Cylinder Cover 101-1

MAN B&W Diesel Data

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 200 Nm

D01-05 Cylinder cover stud, check distance 110±3 mm
D01-06 Cylinder cover, complete 1100 kg
D01-07 Cylinder cover without valves 700 kg
D01-08 Cooling jacket 40 kg
D01-09 Exhaust valve stud 25 kg
D01-10 Cylinder cover stud 15 kg
D13-01 Hydraulic pressure, mounting 900 bar
D13-02 Hydraulic pressure, dismantling 800 - 990 bar

When referring to this page, please quote Data D10101 Edition 0075 Page 1 (2)
101-1 Cylinder Cover
Data 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
the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909.

Plate Item No. Description

P90151 046 Grinding tool for exhaust valve seat

P90151 058 Milling and grinding wheel for fuel valve seat
P90151 060 Milling and grinding wheel for starting valve seat
P90151 083 Grinding handle
P90151 130 Lifting chains

P90161 Cylinder Cover - Tools

P91351 010 Hydraulic pump, pneumatically operated

P91351 046 Hose with unions (1500 mm), complete
P91351 058 Hose with unions (3000 mm), complete
P91351 130 9-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10101 Edition 0075
 Cylinder Cover 901-1.2
MAN B&W Diesel Dismantling

Shut off Oil and Water Supply

2.
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.

M90101
0254D01
Shut off the water outlet on the main pipe
above the exhaust valve.

Shut off the water supply placed on the ex-

haust side of the main pipe. 3.

Open the drain next to the inlet valve.

Open the venting cock next to the outlet

valve.
M90101
0255C03

When referring to this page, please quote Procedure M90101 Edition 0258 Page 1 (13)
901-1.2 Cylinder Cover
Dismantling MAN B&W Diesel

Dismantling of Pipe Connections

4.
4. Disconnect the oil pipes.

Remove the hydraulic high pressure pipe

for the exhaust valve. See Procedure
908
1.2

Unscrew the drain pipe for the exhaust

valve.

Remove the fuel oil high pressure pipes.

See Procedure 909
14.2.
M90101-0258D04

Disconnect the pipes for return fuel oil from

the fuel valves.

5. Disconnect the water pipes.

5. 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 screws from the flanges be-

tween the intermediate pipe and the ex-
haust receiver.
M90101-0258D05

6.
M90101-0258D06

Page 2 (13) When referring to this page, please quote Procedure M90101 Edition 0258
 Cylinder Cover 901-1.2
MAN B&W Diesel Dismantling

7. Disconnect the starting air pipe.

7.
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,

M90101-0258D07
see Data.

For use of hydraulic tools, see Procedure

913
1.

8.

D13-02
M90101-0258D08

When referring to this page, please quote Procedure M90101 Edition 0258 Page 3 (13)
901-1.2 Cylinder Cover
Dismantling MAN B&W Diesel

Cylinder Cover Lifting and Landing

9.
9. Cylinder cover lifting.
D01-06
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.

M90101-0258D09

Land the cylinder cover on a couple of

wooden planks.

11. Remove sealing ring.

10. Remove and discard the sealing ring be-

tween the cylinder cover and cylinder liner.
M90101-0258D10

11.
M90101-0258D11

Page 4 (13) When referring to this page, please quote Procedure M90101 Edition 0258
 Cylinder Cover 901-1.3
MAN B&W Diesel Overhaul

Overhaul Preparations 1.

1. Dismantle valves and pipes.

Dismantle all valves and pipes from the

cylinder cover. See Procedure 907
2.2,
908
2.2 and 909
11.2. D01-09

Remove all studs on top of the cylinder

cover.

Cooling Water Jacket

M90101-0258O01
2. Remove the cooling water jacket.

Mount four eyebolts and the lifting chains

as shown in the sketch.
2.
Remove the screws which secure the cool-
ing jacket to the cylinder cover.

Lift the cylinder cover free of the cooling D01-07

jacket and land it on a couple of planks.

Remove and discard the O
rings from the

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

3. Mount the cooling water jacket.

M90101-0258O02

Provide the cylinder cover with new

O
rings, well lubricated with oil.

Lift the cylinder cover and guide the jacket/

cover into position, so the marking scratch-
es on the cover and the cooling jacket are
3.
in line (manoeuvre side).

Fit and tighten the screws for the cooling

jacket.
M90101-0258O03

When referring to this page, please quote Procedure M90101 Edition 0258 Page 5 (13)
901-1.3 Cylinder Cover
Overhaul MAN B&W Diesel

Reconditioning of Bores
4.
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

M90101-0258O04

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-
5. dum No. 200).

After the milling/grinding, clean the bore

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

1 2 3
M90101-0258O05

Page 6 (13) When referring to this page, please quote Procedure M90101 Edition 0258
 Cylinder Cover 901-1.3
MAN B&W Diesel Overhaul

6. Exhaust valve bore.

6.
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.

M90101
0255O06
7. Starting valve bore.

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

grinding disc.

Recondition the starting valve bore and 7.

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.
M90101
0255O07

When referring to this page, please quote Procedure M90101 Edition 0258 Page 7 (13)
901-1.3 Cylinder Cover
Overhaul MAN B&W Diesel

8. Indicator
safety valve bore.

8.
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 fit the
valve studs.

