6s 50 mc-c, vol. ii - maintenance manual

7/13/2019 6S 50 MC-C, Vol. II - Maintenance Manual

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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 Filesand 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 thediesel 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.


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S50MC-CDS 09091718 VOLUME IIMAINTENANCE


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MAN B&W Diesel A/S

900 - Introduction

Documents in this Chapter

Table of Contents, Volume II

90023 0027 Instructions for Main Engine

90060 0001 General - Safety Precautions


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MAN B&W Diesel A/S


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Table of Contents 900

Volume II - Maintenance

Page 1 (5)MAN B&W Diesel A/S

No. Edition Title

900 - IntroductionTable of Contents

90023 0027 Instructions for Main Engine90060 0001 General - Safety Precautions

901 - Cylinder Cover101-01 0041 Cylinder Cover, Data901-01 0250 Cylinder Cover90151 0199 Cylinder Cover - Panel90161 0105 Cylinder Cover - Tools

902 - Piston with Rod & Stuffing Box102-01 0065 Piston, Data902-01 0270 Piston102-02 0048 Piston Rod Stuffing Box, Data902-02 0221 Piston Rod Stuffing Box90251 0237 Piston and Piston Rod - Panel90261 0108 Piston and Piston Rod - Tools90264 0002 Piston and Piston Rod - Tilting Tools90265 0001 Piston and Piston Rod - Support Tools90266 0002 Piston - Lifting Tools

903 - Cylinder Liner and Cylinder Lubrication103-01 0056 Cylinder Liner, Data903-01 0253 Cylinder Liner103-02 0031 Cylinder Lubricator, Data903-02 0253 Cylinder Lubricator90361 0084 Cylinder Liner - Tools90362 0002 Cylinder Liner - Milling Tools90364 0004 Test Equipment for Lubricators90366 0007 Cylinder Liner - Lifting Tools

904 - Crosshead with Connecting Rod104-01 0048 Crosshead Bearing, Data904-01 0239 Crosshead Bearing104-02 0050 Crosshead, Data904-02 0239 Crosshead104-03 0034 Reciprocating Parts, Data904-03 0217 Reciprocating Parts104-04 0042 Crankpin Bearing, Data904-04 0226 Crankpin Bearing104-05 0043 Connecting Rod, Data904-05 0231 Connection Rod90451 0151 Connecting Rod and Crosshead - Panel90461 0069 Connecting Rod - Hydraulic Tools


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No. Edition Title

90462 0020 Connecting Rod - Tools

905 - Crankshaft, Thrust Bearing and Turning Gear105-01 0004 Crankshaft Deflection, Data905-01 0209 Crankshaft Deflection105-02 0044 Main Bearing, Data905-02 0241 Main Bearing105-03 0039 Thrust Bearing, Data905-03 0224 Thrust Bearing105-04 0003 Journal Bearing, Data905-04 0212 Journal Bearing

105-05 0033 Axial Vibration Damper, Data905-05 0224 Axial Vibration Damper105-08 0007 Angle Encoder, Data905-08 0204 Angle Encoder90551 0227 Crankshaft, Thrust Shaft, Main Bearing, etc. - Panel90561 0093 Main Bearing - Hydraulic Tools90562 0125 Crankshaft - Tools90564 0018 Crankshaft - Measuring Tools90570 0004 Thrust Shaft - Tools90572 0003 Main Bearing - Measuring Tools

90573 0002 Tuning Wheel - Tools

906 - Control Gear106-01 0041 Chain, Data906-01 0236 Chain106-02 0054 Chain Tightener, Data906-02 0239 Chain Tightener106-03 0036 Camshaft, Data906-03 0214 Camshaft106-04 0034 Camshaft Bearings, Data906-04 0216 Camshaft Bearings

106-05 0024 Moment Compensator, Data906-05 0220 Moment Compensator106-06 0007 Replacement of Cams on Camshaft, Data906-06 0203 Replacement of Cams on Camshaft90651 0173 Chain Drive and Camshaft - Panel90662 0046 Camshaft - Hydraulic Tools90664 0005 Crankshaft - Pin Gauge90668 0003 Camshaft - Pin Gauge

907 - Starting Air System107-01 0017 Starting Air Distributor, Data907-01 0216 Starting Air Distributor107-02 0032 Start Air Valve, Data


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No. Edition Title

907-02 0214 Starting Air Valve

908 - Exhaust Valve108-01 0017 High-Pressure Pipe, Data908-01 0212 High-Pressure Pipe108-02 0087 Exhaust Valve, Data908-02 0256 Exhaust Valve108-03 0017 Exhaust Valve Actuator, Data908-03 0218 Exhaust Valve Actuator108-04 0015 Exhaust Valve Roller Guide, Data908-04 0210 Exaust Valve Roller Guide

108-05 0002 Exhaust Valve Cam, Data908-05 0203 Exhaust Valve Cam108-07 0020 Exhaust Valve - Special Running, Data908-07 0210 Exhaust Valve90851 0200 Exhaust Valve - Panel90862 0043 Exhaust Valve - Hydraulic Tools90863 0014 Exhaust Valve - Extra Tools90863 0016 Exhaust Valve - Extra Tools

909 - Fuel Oil System

109-01 0055 Fuel Pump Lead, Data909-01 0240 Fuel Pump Lead109-02 0004 VIT System, Data909-02 0205 VIT System109-03 0044 Fuel Pump Cam, Data909-03 0229 Fuel Pump Cam109-04 0050 Fuel Pump, Data909-04 0224 Fuel Pump109-05 0052 Fuel Pump Top Cover, Data909-05 0223 Fuel Pump Top Cover109-06 0042 Fuel Pump Barrel Assembly, Data

909-06 0219 Fuel Pump Barrel Assembly109-07 0034 Fuel Pump Suction Valve, Data909-07 0214 Fuel Pump Suction Valve109-08 0043 Fuel Pump Puncture Valve, Data909-08 0217 Fuel Pump Puncture Valve109-09 0025 Fuel Pump Shock Absorber, Data909-09 0214 Fuel System Shock Absorber10911 0047 Fuel Valve, Data90911 0231 Fuel Valve10912 0038 Spindle Guide, Data90912 0222 Spindle Guide10913 0031 Non-Return Valve for Fuel Valve, Data90913 0206 Non-Return Valve for Fuel Valve


