Main Engine MAN B&W K 80 MC-C

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



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



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



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



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)


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.


Checking and Maintenance Schedule, 80-108 MC/MC-C Engines900-1






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







-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


Checking and Maintenance Schedule, 80-108 MC/MC-C Engines900-1






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

(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


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

(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

(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


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.


Cylinder Cover


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


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.


Cylinder Cover


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


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


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


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.


Cylinder Cover


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


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


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.



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


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.



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


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


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



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 B&W Diesel A/S

902 - Piston with Rod & Stuffing Box


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

(2)

SAFETY PRECAUTIONS

Data

PistonData

102-1

When referring to this page, please quote Data D10201 Edition 0090MAN 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 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

(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


(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


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.

(23)

902-1.1


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


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.

(23)

902-1.2


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


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.

(23)

902-1.2



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



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.

(23)

902-1.2



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



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.

(23)

902-1.2



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


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.

(23)

902-1.3


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


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

(23)

902-1.3



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



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.

(23)

902-1.3



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


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

(23)

902-1.4


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


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.

(23)

902-1.4



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


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.

(23)

902-1.4



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.

(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


X




XXXXXXXXXX

(2)

MAN B&W Diesel


Piston Rod Stuffing BoxData

102-2


P90251 109 Mounting tool for stuffing box springP90251 122 Worktable for stuffing box

P90451 120 Rubber cover for crosshead


(10)

902-2.1


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



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.

(10)

902-2.2


MAN B&W Diesel DismantlingPiston Rod Stuffing Box

M90

202

0230

D05

M90

202

0230

D04

M90

202

0229

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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.


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902-2.3



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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.

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(10)

902-2.3


MAN B&W Diesel OverhaulPiston Rod Stuffing Box

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O08

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O03

D0245

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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.


Page 6 (10)

902-2.3



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202

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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.

(10)

902-2.3


MAN B&W Diesel OverhaulPiston Rod Stuffing Box

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O12

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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.


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902-2.3



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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.

(10)

902-2.4


MAN B&W Diesel MountingPiston Rod Stuffing Box

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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.


Page 10 (10)

902-2.4


MAN B&W DieselMountinglM

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D0226D0227

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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.

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Plate


Piston and Piston Rod Panel P90251-0258

P90251 0258

Plate


P90251-0258 Piston and Piston Rod Panel



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



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

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

(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


Plate


Piston and Piston Rod - Support Tools P90265-0001

P90265 0001

Plate


P90265-0001 Piston and Piston Rod - Support Tools



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

(2) When referring to this page, please quote Plate P90266 Edition 0001MAN B&W Diesel A/S

Piston - Lifting ToolsPlateP90266-0001


016 Lifting tool for piston


MAN B&W Diesel A/S

903 - Cylinder Liner and Cylinder Lubrication


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

(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


X




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

(2)

MAN B&W Diesel


Cylinder LinerData

103-1


P90251 051 Lifting tool for cylinder liner

P90361 Measuring tool for cylinder linerP90366 Cylinder Liner - Lifting Tools


(11)

903-1.1


MAN B&W Diesel CheckingCylinder Liner

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C04

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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


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.

M90

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0259

C06 B

5.


Cylinder Liner


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.

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D02

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0259

D03

1.

3.

Cylinder Liner903-1.2MAN B&W DieselDismantling


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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.

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6.


Cylinder Liner


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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

301

0259

O01

1.

2.

Cylinder Liner903-1.3MAN B&W DieselOverhaul


M90

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0259

O03

3. Lower the cooling jacket by means of thetackles and the crane, and land it on thewooden planks.

Check tha

Main Engine MAN B&W K 80 MC-C

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