

6 02

2.

3.

HG

902-

1.1

204

03

(20) When referring to this page, please quote Procedure M90201 Edition 0263MAN B&W Diesel A/S

Piston902-1.1Checking

4. Ring grooves:Measure the total clearance between thepiston rings and the ring grooves.

The total clearance must not exceed thevalue stated in Data.

Measurements are to be taken at the top(E) and bottom (F) between the piston ringand piston ring groove.

Total clearance = E + F.

5. Uppermost piston ring:If possible, measure the depth of the pres-sure relief grooves with a caliper.

The piston rings must be replaced if the ra-dial depth of the grooves has worn down toless than stated in Data D02-46.

Checking of piston rings and piston crown, in connection with piston overhaul:

6. Remove the piston from the cylinder andplace it on the piston support. See Procedure 902-1.2.

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.

4.

HM

902-

1.1

246

15

D02-18

D02-19

GN9

02-1

.2 2

04 08

5. Min. 1 mmD02-46

6.

MN

902-

1.22

42 0

8

D02-20


Piston 902-1.1Checking

7. Before dismantling the piston rings, meas-ure the free ring gap of all the piston rings.

8. Take off the piston rings by means of thering expander.

Clean and inspect the rings.

9. Measure the radial width of the rings. Notedown the resultsSee Volume I, Operation, Chapter 707.

7.

NA9

02-1

.1 2

12 07

D02-15D02-16D02-17

Top

8.M

B902

-2.

2 11

4 01

9.

GN9

02-1

.1

204

08

Worn

NewD02-08

D02-09


Piston902-1.1Checking

10. Clean the ring grooves and check them forburn marks or other deformation.

Measure the ring grooves with a calipergauge, see Data D02-10 and D02-11.

Clearance in piston ring grooves:The maximum vertical height in a worn ringgroove must not exceed the value stated inData.

The groove is also worn out if there is nochromium layer.

11. Clean the piston crown and check the burn-away by means of the template. For maximum permissible burn-away value,see Data.

Check the burn-away on the whole circum-ference of the piston crown. Note down theresults for later reference.

12. Fit the new piston rings (alternately right-hand and left-hand cuts, with the ring gapsstaggered 180 and with the TOP mark up-wards), using the ring expander.

When mounting the piston rings, use thering expander to prevent unintended defor-mation of the rings.

Do not expand the rings more than neces-sary. The uppermost ring (CPR-ring) shouldnot be expanded more than to the milledmark on the ring expander.

10.

KM90

2-3.

0 47

05

Max 2 mm

Max 2 mm

D02-10D02-11

11.

NA9

02-1

.1

263

11

D02-12

12.

GN9

02-1

.1 2

22 1

4


Piston 902-1.2Dismantling

902-1.2Dismantling

1. Turn the crosshead down far enough to giveaccess to the piston rod stuffing box andthe piston rod nuts.

2. Release the stuffing box by removing theinnermost screws from the stuffing boxflange.

3. Place the spacer rings on the piston rodnuts and screw the hydraulic jacks on to thestuds.

Loosen the nuts. For operation of the hydraulic jacks, seeProcedure 913-1.

Note!

Do NOT remove the outermost screws from the flange.

1.

MN

902-

1.2

235

012.

GN9

02-1

.2 20

4 02

3.

MN

902-

1.2

218

03

D13-02


Piston902-1.2Dismantling

4. Mount the two distance pieces on the pistonrod foot to protect the lower scraper ringand to guide the stuffing box.

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

6. Make a scratch mark in liner and pistoncleaning ring to ensure the correct mount-ing.

Remove the piston cleaning ring.

Carefully remove any wear ridges at the topof the cylinder liner.See Procedure 903-1.3.

4.

NA9

02-1

.2 2

12 0

4

6.

KB90

2-1.

2 22

5 09



7. Turn the piston to TDC.

The top of the piston is now free of the cyl-inder liner.

If the engine is equipped with long distancepieces for the stuffing box, the piston rodfoot can pass between two cylinder coverstuds.

If necessary, remove one or two cylindercover studs, using a stud setter.

Clean the lifting groove of the piston crownand mount the lifting tool.

8. Place the two halves of the support aroundone of the openings in the platform.

Lift the piston out of the cylinder and lowerthe piston rod foot and stuffing box throughthe opening in the platform.

Place the two halves of the support aroundthe piston rod and secure the two halveswith screws.