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No. Edition Title

10914 0060 Fuel Oil High-Pressure Pipes, Data90914 0235 Fuel Oil High-Pressure Pipes10915 0050 Fuel Pump Roller Guide, Data90915 0226 Fuel Pump Roller Guide10916 0016 Fuel Pump Spec. Running90916 0204 Fuel Pump Special Running90951 0462 Fuel Valve and Fuel Pump - Panel90961 0069 Fuel Valve - Tools90966 0008 Fuel Valve Nozzle - Tools90968 0001 Fuel Valve - Inspection Tools90974 0001 Fuel Valve Nozzle - Cleaning Tools

90977 0001 Mounting Tools - Pump Barrel Seals90979 0001 Mounting Tools - Suction Valve Seals90980 0001 Mounting Tools - Air Piston Seals

910 - Turbocharger System110-01 0032 Air Cooler Element, Data910-01 0229 Air Cooler Element110-02 0009 Non-Return Valve in Turbocharger, Data910-02 0205 Non Return Valve in Tubocharger910-03 0218 Auxilary Blower

110-03 0019 Auxilary Blower, Data110-04 0005 Butterfly Valve, Data910-04 0208 Butterfly Valves110-05 0005 Turbocharger Turbine, Data910-05 0206 Turbocharger Turbine110-06 0018 Water Mist Catcher, Data910-06 0214 Water Mist Catcher91061 0071 Turbocharger System - Tools91063 0017 Air Cooler - Tools91063 0019 Air Cooler - Tools91064 0002 Travelling Trolley

91066 0001 Air Cooler - Lifting Tools

911 - Safety Equipment111-01 0025 Safety Valve, Data911-01 0211 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 0007 Holding Down and End Chock Bolts (Epoxy), Data912-02 0207 Holding Down and End Chock Bolts (Epoxy)


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No. Edition Title

112-03 0015 Stay Bolts, Data912-03 0210 Stay Bolts912-05 0201 Crankcase Oil Outlet91261 0073 Hydraulic Tools for Large Parts91265 0003 Hydraulic Tools - Holding-Down Bolts (Epoxy Chocks)91268 0001 Hydraulic Tools - End Chock Bolts (Iron Chocks)

913 - General Tools913-01 0215 Hydraulic Tools913-04 0201 Standard Tightening Torques913-05 0205 Torque Spanner

913-06 0205 Tightening Gauge913-07 0207 Screws and Nuts91311 0204 Lubricating91351 0037 Accessories - Hydraulic Tools91356 0058 Lifting Tools, etc.91357 0005 Open-Ended Spanners91358 0013 Open Ended Slugging Spanners91359 0003 Torque Spanners91360 0003 Pliers91361 0052 Combination Spanners

91362 0064 Ring Slugging Spanners91363 0040 Spanners91364 0059 Open-Ended Spanners91366 0066 Instruments91368 0004 Working Platforms


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Instructions for Main Engines

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

Vol. I OPERATION

Vol. II MAINTENANCEVol. III COMPONENTS, DESCRIPTIONS

The purpose of these books is to provide general guidance on operation and maintenance andto describe the constructional features of a standard version of an MAN B&W main diesel en-gine. Deviations may be found in a specific plant. In addition, the books can be used for ref-erence 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 ensurethe supply of the correct parts for the individual engines:

1. Name of vessel2. Engine No. built by3. Plate No.4. Part No.5. Quantity required (and description)

Example: M/S Nybo 7730 B&W P90201-0036 05910 off (piston ring)

)The Plate No. may consist of either of these two sets of digits, as the pages arein the process of being updated with new numbers: P90201-0036 or 90201-036.

To ensure optimum efficiency, reliability and lifetime of the engine and its components, onlyoriginal 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 thedata sheets inserted in the respective books.

Reliable and economical operation of the diesel engines is conditional upon its correct oper-ation and maintenance in accordance with MAN B&W Diesel A/S instructions. Emissions re-lated maintenance of the diesel engine shall be performed as specified in MAN B&W DieselA/S instructions and any additional instructions to that effect included in the Technical File.

Consequently, it is essential that the engine room personnel are fully acquainted with the con-tents of this book and, in respect of instructions on emissions related maintenance of the die-sel 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, becopied, reproduced, made public or in any other way made available to a third party withoutthe written consent of this effect from MAN B&W Diesel A/S.

MAN B&W Diesel A/STeglholmsgade 41 Teleph.:+45 33 85 11 00DK-2450 Copenhagen Telex :16592 manbw dkDenmark Telefax:+45 33 85 10 30

CVR No. 39 66 13 14A90023-002

7


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Page 1 (1)

SAFETY PRECAUTIONS

General Safety Precautions 900-2

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

X

X

X

X

X

X

X

X

X

X

X

X

Stopped engineShut off starting air supply At starting air receiver

Block the main starting valve

Shut off starting air distributor/distributing system supply

Shut off safety air supply Not ME-engines

Shut off control air supply

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

Engage turning gear

Shut off cooling water

Shut off fuel oilStop lubricating oil supply

Lock 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:


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MAN B&W Diesel A/S

901 - Cylinder Cover


101-01 0041 Cylinder Cover, Data

901-01 0250 Cylinder Cover

90151 0199 Cylinder Cover - Panel

90161 0105 Cylinder Cover - Tools


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MAN B&W Diesel A/S


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When referring to this page, please quote Data D10101 Edition 0041 Page 1 (2)MAN B&W Diesel A/S

SAFETY PRECAUTIONS

Data

101-1Cylinder Cover

Data

Special DataD10101 Edition0041 S50ME-CCylinder Cover101-1

X Stopped engine

X Block the starting mechanism

X Shut off starting air supply

X Engage turning gear

X Shut off cooling water

X Shut off fuel oil

X Shut off lubricating oil

Lock turbocharger rotors

Ref. Description Value Unit

D01-01 Exhaust valve stud, screwing-in torque 680 Nm

D01-02 Starting valve stud, screwing-in torque 150 Nm

D01-03 Fuel valve stud, screwing-in torque 40 Nm

D01-04 Cylinder cover stud, screwing-in torque 500 Nm

D01-05 Cylinder cover stud, check distance 128 - 129 mm

D01-06 Cylinder cover, complete 1700 kg

D01-07 Cylinder cover without valves 1200 kg

D01-08 Cooling jacket 40 kg

D01-09 Exhaust valve stud 8 kgD01-10 Cylinder cover stud 22 kg

D13-01 Hydraulic pressure, mounting 1500 bar

D13-02 Hydraulic pressure, dismantling 1400 -1650 bar


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Page 2 (2) When referring to this page, please quote Data D10101 Edition 0041MAN B&W Diesel A/S

Cylinder Cover101-1

Data

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the

chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.