Tighten up the studs in accordance with

M90101
0255O08

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-
9. 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

D01-01 Procedures 907
2.4, 908
2.4 and 909
11.4.
M90101-0258O09

Page 8 (13) When referring to this page, please quote Procedure M90101 Edition 0258
 Cylinder Cover 901-1.4
MAN B&W Diesel Mounting

Landing Preparation
1.
1. Sealing ring.

Check that the liner sealing surface is

clean.

Place a new sealing ring on top of the cyl-

inder liner.

If necessary fit a new ‘klinger’ sealing ring

in the groove of the flange of the intermedi-
ate pipe.

M90101-0258M01
2. Water connections.

Check that the water connections are clean

and provided with new O
rings.

Lubricate the O
rings with Vaseline and fit 2.

them on the cylinder liner.
M90101
0255M02

When referring to this page, please quote Procedure M90101 Edition 0258 Page 9 (13)
901-1.4 Cylinder Cover
Mounting MAN B&W Diesel

Cylinder Cover Mounting

3.
3. Cylinder cover landing.
D01-06
Carefully wipe the cylinder cover contact
surface facing the cylinder liner.

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.
M90101-0258M03

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
4. cover.

If necessary, adjust to the distance D01
05

by turning the stud.
D01
05
M90101
0254M04

Page 10 (13) When referring to this page, please quote Procedure M90101 Edition 0258
 Cylinder Cover 901-1.4
MAN B&W Diesel Mounting

5. Cylinder cover tightening.

5.
Fit and tighten the cylinder cover nuts.
D13-01
For operation of hydraulic jacks, see Proce-
dure 913
1.

Fit the protective caps on the cylinder cov-

er studs.

Fitting Pipe Connections

6. Fit the exhaust gas compensator.

M90101-0258M05
Fit the screws in the flanges between the
intermediate pipe and the exhaust receiver,
tight the screws.

Note!
Lubricate the screws with ‘Never Seize’ 6.
or molybdenum disulphide (MoS2) before
fitting.

Fit the insulating jacket around the interme-

diate pipe.
M90101-0258M06

When referring to this page, please quote Procedure M90101 Edition 0258 Page 11 (13)
901-1.4 Cylinder Cover
Mounting MAN B&W Diesel

7. Connect the starting air pipe.

7.
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.

M90101-0258M07

Mount the hydraulic high pressure pipe for

the exhaust valve. See Procedure 908
1.4.

Connect the drain pipe for the exhaust

valve.
8.
Connect the fuel oil high pressure pipes.
See Procedure 909
14.4.

Connect the pipes for return fuel oil from

the fuel valves.

Check that all the pipe connections are fit-

ted and tightened.
M90101-0258M08

9.
M90101-0258M09

Page 12 (13) When referring to this page, please quote Procedure M90101 Edition 0258
 Cylinder Cover 901-1.4
MAN B&W Diesel Mounting

Open Oil and Water Supply

10.
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

on the exhaust side of the main pipe.

Vent the unit by releasing air through the

venting cock next to the outlet valve.

When the venting is finished, close the

venting cock. Open the water outlet valve
on the main pipe.

11. Open the oil supply.

M90101
0255M10

Open the fuel oil supply for the unit con-

cerned.

11.
M90101
0254M11

When referring to this page, please quote Procedure M90101 Edition 0258 Page 13 (13)
 Cylinder Cover Panel Plate
P90151-0186

When referring to this page, please quote Plate P90151 Edition 0186 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover Panel
P90151-0186

Item Item Description Item Item Description

No. No.

010 Panel for tools

022 Name plate
046 Grinding tool, exhaust valve seat
058 Milling and grinding tool, fuel valve
seat
060 Milling and grinding wheel, fuel start-
ing valve
071 Dismantling tool, fuel valve
083 Handle, grinding tools
095 Grinding ring, starting valve seat
105 Pin spanner, starting valve
117 Test equipment, combined safety
valve
130 Lifting chains, cylinder cover

Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0186
MAN B&W Diesel A/S
 Cylinder Cover - Tools Plate
P90161-0103
Cylinder Cover - Tools
0103
P90161

When referring to this page, please quote Plate P90161 Edition 0103 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover - Tools
P90161-0103

Item Item
Item Description Item Description
No. No.

027 Hydraulic jack, complete

039 Support
040 Support
052 O-ring with back-up ring
064 O-ring with back-up ring
090 Key, hexagon socket screw
100 Tommy bar
111 Stud setter
206 Hydraulic, tool set, complete
218 Hydraulic, tool set, complete

Page 2 (2) When referring to this page, please quote Plate P90161 Edition 0103
MAN B&W Diesel A/S
 Cylinder Cover - Lifting Tools Plate
MAN B&W P90165-0003

When referring to this page, please quote Plate P90165 Edition 0003 Page 1 (2)
Plate Cylinder Cover - Lifting Tools
P90165-0003 MAN B&W

Item Item
Item Description Item Description
No. No.

017 Lifting tool for cylinder cover

029 Lifting tool for cylinder cover

Page 2 (2) When referring to this page, please quote Plate P90165 Edition 0003