9. Place a cover over the opening for the pis-ton rod stuffing box in the bottom of the cyl-inder unit.

Clean, measure and recondition the cylin-der liner.See Procedure 903-1.

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.

7.

HN

902-

1.2

241.

07

D02-25D02-20

8.H

N90

2-1.

2 24

2 08

D02-20

9.

NA9

02-1

.2 21

2 09


Piston902-1.2Dismantling

10. Turn the crosshead down far enough to per-mit mounting of the protective rubber coveron the crosshead bearing cap.

The protective rubber cover should remainin place to protect the crosshead bearingjournal from impurities until the piston is re-mounted.

Low lifting height

11. Turn the piston to TDC.

Remove the clamp from the tilting tool andplace it on the supporting tools by means ofthe engine room crane and crossbar.

Remove the crossbar.

10.

NA9

02-1

.2 2

17 1

0

11.

MN

902-

1.2

235

11



12. Mount the lifting tool for piston.

Lift the piston high enough to give amplespace above the tilting tool.

Mount the tilting tool around the piston rodand lower the piston so that the distancepieces of the tilting tool are in contact withthe piston.

Fasten the clamp to the tilting tool.

13. Remove the upper piston lifting tool, and at-tach the wire ropes from the tilting tool tothe crossbar.

Lift the piston to the maximum crane height.Run the crane athwartship and, at the sametime, tilt the piston

Keep the piston rod clear of the cylinder lin-er and studs while carrying out the tilting.

When space conditions permit, straightenup the piston and lead it over to the cut-outin the platform for overhauling the piston.

When the piston is at a suitable heightabove the platform cut-out, position the pis-ton support around the piston rod andclamp.

Now lower the piston while guiding the sup-port to the platform cut-out.

After landing the piston and ensuring that itrests correctly on the support, remove thetilting tool.

Note!

On engines with extremely low lifting height, use the engine room double-jib crane instead of the transverse piece.

12.

HN

902-

1.2

242

12

D02-20D02-25

13.

MN

902-

1.2

235

13


Piston902-1.3Overhaul

902-1.3Overhaul

1. Ease the piston down so that the stuffingbox is below the floor.

2. Assemble the two halves of the piston sup-port around the piston rod.

Remove the piston rings. See Procedure 902-1.1.

3. Dismount the hydraulic nuts between therod and the piston crown. See Data.

1.

HN

902-

1.3

242

01

D02-20

2.

HN

902-

1.3

242

02

3.

MB9

02-4

.2 11

7 01

D13-02


Piston 902-1.3Overhaul

4. Screw the support screws up to contactwith the piston skirt.

Dismount the locking wires and the screwsof the piston skirt.

Land the piston skirt on the piston support.

5. Lift away the piston crown.Lift away the piston skirt.

Thoroughly check the cooling spaces of thepiston crown for coke deposits. Any cokedeposits found must be removed, see step12.

6. Dismount the screws of the cooling oil pipeflange.

Mount the eye bolts and lift out the coolingoil pipe.

Clean and inspect, then re-mount the cool-ing oil pipe.

4.

KB90

2-1.

3 23

3 03

D02-21D02-23

6.

JM90

2-4.

2 89

02

D02-24

D02-06



Alternatively, the piston can be dismantledin the following way:

7. With the piston standing in the piston sup-port tool, remove the piston rod stuffingbox. See Procedure 902-2.3.

8. Lift the piston with the normal lifting tool.

Lower the piston rod foot until it is close tothe platform. Land the foot on a woodenblock.

9. Lower the piston crown to the platform andland it on a wooden block in such a way thatit is possible to remove the lifting tool.

10. Mount an eyebolt in the side of the liftingtool, hook on the crane and remove the lift-ing tool from the piston crown.

Attach the lifting bracket to the bottom ofthe piston rod foot. Hook the crane on to thelifting bracket.

Note!

During the lift, follow with the crane to keep the crane positioned vertically above the piston crown.

7.

HN

902-

1.3

242

07

8.

HM

902-

1.3

242

08

10.

HN

902-

1.3

242

10



11. Lift the piston rod foot clear of the woodenblock.

Keep lifting until the piston rod is in a verti-cal position.

12. Place the piston in an upright position withthe piston crown resting on wooden planks.

Dismount the hydraulic nuts. Lift the pistonrod away and land it in a horizontal positionon a couple of wooden planks.