Plate Item No. Description

P90151 46 Grinding tool for exhaust valve seat

P90151 58 Milling and grinding wheel for fuel valve seat

P90151 60 Milling and grinding wheel for starting valve seat

P90151 83 Grinding handle

P90151 130 Lifting chains

P90161 Cylinder cover tightening tool

P91351 10 Hydraulic pump, pneumatically operated

P91351 34 Hose with unions (1000 mm), complete

P91351 58 Hose with unions (3000 mm), complete

P91351 130 9-way distributor block, complete


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901-1.2

MAN B&W Diesel Dismantling

Cylinder Cover

Page 1 (12)When referring to this page, please quote Procedure M90101 Edition 0250

M901010

250D01

E

C

AD

F

G

B

2.

1.1. Set blocking deviceA on the main startingvalve in the blocked position.

Engage turning gear B.

Close fuel oil inlet valve C.

Close cooling water inlet valve B.

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 minimesspoint 455.

Check the pressure.

Close valve 420 and open valve 421 on the

hydraulic block.

Check that the system is pressure free.


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Cylinder Cover901-1.2

MAN B&W DieselDismantling

Page 2 (12) When referring to this page, please quote Procedure M90101 Edition 0250

3. Close valve 531 for hydraulic operation of

the exhaust valve.

4. Remove the cooling water inlet and outlet

pipes from the exhaust valve and cylinder

cover.

Remove the drain pipe from the intermedi-ate pipe between the cylinder cover and

the exhaust valve.

Remove the oil supply pipe for the hydrau-

lic damper in the exhaust valve.

Dismount the fuel oil high-pressure pipes

between fuel valves and fuel pump.See Procedure 909-14.2.

Dismount the control air pipe from the

starting valve.

Remove the starting air pipe.

Disconnect the plug for the electrical ex-haust valve sensor.

5. Remove the exhaust valve high-pressure

pipe.

See Procedure 908-1.2.

Dismount the drain oil pipe from the ex-haust valve oil cylinder and air cylinder, the

air pipe for pneumatic closing of the ex-haust valve, and the pipes for the sealingair arrangement.

M

901010

250D03

M901010

248D04

M901010

248D05

3.

4.

5.


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901-1.2

MAN B&W Diesel Dismantling

Cylinder Cover


M901010

248D11

M901010

250D07

M

901010

248D06

6. Remove the protective jacket enclosing the

intermediate pipe between the exhaust re-ceiver and the exhaust valve.

Dismount the screws in the flange between

the intermediate pipe and the exhaust re-ceiver. The four lowermost screws need notbe dismantled, just loosened.

Remove the protective caps from the cylin-

der cover nuts.

7. Place eight spacer rings, one around eachnut, and screw the eight hydraulic jacks

onto the studs.

Connect the high-pressure pump to the

jacks by means of the distributor block andthe high-pressure hoses.

Using the vent screws of the hydraulicjacks, vent the system and increase the

pressure as stated in Data.

For operation of the hydraulic tools, see

Procedure 913-1.

Loosen the nuts by applying the tommy

bar through the slots in the spacer rings.

Relieve the system of pressure.

Disconnect the high-pressure hoses fromthe jacks.

Remove the hydraulic jacks and spacerrings, and unscrew the nuts.

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

Lift away the cylinder cover complete, andland it on a couple of wooden planks.

6.

7.

8.


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9. Remove and discard the sealing ring be-

tween cylinder cover and cylinder liner.

M

901010

248D12

9.


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901-1.3

MAN B&W Diesel Overhaul

Cylinder Cover


M

901010

248O01

D0109

1. Dismount all valves and pipes on the cylin-

der cover.See Procedure 907-2.2, 908-2.2 and 909-11.2.

Dismount all studs on top of the cylindercover.

2. 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 O-rings from the

cover, and carefully clean the cooling jacketand the cylinder cover.

3. Provide the cylinder cover with new O-

rings, well lubricated with oil.

4. Lift the cylinder cover and guide the jacket/cover into position, using the guide pin as

a reference (camshaft side).

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

M901010

248O02

D0107

D0108

M901010

248O03

1.

2.

3.

4.


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MAN B&W DieselOverhaul


5. Recondition the valve bores as follows:

Fuel valve bore

6. The tool consists of a common spindle with

handle, a guide, a carbon cutter, a seatingface 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 mandreland a grinding compound (e.g. Carborun-

dum No. 200).

After the milling/grinding, clean the bore

and seating carefully, and check that theseating is not damaged.

Exhaust valve bore

7. The tool consists of a spindle with handleand 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.

M

901010

246O04

M901010

246O06

M901010

248O07

5.

6.

7.


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901-1.3

MAN B&W Diesel Overhaul

Cylinder Cover


Starting valve bore

8. The tool consists of a guide, a cutter, and

a grinding disc.

Recondition the starting valve bore andseating in the same way as described for

the fuel valve bore.

When replacing valves on a cylinder cover

that is mounted on the engine, reconditionthe valve bores/seating in the same way as

described here, but without dismountingthe studs.

9. Clean the bores for safety valve/indicatorcock.

M901010

248O08

M901010

248O09

8.

9.


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MAN B&W DieselOverhaul


10. Lubricate the threads with Never Seize' or

Molybdenum Disulphide (MoS2) and mountthe valve studs.

Tighten up the studs in accordance with

the screwing-in torque stated on the datasheet.

Fill up the grooves between the valve studs

and the bores for the valve studs with

permatex to prevent water or oil from en-tering the bores during operation of the en-gine.

Provide the water connection flanges with

new gaskets, and keep the cylinder coverready for replacement.

Always fit new or overhauled valves before

a cylinder cover is mounted on the engine.

M

901010

248O10

D0101

D0103

D0102

10.


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901-1.4

MAN B&W Diesel Mounting

Cylinder Cover


M901010

246M03

D0105

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

inder liner with the guide tabs in the foreand aft direction.

This is to ensure that the tabs fit into the

two gas blow-out grooves milled in the cyl-inder cover guide recess.

2. Lift the cylinder cover by means of the

crane and carefully wipe the contact sur-

face which faces the cylinder liner.

Provide the cooling water connecting pipeswith new O-rings and lubricate them with

grease or soft soap.

Mount a new sealing ring in the groove of

the flange of the intermediate pipe.

Lower the cover carefully into position.

During the landing, carefully check that thecooling water connecting pipes engage

correctly with the holes in the coolingjacket.

3. If cylinder cover studs have been removedand remounted, check the distance the

stud is protruding from the cylinder cover.

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

M

901010

248M01

D0106

M901010

248M02

1.

2.

3.


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MAN B&W DieselMounting


4. Mount the cover nuts on the studs and

screw down.

