Plate 101-1

MAN B&W Cylinder Cover

Edition 0090
Data Data 1 (1)

SAFETY PRECAUTIONS For detailed sketch, see 900-2

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

Data

Ref. Description Value Unit

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

D01-02 Starting valve stud, screwing-in torque 145 Nm
D01-03 Fuel valve stud, screwing-in torque 145 Nm
D01-06 Cylinder cover, complete 1670 kg
D01-08 Cooling jacket 40 kg
D01-09 Exhaust valve stud 7.8 kg
D01-10 Cylinder cover stud 27 kg

D13-01 Hydraulic pressure, mounting 1500

D13-02 Hydraulic pressure, dismantling 1400-1650

Data D10101 Edition 0090

BLANK
 Plate 901-1.2
MAN B&W Cylinder Cover
Edition 0272
Dismantling Page 1 (10)

1. Set blocking device A on the main starting E

1.
valve in the BLOCKED position.

Engage turning gear B.

C

Close fuel oil inlet valve C.

D F
Close cooling water inlet valve D.
A
Close cooling water outlet valve E.

Open cooling water drain cocks F and G.

Shut off the control air and safety air sup- G

ply. Vent the manoeuvring system through
the ball valve.

Also shut off the air supply on the pressure

reduction unit for the hydraulic/pneumatic
exhaust valve, and vent the system.
M90101
0249D01

M90101 Edition 0272

 Plate 901-1.2
MAN B&W Cylinder Cover
Edition 0272
Dismantling Page 2 (10)

2. Remove the cooling water inlet and outlet

2. 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.

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.
M90101
0249D02

Remove the starting air pipe.

3. Remove the exhaust valve high
pressure

pipe.
3. See Procedure 908
1.2.

Dismount the drain oil pipe between the

exhaust valve and the hydraulic activator,
the air pipe for pneumatic closing of the
exhaust valve.

4. 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-
M90101
0249D03

ceiver. The four lowermost screws need not

be dismantled, just loosened.

Remove the protective caps from the cylin-

der cover nuts.
4.
M90101
0249D04

M90101 Edition 0272

 Plate 901-1.2
MAN B&W Cylinder Cover
Edition 0272
Dismantling Page 3 (10)

5. Place eight spacer rings, one around each

nut, and screw the eight hydraulic jacks 5.
onto the studs.
D13
02
Connect the high
pressure pump to the
jacks by means of the distributor block and
the high
pressure hoses.

Using the vent screws of the hydraulic

jacks, vent the system and increase the
pressure as stated in Data.
For operation of the hydraulic tools, see
Procedure 913
1.

M90101
0249D05
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 from 6.

the jacks.

Remove the hydraulic jacks and spacer

rings, and unscrew the nuts.

6. Hook the engine room crane on to the lift-

ing attachment on top of the exhaust valve. D01
06
Lift away the cylinder cover complete, and
land it on a couple of wooden planks.

7. Remove and discard the gasket between

M90101
0249D06

cylinder cover and cylinder liner.

7.
M90101
0272D07

M90101 Edition 0272

 Plate 901-1.3
MAN B&W Cylinder Cover
Edition 0272
Overhaul Page 4 (10)

1. Dismount all valves and pipes on the cylin-

1. der cover.

D01
09 Dismount all studs on top of the cylinder

cover.

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 jacket
M90101
0249O01

and the cylinder cover.

3. Provide the cylinder cover with new

O
rings, well lubricated with oil.

2. 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.

D01
08
M90101
0249O02

3.
M90101
0249O03

M90101 Edition 0272

 Plate 901-1.3
MAN B&W Cylinder Cover
Edition 0272
Overhaul Page 5 (10)

5. Recondition the valve bores as follows:

5.
Fuel valve bore

6. The tool consists of a common spindle with

handle, a guide, a carbon cutter, a seating
face cutter and a grinding mandrel.

Clean the fuel valve bores, using the car-

bon cutter. If required, recondition the fuel
valve seating with the appropriate cutter.

Grind the seating with the grinding mandrel

and a grinding compound (e.g. Carborun-

M90101
0249O05
dum No. 200).

After the milling/grinding, clean the bore

and seating carefully, and check that the
seating is not damaged.
6.
Exhaust valve bore

7. The tool consists of a spindle with handle

and a grinding disc.

After cleaning the valve bore and seating,

grind the seating with the grinding disc and
a grinding compound (e.g. Carborundum
No. 200).

After the grinding, clean the bore and seat-

ing carefully, and check that the seating is
M90101
0246O06

not damaged.

7.
M90101
0240O07

M90101 Edition 0272

 Plate 901-1.3
MAN B&W Cylinder Cover
Edition 0272
Overhaul Page 6 (10)

Starting valve bore

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

Recondition the starting valve bore and

seating in the same way as described for
the fuel valve bore.

When replacing valves on a cylinder cover

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

9. Clean the indicator cock bore.

M90101
0246O08

9.
M90101
0272O09

M90101 Edition 0272

 Plate 901-1.3
MAN B&W Cylinder Cover
Edition 0272
Overhaul Page 7 (10)

10. Lubricate the threads with ‘Never Seize’ or

Molybdenum Disulphide (MoS2) and mount 10.
D01
01
the valve studs.

Tighten up the studs in accordance with D01
03

the screwing
in 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. D01
02
Provide the water connection flanges with

M90101
0249O10
new gaskets, and keep the cylinder cover
ready for replacement.