13. Remove the locking wire and the screws inthe skirt and mount two eye bolts in theholes intended for dismantling screws. Liftthe skirt and land it on a couple of planks.

Note!

During the lift, follow with the crane to keep the crane positioned vertically above the piston rod foot.

11.

HN

902-

1.3

240

0912.

HN

902-

1.3

242

12

D13-02

D02-22

13.

MB9

02-1

.3 2

50 1

3

D02-23



14. Thoroughly clean and inspect all parts ofthe piston.

If coke deposits are found in the coolingspaces of the piston crown, the pistoncrown cooling spaces should be washedout with Carbon Remover or a similarcleaning fluid. When all coke deposits havebeen dissolved, clean and inspect the pis-ton crown again.Regarding check of the piston crown, seeProcedure 902-1.1.

Replace all sealing rings on the piston. Allthe new sealing rings must be coated withlubricating oil before the piston is assem-bled.

Coat all screws with Molybdenum Disul-phide (MoS2).

Assemble the piston in the reverse order todisassembly.

If the piston crown is renewed, the pistoncrown studs must be tightened to torqueD02-04.

Tighten all the hydraulic nuts to the tighten-ing pressure stated in Data. For correct tightening sequence, see thesketch.

15. Lock the screws with locking wire.

Mount the locking wire in such a way thatthe wire is tightened if one of the screwsworks loose. See Procedure 913-7.

14.

HN

902-

1.3

242

14

D02-05

D02-04D13-01

15.

HM

902-

4.2

52 07



16. Fill the piston and piston rod with lubricat-ing oil.

Mount the pressure-testing tool around thebase of the piston rod.

Pressure-test the piston at the pressurestated on the data sheet.

Check the contact surfaces of the pistonand the sealing rings for tightness.

Check that there are no cracks in the pistoncrown.

17. Drain the piston of oil.

Place the piston in the piston support tooland mount the piston rod stuffing box.See Procedure 902-2.3.

Oil

16.

MB9

02-4

.0 9

6 14

D02-01


Piston902-1.4Mounting

902-1.4Mounting

1. Check the piston rings and piston crown inaccordance with Procedure 902-1.1.

2. Mount the lifting tool on the piston crown.

3. Ensure that the stuffing box is correctly po-sitioned over the guide pins in the distancepieces mounted on the piston rod foot.

2.

MB9

02-4

.1 1

17 02

D02-25

D02-20

3.

NA9

02-1

.4 2

63 0

3


Piston 902-1.4Mounting

4. Coat the O-rings of the stuffing box with oil.Remove the cover from the piston rod stuff-ing box opening in the bottom of the cylin-der unit. Clean the stuffing box flange.

Remove the protective rubber cover fromthe crosshead.

5. Turn the crosshead to a position 45 fromTDC.

6. Coat the piston rings, piston rod and cylin-der liner with lubricating oil.

Coat the O-rings of the stuffing box with oil.

Mount the guide ring for piston rings on thecylinder liner.

Lower the piston into the cylinder liner while guiding the piston rod foot through thecut-out in the stuffing box flange until thepiston rings are inside the liner.

4.

MB9

02-1

.4 2

52 0

4

45

5.N

A902

-1.4

212

05

6.

HN

902-

1.4

241

06

D02-20



7. Turn the crosshead almost to TDC.

If necessary:

Place a 2 wooden plank on the cross-head face, taking care not to cover theguide ring. The plank must be dimen-sioned so that it is higher than the pis-ton foot studs.

Turn the crosshead upwards until thepiston rod foot lands on the plank,thereby turning the crosshead until theface is parallel to the piston rod foot.

Lower the crosshead just enough to en-able the plank to be removed.

Turn the crosshead upwards until the pistonrod lands on the crosshead. When mount-ing the piston on the crosshead, make surethat the piston rod foot does not damagethe threads of the studs. Ensure that theguide ring in the crosshead fits correctly inthe centre hole of the piston rod.

Unscrew the adjustable claw of the liftingtool and pull the lifting tool free of the liftinggroove in the piston

Remove the lifting tool and the guide ringfor piston rings.

8. Turn down and land the stuffing box on thestuffing box flange. Check that the holes inthe stuffing box and stuffing box flange arecorrectly centered.

Remove the distance pieces from the pistonrod foot.

9. Mount and tighten the piston rod nuts, us-ing the hydraulic jacks. See Data.

For operation of the hydraulic jacks, seeProcedure 913-1.