Place eight spacer rings, one around each

nut, and mount the eight hydraulic jacks on

the studs.

Connect the high-pressure pump to thejacks by means of the distributor block and

the high-pressure hoses.

Using the vent screws of the hydraulic

jacks, vent the system, and then increasethe pressure as stated in Data.

For operation of the hydraulic tools, see

Procedure 913-1.

Tighten the nuts by applying the tommy barthrough the slots in the spacer rings.

Relieve the system of pressure.

Finally, remove the hydraulic jacks and

spacer rings from the nuts.

5. Mount the protective caps on the cylindercover studs.

Align the intermediate pipe so that theholes in the flange of the intermediate pipe

are in line with the threaded holes in theexhaust receiver.

Mount the screws of the flange betweenthe intermediate pipe and the exhaust re-

ceiver.

Mount the insulating jacket around the in-termediate pipe.

Note!

Lubricate the screws with anti-seize

paste containing Molybdenum Disulphide(MoS2) before mounting.

M901010

248M04

5.

M

901010

250D07

4.


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901-1.4

MAN B&W Diesel Mounting

Cylinder Cover


6. Mount the drain oil pipes and the air pipe

for pneumatic closing of the exhaust valve.

Mount the high-pressure pipe for the hy-

draulic valve gear.


7. Mount the starting air pipe and control airpipe for the starting valve.

Mount the cooling water inlet and outletpipes on the exhaust valve.

Mount the plug for the electrical sensor for

the exhaust valve.

Mount the drain pipe on the intermediate

pipe between the exhaust valve and thecylinder cover.

Mount the fuel oil high-pressure pipes forthe fuel valves.See Procedure 909-14.4.

Mount the oil supply pipe for the hydraulic

damper in the exhaust valve.

Connect the outlet pipe from the return oil

pipe on the fuel valves.

Shut the drain valves and open the coolingwater inlet. After venting the cylinder sec-

tion, shut the vent cocks and open thecooling water outlet valve.

Open the fuel oil. Open the lubricating oiland air supplies to the exhaust valve.

Caution!

The air supply to the exhaust valve mustalways be connected before starting thehydraulic oil pumps.

M

901010

248M05

M901010

248M06

6.

7.


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MAN B&W DieselMounting


8. Open valve 531 for hydraulic operation of

the exhaust valve.

9. Close valve 421 and open valve 420 on the

hydraulic block.

M

901010

250M07

M90101

0250M08

8.

9.


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When referring to this page, please quote Plate P90151 Edition 0199 Page 1 (2)MAN B&W Diesel A/S

Cylinder Cover Panel PlateP90151-0199

0199Cylinder CoverPanelP90151


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Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0199MAN B&W Diesel A/S

Cylinder Cover PanelPlateP90151-0199

ItemNo.

Item Description

010 Panel for tools

022 Name plate

046 Grinding tool for exhaust valve seat058 Milling and grinding wheel for fuel

valve seat

060 Milling and grinding wheel for startingvalve seat

071 Dismantling tool for fuel valve seat

083 Handle for cutting and grinding tool

095 Grinding ring for starting valve

105 Grinding handle

117 Pressure tester for safety valve

130 Lifting chains

201 Handle for cutting and grinding tool

ItemNo.

Item Description


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Plate

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

Cylinder Cover - ToolsP90161-0105

P90161 0105


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Plate

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

P90161-0105Cylinder Cover - Tools

ItemNo.

Item Description ItemNo.

Item Description

P90161 0105

027 Hydraulic jack, complete039 Support040 Support

052 O-ring with back-up ring064 O-ring with back-up ring090 Spanner100 Tommy bar111 Stud setter206 Hydraulic tool set, complete218 Hydraulic tool set, complete


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MAN B&W Diesel A/S

902 - Piston with Rod & Stuffing Box


102-01 0065 Piston, Data

902-01 0270 Piston

102-02 0048 Piston Rod Stuffing Box, Data

902-02 0221 Piston Rod Stuffing Box90251 0237 Piston and Piston Rod - Panel

90261 0108 Piston and Piston Rod - Tools

90264 0002 Piston and Piston Rod - Tilting Tools

90265 0001 Piston and Piston Rod - Support Tools

90266 0002 Piston - Lifting Tools


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SAFETY PRECAUTIONS

Data

102-1Piston

Data

Special DataD10201 Edition0065 S50ME-CPiston102-1

X Stopped engine





X Shut off fuel oil




D01-05 Cylinder cover stud, check distance 128 - 129 mm

D02-01 Test pressure 7 bar

D02-02 Piston rod/crosshead, tightening torque 430 Nm

D02-03 Piston rod/crown, tightening torque 300 Nm

D02-05 Piston skirt, tightening torque 80 Nm

D02-06 Cooling oil pipe, tightening torque 80 Nm

D02-07 Piston rod/crosshead, tightening torque + angle 100/30 Nm/

D02-08 Piston ring new, radial width 17.2 mm

D02-09 Piston ring worn, min. radial width 14.2 mmD02-10 Groove No.1, max. vertical height 13.2 mm

D02-11 Groove Nos. 2, 3 and 4, max. vertical height 10.2 mm

D02-12 Piston top, max. permissible burn-away 15 mm

D02-13 Piston ring new, height of ring No. 1 12.4 mm

D02-14 Piston rings new, height of ring Nos. 2, 3 and 4 9.4 mm

D02-15 Minimum free ring gap (before dismantling) 28 mm

D02-16 Minimum ring gap, ring No. 1 (new ring in new liner) 3.4 mm

D02-17 Minimum ring gap, ring Nos. 2, 3 and 4 (new ring in new liner) 2.4 mm

D02-18 Vertical clearance, new parts 0.35-0.4 mm

D02-19 Vertical clearance, worn parts, max. 0.87 mm

D02-20 Piston complete 921 kg

D02-21 Piston crown 200 kg

D02-22 Piston rod 565 kg

D02-23 Piston skirt 57 kg

D02-24 Piston cooling pipe 21 kg

D02-25 Lifting tool, tightening torque 150 Nm

D02-46 CPR ring CL groove, min. depth 1.1 mm


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Piston102-1

Data




P90251 40 Lifting tool for piston rod foot

P90251 75 Template for piston top

P90251 87 Distance piece for stuffing box

P90251 99 Cover for stuffing box hole

P90251 110 Pressure test tool for piston

P90251 134 Piston ring expander

P90251 158 Guide screw for piston crown

P90251 171 Dismantling screw piston skirt

P90261 Guide ring for piston

P90264 Tools for tilted lift

P90265 Support for piston

P90266 Lifting tool for piston

P90366 Crossbar for cylinder liner

P90451 118 Rubber cover for crosshead


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When referring to this page, please quote Procedure M90201 Edition 0270 Page 1 (20)MAN B&W Diesel A/S

Piston 902-1.1

Checking

0270S60MC-CPiston

902-1.1Checking

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 maneouvring 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 with

a wooden stick.