Always fit new or overhauled valves before

a cylinder cover is mounted on the engine.

M90101 Edition 0272

 Plate 901-1.4
MAN B&W Cylinder Cover
Edition 0272
Mounting Page 8 (10)

1. Place a new gasket on top of the cylinder

1. liner with the three guide tabs centering the
gasket on top of the piston cleaning ring.

This is to ensure that the tabs fit into the

two gas blow
out grooves milled in the cyl-
D01
06 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 pipes

M90101
0272M01

with new O
rings and lubricate them with

grease or soft soap.

Mount a new ‘klinger’ sealing ring in the

groove of the flange of the intermediate
pipe.
2.
Lower the cover carefully into position.

During the landing, carefully check that

the cooling water connecting pipes en-
gage correctly with the holes in the cooling
jacket.

3. 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
M90101
0249M02

the studs.

Connect the high
pressure pump to the

jacks by means of the distributor block and
the high
pressure hoses.
3.
Using the vent screws of the hydraulic
D13
01 jacks, vent the system, and then increase
the pressure as stated in Data.
For operation of the hydraulic tools, see
Procedure 913
1.

Tighten the nuts by applying the tommy bar

through the slots in the spacer rings.

Relieve the system of pressure.

Finally, remove the hydraulic jacks and

M90101
0249M03

spacer rings from the nuts.

M90101 Edition 0272

 Plate 901-1.4
MAN B&W Cylinder Cover
Edition 0272
Mounting Page 9 (10)

4. Mount the protective caps on the cylinder 4.

cover studs.

Align the intermediate pipe so that the

holes in the flange of the intermediate pipe
are in line with the threaded holes in the
exhaust receiver.

Mount the screws of the flange between

the intermediate pipe and the exhaust re-
ceiver.

Note!

M90101
0249M04
Lubricate the screws with anti
seize
paste containing Molybdenum Disulphide
(MoS2) before mounting.

5. Mount the insulating jacket around the in-

termediate pipe. 5.
M90101
0249M05

M90101 Edition 0272

 Plate 901-1.4
MAN B&W Cylinder Cover
Edition 0272
Mounting Page 10 (10)

6. Mount the return oil pipe and the air pipe

6. for pneumatic closing of the exhaust valve.

Mount the high
pressure pipe for the hy-

draulic valve gear.
See Procedure 908
1.4.

7. Mount the starting air pipe and control air

pipe for the starting valve.

Mount the cooling water inlet and outlet

pipes on the exhaust valve.
M90101
0249M06

Mount the drain pipe on the intermediate

pipe between the exhaust valve and the
cylinder cover.

Mount the fuel oil high
pressure pipes for

the fuel valves.
7. See Procedure 909
14.4.

Connect the outlet pipe from the return oil

pipe on the fuel valves.

Shut the drain valves and open the cool-

ing water inlet. After venting the cylinder
section, shut the vent cocks and open the
cooling water outlet valve.

Open the fuel oil, lubricating oil and air

supplies to the alarm system.
M90101
0272M07

Note!
The air supply to the exhaust valve must
always be connected before starting the
camshaft oil pumps.

M90101 Edition 0272

 Plate 901-1.5
MAN B&W Cylinder Cover Stud
Edition 0001
Checking Page 1 (1)

Inspect the cyl. cover stud visually in

condition that the cyl. cover studs are
tightened fully.

Check with a 0.05mm feeler gauge that

there is no clearance between bottom of
cyl. cover stud nut and top surface of cyl.
cover.

M90101 Edition 0001

BLANK
 MAN B&W Cylinder Cover Panel Plate
90151-0199

P90151 Edition 0199

 MAN B&W Cylinder Cover Panel Plate
90151-0199

Item Item
Item Description Item Description
No. No.

9621 Milling and grinding wheel for starting

valve seat
9622 Milling and grinding wheel for fuel
valve seat
9623 Grinding ring for starting valve
9627 Handle for cutting and grinding tool
9821 Grinding tool for exhaust valve seat
9822 Dismantling tool for fuel valve seat
9823 Handle for cutting and grinding tool
9824 Grinding handle
9921 Lifting chains

P90151 Edition 0199

 MAN B&W Cylinder Cover - Tools Plate
90161-0105

P90161 Edition 0105

 MAN B&W Cylinder Cover - Tools Plate
90161-0105

Item Item
Item Description Item Description
No. No.

922A Spanner
922B Tommy bar
922D O-ring with back-up ring
922E O-ring with back-up ring
922F Stud setter
922G Support
922H Hydraulic jack cylinder
922J Hydraulic tool kit, complete

P90161 Edition 0105

 MAN B&W Cylinder Cover - Lifting Tools Plate
90165-0001

P90165 Edition 0001

 MAN B&W Cylinder Cover - Lifting Tools Plate
90165-0001

Item Item
Item Description Item Description
No. No.

9921 Lifting chains for cylinder cover

P90165 Edition 0001

 MAN B&W Cylinder Cover - Lifting Tools Plate
90165-0003

P90165 Edition 0003

 MAN B&W Cylinder Cover - Lifting Tools Plate
90165-0003

Item Item
Item Description Item Description
No. No.

982A Lifting tool for cylinder cover

982B Lifting tool for cylinder cover

P90165 Edition 0003