7.

MN

902-

1.4

260

08

8.

KB90

2-1.

4 22

5 09

9.

MN

902-

1.2

218

03

D13-01


Piston 902-1.4Mounting

10. Tighten down the piston rod stuffing box bymeans of the screws, through the innerholes in the stuffing box flange

11. Mount the piston cleaning ring according tothe scratch mark.

If the PC-ring is damaged (broken orcracked), it must be replaced by anotherring. See Procedure 903-1.

12. If the cylinder cover studs have been re-moved, remount them.

Carefully clean the surfaces around thebase of the studs and check the O-rings onthe studs.

Mount the cylinder cover studs with the studsetter. Screw the stud down to contact andhalf a revolution back.

10.

Gn9

02-1

.2 2

04 02

D02-27

11.H

N90

2-1.

4 23

7 13

12.

HM

902-

1.4

262

14



13. Land the cylinder cover on the liner andcheck the distance the stud is protrudingfrom the cylinder cover.

If necessary, adjust the distance D01-05 byturning the stud.

14. Tighten the cylinder cover and mount thenecessary pipes.See Procedure 901-1.4.

Smear the piston rod with molybdenum di-sulphide, and turn the crankshaft a coupleof revolutions.

At the first opportunity:

Start the engine and keep it running forabout 15 minutes at a number of revolutionscorresponding to very slow.

Then stop the engine and inspect the pistonrod and stuffing box.

15.

HN

902-

1.4

256

15

D01-05

When referring to this page, please quote Data D10202 Edition 0055 Page 1 (2)MAN B&W Diesel A/S

SAFETY PRECAUTIONS

Data

102-2Piston Rod Stuffing BoxData

Special DataD10202 Edition 0055 K98MCPiston Rod Stuffing Box102-2

X Stopped engineX Block the starting mechanismX Shut off starting air supplyX Engage turning gearX Shut off cooling waterX Shut off fuel oilX Shut off lubricating oil

Lock turbocharger rotors


Data # Description UnitD02-26 Stuffing box flange, outer screws tightening torque 350 NmD02-27 Stuffing box flange, inner screws tightening torque 350 NmD02-28 Stuffing box halves, tightening torque 80 NmD02-29 Uppermost rings, ring-end clearance 4x6 mmD02-30 Lowermost rings, ring-end clearance 3x3 mmD02-33 Check length for the six uppermost springs:D02-34 F 0 = 0 N................ L 0 = 889 mmD02-35 F 1 = 153 +/ 7 N....... L 1 = 1278 mmD02-36 F 2 = 163 +/ 10 N..... L 2 = 1352 mmD02-37 Check length for the four lowermost springs:D02-38 F 0 = 0 N................ L 0 = 839 mmD02-39 F 1 = 150 +/ 7 N....... L 1 = 1217 mmD02-40 F 2 = 200 +/ 10 N..... L 2 = 1263 mmD02-44 Stuffing box complete 300 kgD02-45 Stuffing box half 105 kg

(2) When referring to this page, please quote Data D10202 Edition 0055MAN B&W Diesel A/S

Piston Rod Stuffing Box102-2Data

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.


P90251 109 Mounting tool for stuffing box springP90251 122 Worktable for stuffing boxP90451 120 Rubber cover for crosshead


Piston Rod Stuffing Box 902-2.1Checking

0225K98MCPiston Rod Stuffing Box902-2.1Checking

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. Check the length of the springs at differentloads. Adjust the loads to achieve thelengths stated in Data.

If the loads necessary are outside the limitsstated in Data, the springs must be discard-ed.

1.

NB9

02-2

.1

220

01

D02-29

D02-30

D02-29 D02-30

2.

HM

902-

5.0

70 02

D02-33

D02-37


Piston Rod Stuffing Box902-2.2Dismantling

902-2.2Dismantling

If, in the period between piston overhauls, it be-comes 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 loosened throughthe holes.

1.

NA9

02-2.

2 21

0 01

2.

NA9

02-2

.2 2

10 0

2

3.

MB9

02-5

.2

94 0

3


Piston Rod Stuffing Box 902-2.2Dismantling

4. Remove the two long dismantling screwsfrom 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.

Remove the two long dismantling screwsfrom the stuffing box and mount them in theworktable.

6. 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.

4.