1.

HN902-1.125601

HN902-1.125602

2.

3.

HG902-1.120403


42/639

Page 2 (20) When referring to this page, please quote Procedure M90201 Edition 0270MAN B&W Diesel A/S

Piston902-1.1

Checking

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

The total clearance must not exceed the

value 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 removedfrom the engine.

4.

HM902-1.124615

D02-18

D02-19

GN902-1.220408

5.n. 1 mmD02-46

6.

GN902-1.2

20408


43/639


Piston 902-1.1

Checking

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.

BM902-1.123207

D02-15

8.

GN902-1.122214

9.

GN902-1.120408

Worn

NewD02-08

D02-09


44/639


Piston902-1.1

Checking

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 notexceed 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 maxi-

mum permissible burn-away value, see Da-ta.

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 gaps

staggered 180and with the TOPmark 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 upper ring (CPR-ring) should notbe expanded more than to the milled markon the ring expander.

10.

KM902-3.047

05

Max2 mm

Max 2 mm

D02-10D02-11

11.

AM902-3.07704

D02-12

12.

GN902-1.1

22214


45/639


Piston 902-1.2

Dismantling

902-1.2Dismantling

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

2. Release the stuffing box by removing the

innermost screws from the stuffing boxflange.

3. Remove the screws from the piston rod.

Note!

Do NOT remove the outermost screwsfrom the flange.

1.

MN902-1.223501

2.

GN902-1.2204

02

3.

HN902-1.223703


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Piston902-1.2

Dismantling

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.


Carefully smooth out any wear ridges at thetop of the cylinder liner.See Procedure 903-1.3.

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.

HN902-1.225604

5.

GN902-1.220405

6.

GN902-1.223706


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Piston 902-1.2

Dismantling

7. Turn the crosshead towards TDC, whilechecking that the stuffing box lands correct-ly on the distance pieces.

8. Turn to TDC.

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

Clean the lifting groove of the piston crownand mount the lifting tool in such a mannerthat the two fixed claws of the tool fit intothe lifting groove of the piston.

Fit the third, adjustable, claw of the tool tothe lifting groove and tighten it up against

the stop of the tool, see Data D02-25.

Lift the piston out of the cylinder liner.

7.

GN902-1.220406

8.

GN902-1.220407


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Piston902-1.2

Dismantling

9. If the lifting height is limited, it can be nec-essary to guide the piston rod foot in be-tween the cylinder cover studs.

10. Lower the piston rod foot and stuffing boxthrough the opening in the platform.

Place the two halves of the support around

the piston rod and secure the two halveswith screws.

11. 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!

Alternatively, with low lifting height,remove one of the cylinder cover studswith the stud setter.

9.

MN902-1.225609

10.

GN902-1.220408

D02-20

11.

GN902-1.220409


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Piston 902-1.2

Dismantling

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

The protective rubber cover should remain

in place to protect the crosshead bearingjournal from impurities until the piston is re-mounted.

Low lifting height

If the space conditions above the engine makeit impossible to remove the piston in the normalway, the piston can be removed as follows:

13. Remove one or two cylinder cover studs,

using the stud setter.

Lift the piston high enough to give ampleroom over the cylinder cover studs.

Place the supporting tools on the cylindercover studs.

12.

GN902-1.220410

13.

GN902-1.2243

11


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Piston902-1.2

Dismantling

14. Place the collar ring on the supporting toolsand mount the clamp on the collar ring.Check that the distance pieces have con-tact with the piston.

Remove the lifting tool from the piston.

Hook the crossbar on to the crane and at-tach the collar ring to the crossbar.

15. 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!

Tilting of the piston must only take placewith the piston rod stuffing box mountedon the piston rod.

Note!

On engines with extremely low liftingheight, use the engine room double-jibcrane instead of the transverse piece.

14.

GN902-1.224312

15.

GN902-1.224313


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Piston 902-1.3

Overhaul

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 and land the pis-

ton on the support.

Check and remove the piston rings.See Procedure 902-1.1.

3. Dismount the locking wire and the inner-most screws between the rod and the pis-ton crown.

1.

JM902-1.323401

D02-20

2.

JM902-1.323402

3.

JM902-1.323403


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Piston902-1.3

Overhaul

4. Dismount the locking wire and screw up thesupport screws of the piston support to aposition just below the piston skirt.

Remove the piston skirt screws.

5. Screw the four screws of the support down-wards until the skirt rests on the support.

If the skirt will not budge, free it by meansof two dismantling screws.

Lift away the piston crown.

Remove and discard the sealing rings onthe piston rod and on the skirt.

6. Dismount the bolts of the cooling oil pipeflange.

Mount the eye bolts and lift out the coolingoil pipe.

After inspection of the cooling oil pipe, re-mount the pipe.

4.

JM902-1.323404

D02-23

5.

JM902-1.323405

D02-21

6.

GN902-1.

320406

D02-24

D02-06


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Piston 902-1.3

Overhaul

Alternatively, the piston can be dismantledin the following way:

7. With the piston standing in the piston sup-port tool, remove the piston rod stuffing

box, see Procedure 902-2.3.

8. Lift the piston with the lifting tool. Land thepiston rod foot on a wooden plank.

Lower the piston crown to the platform andland it on a wooden plank, so that it is pos-sible to remove the lifting tool.

9. Remove the lifting tool from the pistoncrown. Attach the lifting bracket to the bot-tom of the piston rod foot. Hook the craneon to the lifting bracket.

10. Lift the piston rod foot clear of the woodenplank.

Keep lifting until the piston rod is in a verti-

cal position.

Note!

During the lift, follow with the crane tokeep the crane positioned verticallyabove the lifting point.

7.

KM902-1.324006

8.

GN902-1.324308

GN902-1.324309

9.

10.

KM902-1.324009


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Piston902-1.3

Overhaul

11. Place the piston in an upright position withthe piston crown resting on wooden blocks.

Dismount the locking wire and the inner-most screws between the rod and the pis-

ton crown. Lift the piston rod away and landit in a horizontal position on a couple ofwooden planks.

12. 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.

13. Thoroughly clean and inspect all parts ofthe piston.

Regarding check of the piston crown, seeProcedure 902-1.1.

Replace all sealing rings of 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 to

disassembly. Use the guide screw to ensurethe correct positioning of the piston rod inrelation to the piston crown.

