For training

F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

<1>

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

High pressure pipes

Hydraulic Cylinder Unit
Distribution block
End cover
ELFI Valve
Fuel oil pressure booster
Accumulator
Cylinder
y
Lubrication
Pressure Decay Time and other trouble
shooting issues

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

<2>

For training
F
pu
urposes only

Mechanical/Hydraulic Diagram

HCU
Hydraulic Cylinder Unit

HPS
Hydraulic Power Supply

BOLL filter

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

<3>

For training
F
pu
urposes only

Layout of High Pressure Pipes

HPS

Dual cylinder
HCU

High Pressure Pipes

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

<4>

For training
F
pu
urposes only

Layout of High Pressure Pipes

300 bar hydraulic oil

Safety block

rail from the Safety

Block to the HCUs

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

<5>

For training
F
pu
urposes only

HCU from below

H.p. pipe
connection

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

<6>

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

Fuel Oil Pressure booster
ME Lubricator

Accumulator
End cover

ELFI valve
Distribution block
3333572.2006.04.12
ME-B Hydraulic
Cylinder Unit

(2200/OZS)

MAN Diesel & Turbo

01/01/2012

<7>

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

<8>

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

<9>

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 10 >

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 11 >

For training
F
pu
urposes only

Distribution Block

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 12 >

For training
F
pu
urposes only

Distribution Block

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 13 >

For training
F
pu
urposes only

Distribution Block

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 14 >

For training
F
pu
urposes only

End cover fore side

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 15 >

For training
F
pu
urposes only

End cover fore side

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 16 >

For training
F
pu
urposes only

End cover aft side

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 17 >

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 18 >

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 19 >

For training
F
pu
urposes only

Hydraulic Cylinder Unit (HCU)

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 20 >

For training
F
pu
urposes only

ELFI for ME-B

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 21 >

For training
F
pu
urposes only

ME Fuel Injection System

High pressure pipe

Suction valve

Fuel pump
plunger
l

Slide Fuel
valve
l
Fuel pump
Fuel oil inlet
8 bar

Hydraulic
piston
ELFI
Proportional
valve

To
drain

ME-B Hydraulic Cylinder Unit

Membrane
accumulator

High pressure hydraulic oil inlet

MAN Diesel & Turbo

01/01/2012

< 22 >

For training
F
pu
urposes only

Fuel Oil Pressure Booster

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 23 >

For training
F
pu
urposes only

Fuel Oil Pressure Booster

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 24 >

For training
F
pu
urposes only

Fuel Oil Pressure Booster

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 25 >

For training
F
pu
urposes only

Fuel Oil Pressure Booster

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 26 >

For training
F
pu
urposes only

Fuel Oil Pressure Booster

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 27 >

For training
F
pu
urposes only

Fuel Oil Pressure Booster and ELFI valve

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 28 >

For training
F
pu
urposes only

Engine:
Process Adjustment > Max Pressure

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 29 >

For training
F
pu
urposes only

Engine:
Process Adjustment > Mean Pressure

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 30 >

For training
F
pu
urposes only

Engine:
Chief Limiters

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 31 >

For training
F
pu
urposes only

Supervision of ELFI feedback signal

The ELFI is immediately set to Drain Position (safe position) if:

The ELFI valve feedback signal is not valid, i.e. outside 3.5 - 20.5 mA
The ELFI valve feedback signal indicates a too high (not physical possible)
speed

The ELFI valve feedback signal indicates a position not allowed outside a
window around TDC
Fuel Injection is re-enabled by either:

Pressing the Re-enable button on the Engine->Chief Limiters Screen

Invalidation and then re-validation of the input ch. 30(cyl. A) or ch. 33 (cyl. B)
on the relevant CCU

Resetting the CCU

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 32 >

For training
F
pu
urposes only

Crankshaft related control processes

Injection start
angle trig
Injection preparation

Injection
TDC

Injection
j
control

ELFI valve window

supervision

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 33 >

For training
F
pu
urposes only

Engine:
Chief Limiters > Re-enable Fuel Injection

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 34 >

For training
F
pu
urposes only

Accumulator and HCU

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 35 >

For training
F
pu
urposes only

Accumulator
Diaphrame Working Principle
Diaphrame,

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 36 >

For training
F
pu
urposes only

Accumulator
Nitrogen check and charging
The accumulator charge pressure should be
checked within the first week of service.

Next check
N
h k should
h ld b
be made
d around
d 4 months
h
later, followed by checking every 6 months.

A minor leakage from the accumulators is

unavoidable, and service experience shows
that a pressure drop in the range of 2-5
bar/month is to be expected.

The charge pressure is dependent on the

accumulator temperature. E.g.:
136 bar @ 20C, 154 bar @ 50C
ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 37 >

For training
F
pu
urposes only

Cylinder Lubricator

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 38 >

For training
F
pu
urposes only

Cylinder Lubricator

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 39 >

For training
F
pu
urposes only

Cylinder Lubrication System

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 40 >

For training
F
pu
urposes only

Cylinder Liner,
Liner Injection Nozzles

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 41 >

For training
F
pu
urposes only

Cylinder Liner,
Liner Injection Nozzles

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 42 >

For training
F
pu
urposes only

The ME Engine
Cylinder Lubricator
Cylinder
y
lub. oil
inlet

Inductive proximity sensor

giving
g
g feedback
eedbac ssignal
g a for
o
control of piston movement

Lubricator
activation signal
from controller

Flow sensor
Fl

Injection plunger

Spacer for
basic setting of
pump
stroke
Non-return valve

Stroke
adjusting
screw

Drain
oil
outlet

200 to 300 bar system oil supply

Actuator
piston

Sealing ring

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 43 >

For training
F
pu
urposes only

Cylinder Lubrication Backup

Channel J51 on a working CCU

In case of CCU failure,, where the

CCU cannot be replaced
immediately, backup cylinder
lubrication can be achieved as
follows:

Connect temporary cables from

two other CCU units, plug 51, to
the solenoid valves on the
lubricators on the units in question.

The lubrication will be with random

timing.

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 44 >

For training
F
pu
urposes only

Cylinder Lubrication Backup

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 45 >

For training
F
pu
urposes only

Hydraulic Pressure Decay

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 46 >

For training
F
pu
urposes only

Hydraulic Pressure Decay

Time measurement example:

250

200
Start level at 180 bar

150
Bar
100

Stop level at 50 bar

50

0
0

10

15

20

25

30

Seconds
Pressure Decay Time
ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 47 >

For training
F
pu
urposes only

Hydraulic System, complete

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 48 >

For training
F
pu
urposes only

Disclaimer
All data p
provided in these training
g materials is non-binding.
g
This data serves informational purposes only and is especially not
guaranteed in any way.
Depending on the subsequent specific individual projects
projects, the relevant data
may be subject to changes and will be assessed and determined
individually for each project. This will depend on the particular
characteristics of each individual p
project,
j , especially
p
y specific
p
site and
operational conditions.

ME-B Hydraulic Cylinder Unit

MAN Diesel & Turbo

01/01/2012

< 49 >