MB9

02-5

.2 9

4 04

5.M

B902

-5.2

94

05

D02-44

6.

NB9

02-2.

2 22

0 06


Piston Rod Stuffing Box902-2.3Overhaul

902-2.3Overhaul

Outside the engine

Normally, overhaul of the piston rod stuffing boxis carried out by routine methods in connectionwith the dismantling (pulling) of the pistons.

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.

1. Mount two eye bolts in the stuffing boxflange, and hook on two tackles.

Lift the stuffing box a little up the piston rod,and mount the worktable round the pistonrod at a suitable working height.

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

2. Remove the O-rings of the stuffing box. Ifthe O-rings are intact and are to be usedagain, move them up the piston rod and se-cure them in this position, for example withtape.

Remove the nuts from the stuffing box as-sembling bolts.

NB9

02-2

.3 22

0 00

1.

NB9

02-2.

3 22

0 01

D02-44

2.

NB9

02-2.

3 22

0 02


Piston Rod Stuffing Box 902-2.3Overhaul

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

Mount two eye bolts on the stuffing box halfand 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 carborundum stone.In the case of coarse scratches, it mayprove necessary to machine-grind the sur-face in a workshop.

9. Clean the halves of the stuffing box hous-ing.

3.

NB9

02-2

.3 22

0 03

D02-45

8.H

C902

-5.

1 98

07


Piston Rod Stuffing Box902-2.3Overhaul

10. Lubricate the piston rod (in the area whereall the ring units in the stuffing box will bepositioned) with molybdenum disulphide(MoS2).

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 that thetwo 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 guide pinsin the lower sealing ring engage with thetwo holes in the upper sealing ring.

Finally, assemble the uppermost ring unit(consisting of a 4-part scraper ring and an8-part sealing ring).

11. 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 ring units.

10.

NB9

02-3

217

10

11.

NB9

02-2

.3

220

11


Piston Rod Stuffing Box 902-2.3Overhaul

12. Check the ring clearance again.

Then place the other half of the stuffing boxhousing on the worktable, pushing it intoplace round the rings.

Mount and tighten up the fitted bolts to thetorque specified on the Data Sheet.

Mount the O-rings in the stuffing boxgrooves.

13. Mount eye bolts and wire ropes, and lift thestuffing 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.

12.

NB9

02-2.

3 22

0 12 D02-28

13.N

B902

-2.3

220

13


Piston Rod Stuffing Box902-2.4Mounting

902-2.4Mounting

1. After overhauling, assemble the stuffingbox halves on top of the four screws.

Mount the two long screws from the workta-ble 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 the flange enter the guide holes in the bottom of the cylinder frame.

1.

NB9

02-2

.2 22

0 06

2.

MB9

02-5

.2

94 0

8

3.

MB9

02-5

.2

94 0

9


Piston Rod Stuffing Box 902-2.4Mounting

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

Remove the worktable from the piston rod.

5. 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 molybdenum di-sulphide.

Then turn the crankshaft a couple of revo-lutions.

Start up the engine and keep it running forabout fifteen minutes at a number of revo-lutions corresponding to very slow or idlespeed.

Then stop the engine and inspect the pistonrod and stuffing box.

4.

MB9

02-5

.2 9

4 10

5.N

A902

-2.4

210

05

D02-26D02-27

6.

Plate


Piston and Piston Rod Panel P90251-0264

P90251 0264

Plate


P90251-0264 Piston and Piston Rod Panel



P90251 0264

014 Panel for tools026 Name plate040 Lifting tool, piston rod foot051 Lifting tool, cylinder liner063 Screw, lifting and tilting075 Template, piston top087 Distance piece, stuffing box099 Cover, stuffing box hole109 Mounting tool, stuffing box spring110 Pressure test tool. piston122 Worktable, stuffing box134 Expander, piston ring



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




Piston and Piston Rod - TPiston and Piston Rod - TPiston and Piston Rod - TPiston and Piston Rod - TPiston and Piston Rod - Toolsoolsoolsoolsools




P90261 0102

019 Guide ring for piston

Plate


Piston and Piston Rod - Hydraulic Tools P90262-0027

P90262 0027

Plate


P90262-0027 Piston and Piston Rod - Hydraulic Tools



P90262 0027

026 Hydraulic jack, complete038 Support040 Support051 O-ring with back-up ring063 O-ring with back-up ring087 Tommy bar099 Spanner109 Stud setter205 Hydraulic tool set, complete



MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN B&W DieselMAN B&W DieselPiston and Piston Rod - Tilting TPiston and Piston Rod - Tilting TPiston and Piston Rod - Tilting TPiston and Piston Rod - Tilting TPiston and Piston Rod - Tilting Toolsoolsoolsoolsools

P90264-0009P90264-0009P90264-0009P90264-0009P90264-0009

P90264 0009




Piston and Piston Rod - Tilting TPiston and Piston Rod - Tilting TPiston and Piston Rod - Tilting TPiston and Piston Rod - Tilting TPiston and Piston Rod - Tilting Toolsoolsoolsoolsools




P90264 0009

015 Collar ring for piston027 Support for tilting tool

Plate


Piston and Piston Rod - Support Tools P90265-0003

P90265 0003

Plate


P90265-0003 Piston and Piston Rod - Support Tools



P90265 0003

010 Support iron for piston



MAN B&W DieselMAN B&W DieselMAN B&W DieselMAN B&W DieselMAN B&W DieselPiston - Lifting TPiston - Lifting TPiston - Lifting TPiston - Lifting TPiston - Lifting Toolsoolsoolsoolsools

P90266-0003P90266-0003P90266-0003P90266-0003P90266-0003

P90266 0003




Piston - Lifting TPiston - Lifting TPiston - Lifting TPiston - Lifting TPiston - Lifting Toolsoolsoolsoolsools




P90266 0003

016 Lifting tool, piston

MAN Diesel A/S

903 - Cylinder Liner and Cylinder Lubrication


103-01 0070 Cylinder Liner, Data903-01 0255 Cylinder Liner103-02 0029 Cylinder Lubricator, Data903-02 0250 Cylinder Lubricator90361 0083 Cylinder Liner - Tools90362 0006 Cylinder Liner - Milling Tools90363 0001 Cylinder Liner - Honing Tools90365 0001 Equipment For Special90366 0008 Cylinder Liner - Lifting Tools

MAN Diesel A/S

(2)

SAFETY PRECAUTIONS

Data

D01-10 Cylinder cover stud 205 kgD03-02 Lifting tool bolts, screwing-in torque 200 NmD03-03 Cylinder diameter, new 980 mmD03-04 Piston cleaning ring diameter, new 977.8 mmD03-05 Cylinder liner, complete 9000 kgD03-06 Cooling jacket 335 kgD03-16 Piston cleaning ring radial width, new 21.1 mmD03-17 PC-ring/Liner max. wear deviation 0.98 mmD03-18 PC-rings replacement criteria:

Cylinder LinerData

103-1

When referring to this page, please quote Data D10301 Edition 0070MAN 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 lubriating oil pumpsEngage turning gearShut off cooling waterShut off fuel oilStop lubricating oil supplyLock the turbocharger rotors


Liner diameter: 980 mmLiner wear: Install:

Standard PC-ring0 0.98 mm (new max. diameter wear of 0.98 mm0.98 1.96 mm Oversize PC-ring

> 1.96 mm No PC-ring

(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.

Cylinder LinerData

103-1

When referring to this page, please quote Data D10301 Edition 0070MAN B&W Diesel A/S

P90251 51 Lifting tool for cylinder linerP90361 Measuring tool for cylinder linerP90362 Cylinder Liner - Extra ToolP90366 Cylinder Liner - Lifting Tools



Cylinder Liner 903-1.1Checking

0255K98MC-CCylinder Liner903-1.1Checking

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 on themeasuring tool.

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

Check and assess the condition of the cyl-inder liner according to the description giv-en 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.

2.

MN

903-

1.1

209

02

D03-03

4.

NB9

03-1.

1 23

9 04


Cylinder Liner903-1.1Checking

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 the lin-er, 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 two com-ponents does not deviate more than D03-17 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 new lineris ordered, also a new PC-ring must be or-dered.

6.

MB9

03-1

.1 2

38 0

6

B


Cylinder Liner 903-1.2Dismantling

903-1.2Dismantling

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 cylinderliner. Check with a feeler gauge that thereis no clearance between lifting tool and cyl-inder liner. For tightening torque, see Data.

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

Depending on pipe layout, disconnect thepipes directly at the non-return valves or atthe distributor block mounted on the liner.

2.

NA9

03-1.

2 25

4 02

D03-02

3.

JM90

3-1.

2 25

1 03

(12) When referring to th