Tighten all the screws diagonally to thetorque stated in Data.

11.

GN902-1.324311

D02-22

12.

GN902-1.320411

D02-23

13.

GN902-1.320412

D02-03

D02-05


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Piston 902-1.3

Overhaul

14. Lock all 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.

15. 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.

For overhaul of the stuffing box, see Proce-dure 902-2.3.

14.

HM902-1.320413

Oil

15.

MB902-1.320414

D02-01


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Piston902-1.4

Mounting

902-1.4Mounting

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

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

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.

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

4. Remove the protective rubber cover fromthe crosshead.

2.

JM902-1.323401

D02-20

3.

GN902-1.420403

4.

GN902-1.220410


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Piston 902-1.4

Mounting

5. Remove the cover from the piston rod stuff-ing box opening in the bottom of the cylin-der unit.

6. Turn the crosshead to a position 45 from

TDC.

Mount the guide ring for piston rings on thecylinder liner.

7. 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.

5.

GN902-1.220409

6.

GN902-1.420406

7.

GN902-1.420407


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Piston902-1.4

Mounting

8. Turn the crosshead nearly to TDC whilechecking that the guide ring of the cross-head enters the centre hole in the pistonrod.

9. After turning the crosshead fully to TDC,and ensuring that the piston rod has fullcontact with the crosshead, unscrew theadjustable claw of the lifting tool and pullthe lifting tool free of the lifting groove in thepiston

Remove the lifting tool and the guide ringfor piston rings.

10. Turn down and land the stuffing box on the

stuffing box flange. Check that the holes inthe stuffing box and stuffing box flange arecorrectly centred.

Remove the distance pieces from the pistonrod foot.

8.

KB902-1.422508

9.

GN902-1.420409

10.

B902-1.422509


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Piston 902-1.4

Mounting

11. Tighten down the piston rod stuffing box bymeans of the screws, through the innerholes in the stuffing box flange.See Procedure 902-2.

12. Mount and tighten the piston rod screws.Tighten the screws to the specified torqueand lock with locking wire. See Data. Useeither Data D02-02 or Data D02-07.

13. 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.

11.

GN902-1.220402

12.

HN902-1.42

3712

D02-02

orD02-07

13.

HN902-1.423713


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Piston902-1.4

Mounting

14. 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 on

the studs.

Mount the cylinder cover studs with the studsetter. Screw the stud down to contact andone half revolution back.

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

If necessary, adjust the distance D01-05 by

turning the stud.

16. Tighten the cylinder cover and mount thenecessary pipes.


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

Start the engine and keep it running for

about 15 minutes at a number of revolutionscorresponding to very slow.

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

14.

GN902-1.420412

15.

HN902-1.4

25615

D01-05


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SAFETY PRECAUTIONS

Data

102-2Piston Rod Stuffing Box

Data

Special DataD10202 Edition0048 S50ME-CPiston Rod Stuffing Box102-2

X Stopped engine





X Shut off fuel oil




D02-26 Stuffing box flange, outer screws tightening torque 80 Nm

D02-27 Stuffing box flange, inner screws tightening torque 80 Nm

D02-28 Stuffing box halves, tightening torque 80 Nm

D02-29 Uppermost rings, ring-end clearance 4x6 mm

D02-30 Lowermost rings, ring-end clearance 3x3 mm

D02-33 Check length for the six uppermost springs:

D02-34 F 0 = 0 N................ L 0 = 639 mm

D02-35 F 1 = 153 +/ 7 N....... L 1 = 763 mm

D02-36 F 2 = 163 +/ 10 N..... L 2 = 835 mmD02-37 Check length for the four lowermost springs:

D02-38 F 0 = 0 N................ L 0 = 496 mm

D02-39 F 1 = 150 +/ 7 N....... L 1 = 646 mm

D02-40 F 2 = 200 +/ 10 N..... L 2 = 714 mm

D02-44 Stuffing box complete 63 kg

D02-45 Stuffing box half 19 kg


62/639


Piston Rod Stuffing Box102-2

Data




P90251 109 Mounting tool for stuffing box spring

P90251 122 Worktable for stuffing box

P90451 120 Rubber cover for crosshead


63/639

When referring to this page, please quote Procedure M90202 Edition 0221 Page 1 (9)

Piston Rod Stuffing Box 902-2.1

Checking

0221 S46MCCPiston Rod Stuffing Box

902-2.1Checking

1. After the piston rod stuffing box has beendismantled, check the following clearanc-es:.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.

It is recommended to renew the springs forthe sealing rings when the rings are re-newed.

1.

NB902-2.1

21601

D02-29

D02-30

D02-29 D02-30

BA

A

B

2.

HM902-5.0

7002

D02-33

D02-37


64/639


Piston Rod Stuffing Box902-2.2

Dismantling

902-2.2Dismantling

In connection with dismantling of the piston,only the innermost screws in the stuffing boxflange should be removed.

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 90from 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.

GN902-2.220301

2.

DM902-5.210802

3.

DM902-5.2

10803


65/639



Dismantling

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.

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

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.

DM902-5.210804

5.

DM902-5.210805

6.

EN902-2.2

22106


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Overhaul

902-2.3Overhaul

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 a

support 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 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-ring of the stuffing box. If theO-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.

GM902-5.19001

1.

2222041a

D02-44

D02-44

2.

2222042a


67/639



Overhaul

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 r ings.

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.

2222043a

D02-45

7.

HM902-5.07002

D02-33

D02-37

8.

HC902-5.1

9807


68/639



Overhaul

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 remaining

scraper 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 the

8-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 assembled

ring 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.

Note!

If the stuffing box is assembled inside theengine, place two pieces of plywood of

the same thickness as the flange on the

worktable, to ease the assembling.

10.

NB902-321710

11.

HC902-5.19811


69/639



Overhaul

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-ring in the stuffing box groove.

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.

HC902-5.19812

D02-28

13.

22320313

D02-44


70/639



Mounting

902-2.4Mounting

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 the

engine, assemble the stuffing box halves ontop 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 theflange enter the guide holes in the bottomof the cylinder frame.

1.

22420416

2.

DM902-5.210808

3.

DM902-5.2

10809


71/639



Mounting

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.

DM902-5.210810

5.

DM902-5.210811 D02-26

D02-27

6.

GN902-2.

220301


72/639


73/639

Plate


Piston and Piston Rod PanelP90251-0237

P90251 0237


74/639

Plate


P90251-0237Piston and Piston Rod Panel

ItemNo.


Item Description

P90251 0237

014 Panel for tools026 Name plate040 Lifting tool, piston rod foot

051 Lifting tool, cylinder liner075 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 ring158 Guide screw, piston crown160 Guide screw, piston crown


75/639

Plate


Piston and Piston Rod - ToolsP90261-0108

P90261 0108


76/639

Plate


P90261-0108Piston and Piston Rod - Tools

ItemNo.

Item DescriptionItemNo.

Item Description

P90261 0108

019 Guide ring for piston


77/639

When referring to this page, please quote Plate P90264 Edition 0002 Page 1 (2)MAN B&W Diesel A/S

Piston and Piston Rod - Extra Tools PlateP90264-0002

0002PistonandPistonRod- ExtraToolsP90264


78/639

Page 2 (2) When referring to this page, please quote Plate P90264 Edition 0002MAN B&W Diesel A/S

Piston and Piston Rod - Extra ToolsPlateP90264-0002

ItemNo.

Item Description

015 Lifting collar

027 Support for tilting tool

ItemNo.

Item Description


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Plate


Piston and Piston Rod - Support ToolsP90265-0001

P90265 0001


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Plate


P90265-0001Piston and Piston Rod - Support Tools

ItemNo.


Item Description

P90265 0001

010 Support iron for piston


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Plate


Piston - Lifting ToolsP90266-0002

P90266 0002


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Plate


P90266-0002Piston - Lifting Tools

ItemNo.

Item DescriptionItemNo.

Item Description

P90266 0002

016 Lifting tool for piston


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MAN B&W Diesel A/S

903 - Cylinder Liner and Cylinder Lubrication


103-01 0056 Cylinder Liner, Data

903-01 0253 Cylinder Liner

103-02 0031 Cylinder Lubricator, Data

903-02 0253 Cylinder Lubricator90361 0084 Cylinder Liner - Tools

90362 0002 Cylinder Liner - Milling Tools

90364 0004 Test Equipment for Lubricators

90366 0007 Cylinder Liner - Lifting Tools


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MAN B&W Diesel A/S


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SAFETY PRECAUTIONS

Data

103-1Cylinder Liner

Data

Special DataD10301 Edition0056 S50ME-CCylinder Liner103-1

X Stopped engine





X Shut off fuel oil




D03-01 Lifting tool screws, tightening torque 150 Nm

D03-03 Cylinder diameter, new 500 mm

D03-04 Piston cleaning ring diameter, new 498.3 mm

D03-05 Cylinder liner, complete 1820 kg

D03-06 Cooling jacket 170 kg

D03-16 Piston cleaning ring radial width, new 38.8 mm

D03-17 PC-ring/Liner max. wear deviation 0.5 mm

D03-18 PC-ring replacement criteria:

Liner diameter: 500 mmLiner wear: Install:

0 0.50 mm Standard PC-ring(new or max. wear of diameter 0.50 mm)

0.50 1 mm Oversize PC-ring

> 1 mm Dummy ring


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Cylinder Liner103-1

Data




P90251 51 Lifting tool for cylinder liner

P90361 Measuring tool for cylinder liner

P90362 Cylinder Liner - Extra Tool

P90366 Cylinder Liner - Lifting Tools


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Cylinder Liner 903-1.1

Checking

0253S50MCCylinderLiner

903-1.1Checking

1. Dismount the cylinder cover, piston andPC-ring.See Procedure 901-1.2.See Procedure 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. See Data.

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

4. Check and assess the condition of the cyl-inder liner according to the description giv-en in Volume I, Chapter 707.

5. Carefully scratch over any scores or marks

on the cylinder liner running surface, andgrind away the wear ridges. See Procedure903-1.3.

6. Check the lubricating points of the cylinderby pumping cylinder oil to each individual

lubricating point.

Clean any blocked lubricating duct.

1.

DM903-2.09001

D03-03

2.

GN903-1.120303

4.

GM903-1.1

25304


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Cylinder Liner903-1.1

Checking

7. 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 liner,the PC ring must also be inspected.

When the piston is removed, the PC-ringmust always be taken up before the piston.See Procedure 902-1.2.

8. Measure the PC ring radial width B, andfind the most worn place. Compare withdata D03-16 and calculate the wear of the

PC ring. Multiply the wear by 2 to get thePC ring diameter wear.

Measure the liner in the fore-and-aft andathwartship 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.

Compare the PC ring diameter wear with

the wear of the liner. If wear of the two com-ponents does not deviate more than D03-17, then reinstall the PC ring.

If the deviation between PC ring wear andliner wear is more than D03-17, or if the PCring is broken or cracked, replace the ringwith a new PC ring, an oversize ring or adummy ring according to the table in D03-18 on the Data sheet.

If it is needed 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.

7.

GW903-1.124707

8.

DM903-1.123708


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Dismantling

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 and the PC-ring.See Procedure 902-1.2.

Mount the two lifting screws in the cylinderliner.

2. Disconnect at the exhaust side of the cyl-inder the oil pipes leading from the cylin-der lubricator to the non-return valves.

Dismount the four cooling water pipes be-tween the cooling jacket and cylinder cover and clean them carefully.

Note!

Tighten the lifting screws to the torquestated in Data.

Check with a 0.05 mm feeler gauge thatthere is no clearance between the screwsand the cylinder liner.

This must be done whenever the lifting

tools are mounted on the liner.

1.

GN903-1.222401

D03-01

2.

GN903-1.222402


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Dismantling

3. Remove the screws of the cooling water in-let pipe.

4. Attach the crane hook to the lifting cross-bar.

Hook the chains from the lifting tools on tothe crossbar and lift the cylinder liner withthe cooling jacket out of the cylinder frame.

Land the cylinder liner vertically on, for in-stance, a couple of planks.

Clean the cylinder frame internally, takingspecial care with the contact surfaces forthe cylinder liner at the top of the cylinderframe.

Discard the O-rings on the cooling waterpipes.

Clean the pipes carefully.

Note!

Low lifting height in the engine room mayrequire the removal of one or more cylin-der cover studs before dismantling thecylinder liner.

3.

EN903-1.420503

4.

GN903-1.222404

D03-05


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Dismantling

5. The lifting screws are also used for trans-porting the cylinder liner.

5.

HN903-1.224405

D03-05


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Overhaul

903-1.3Overhaul

1. Unscrew the nuts on the non-return valvesand remove the valves.

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.

Remove the two lifting screws from the cyl-inder liner.

Remove the four clamps which fix the cool-ing jacket to the cylinder liner.

3. Lift the cooling jacket away by means of thetackles, and land it on the wooden planks.

1.

GN903-1.322401

2.

EN903-1.323702

3.

EN903-1.3

23703

D03-06


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Overhaul

4. Check and assess the condition of the cyl-inder liner according to the description giv-en in Volume I, Chapter 707.

Carefully scratch over any scores or marks

on the cylinder liner running surface, bymeans of a rough grindstone held in thehand.

Check in the top of the liner for a wear ridge(where the piston rings reverse direction). Ifthere is any sign of a wear ridge, it is nec-essary to create a groove by grinding.Thegroove serves to prevent the build-up of anew wear ridge.

5. It is recommended to use a wear ridge mill-ing machine to create the groove. For useof the milling machine, see suppliers in-struction.

6. Alternatively, place an old piston ring on thetop of the piston and turn to a position thatenables the grinding disc to rest on the oldpiston ring while removing the wear ridge.Use a grinding disc with a round edge.

Check the distance Cbefore grinding to as-

certain that the wear ridge was caused bythe top ring at TDC.

The maximum depth of the groove is calcu-lated as Smax.= D x 0.0045.

Note!

It is of the utmost importance that the

groove is made with a regular roundingas shown in the sketch.

4.

HN903-1.322104

5.

MB903-1.323104

S

D

CC

R=4-5mm

6.

MN903-1.3

22905


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Overhaul

7. Replace the two uppermost O-rings on thecylinder liner.

8. Lower the cooling jacket on to the cylinderliner.

9. Mount the four clamps in the groove of theliner, and tighten the screws.

Remove the tackles from the lifting cross-bar and the cooling jacket lifting eye bolts.

10. Mount the non-return valves for cylinder lu-brication. Tighten the nuts and connect thelubricating oil pipes.

Note!

Make sure that the scratch marks in thefuel pump side of the cylinder liner and

cooling jacket coincide.

7.

GN903-1.320304

8.

D03-06

EN903-1.323708

9.

EN903-1.3

23709


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Mounting

903-1.4Mounting

1. Loosen the water connections on the cool-ing jacket.

Mount the two lifting screws in the cylinderliner. See Data D03-01.

Hook the chains from the lifting crossbar onto the lifting screws, and lift the jacket/linerassembly.

Mount the lowermost O-ring and apply a lit-tle lubricating oil on the ring.

2. Check that the joint surfaces on the cylinderframe and cylinder liner are completelyclean.

Coat the joint surfaces with permatex or asimilar liquid sealing compound.

Mount the cylinder liner in the cylinderframe. Replace the O-rings on the waterconnections and mount the water connec-tions on the cooling jacket.

1.

DM903-1.423701

D03-01

2.

GN903-1.422402


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Mounting

3. Fit a new gasket between the cooling waterinlet pipe and the cooling jacket. Mount andtighten the screws.

4. Connect and tighten the oil pipes for the

cylinder lubrication.

Vent the cylinder lubricating system untiloil, without air bubbles, comes out from thenon-return valves. Check that there is noleakage from the system.

When this is in order, check that each indi-vidual lubricating point functions correctly.

5. Lubricate the upper part inside of the cylin-

der liner with cylinder lubricating oil andmount the piston and the PC ring.See Procedure 902-1.4.

6. Mount the sealing ring and the cylinder cov-er.See Procedure 901-1.4.

Tighten the upper water connections on thecooling jacket as soon as the cylinder coveris correctly positioned.

3.

EN903-1.420503

4.

GM903-1.425304

GN901-1.4

20301

6.


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Page 1 (2)

MAN B&W Diesel

SAFETY PRECAUTIONS

Data

Cylinder Lubricator

Data

103-2

When referring to this page, please quote Data D10302 Edition 0031

X

For detailed sketch, see 900-2

Stopped engine

Shut off starting air supply At starting air receiver

Block the main starting valve

Shut off starting air distributor/distributing system supplyShut off safety air supply Not ME engines

Shut off control air supply

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

Engage turning gear

Shut off cooling water

Shut off fuel oil

Stop lubricating oil supply

Lock the turbocharger rotors


X

X

XX

X

X


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Page 2 (2)

MAN B&W Diesel

The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in thechapters indicated by the first three digits in the plate number, e.g. P90951refers to chapter 909.

Cylinder Lubricator

Data

103-2

When referring to this page, please quote D10302 Edition 0031

P90364 Test Equipment for Lubricator



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Page 1 (8)

903-2.1

When referring to this page, please quote Procedure M90302 Edition 0253

MAN B&W Diesel Checking

Cylinder Lubricators

M

903020

242C02

1.Check of Oil Injection:

With stopped engineand normally when thesystem has been disassembled:

1. Activate the prelub.-function on the MOPcontrol panel, and check that the lubrica-tors concerned are operating correctly bywatching through the covers for scavenge

port inspection.

Turn the piston concerned to BDC andcheck inside the liner with a mirror and apowerful light source that all lubrication

points are working properly.

For use of the MOP Panel, see Volume IChapter 703.

With running engine:

2. The system is automatically checked.

The Engine Control System will generate an

alarm if faults occur.

Additionally, it is possible to check thepressure shocks from the injection of the

lubricators on each lubricator pipe by feel-ing with a hand.

If in doubt, disconnect the pipe at the cyl-inder liner to observe the oil flow.


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Cylinder Lubricators

Page 2 (8)

903-2.2

When referring to this page, please quote Procedure M90302 Edition 0253


M903020

253D03

M903020

253D02

M

903020

253D01

ON

OFF

00:00

Bourdon Sedeme

CC

560

565

2.

3.

1.Dismantling of lubricators:

The engine must be stopped and blocked be-

fore dismounting a lubricator. Stop the cylinder

oil pump station.

Disconnect the electrical plug on the side of

the lubricator.

1. Mount a pressure gauge at minimess

point 565.Check the pressure.

Close valve 560. Check that the cylinder lu-

bricator is pressure free. If pressure is still

present, activate the prelub function onthe MOP panel to remove the pressure.

Close the supply valve for cylinder lubricat-

ing oil.

Remove the electrical plug for the lubrica-tor.

2. Unscrew the top cover screws and discon-

nect the cover with pertaining pipes.

Check that the cylinder supply is closed.

Disconnect the cylinder oil supply pipe.Disconnect the drain pipe.

3. Unscrew the four screws on the side that

secure the lubricator to the hydraulic cylin-der unit.

Pull the pipe flange aftwards and pull thelubricator out and clear of the guide pins.

Special running

It is possible to change a lubricator while theengine is running if a spare lubricator with O-rings and the necessary tools is available. The

change should be done in a maximum of 15minutes.

Reduce the engine load to below 40%of MCR

Dismount the lubricator as des