909 - Fuel Oil System: Documents in This Chapter

909 - Fuel Oil System
Documents in this Chapter
10911 0065 Fuel Valve, Data

90911 0240 Fuel Valve
10912 0046 Spindle Guide , Data
90912 0227 Spindle Guide
10913 0033 Non-Return Valve in Fuel Pump, Data
90913 0206 Non-Return Valve in Fuel Pump
10914 0069 Fuel Oil High-Pressure Pipes, Data
90914 0242 Fuel Oil High-Pres Pipes
90961 0069 Fuel Valve - Tools
90966 0007 Fuel Valve Nozzle - Tools
90968 0001 Fuel Valve - Inspection Tools
90974 0001 Fuel Valve Nozzle - Cleaning Tools
90981 0001 Mounting Tools - Top Cover Seals
MAN B&W Diesel A/S

MAN B&W Diesel A/S
Fuel Valve 109-11
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
Engage turning gear
Shut off cooling water
X Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors
Data
Ref. Description Value Unit
D09-40 Fuel valve opening pressure 300 - 380 bar

D09-42 Inlet seat, max. diameter 25 mm
D09-43 Fuel valve 16 kg
When referring to this page, please quote Data D10911 Edition 0065 Page 1 (2)
MAN B&W Diesel A/S
109-11 Fuel Valve
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 71 Dismantling tool for fuel valve

P90951 94 Milling tool for fuel oil pipe seats
P90951 165 Grinding mandrel for valve head
P90951 189 Grinding mandrel for holder - outside
P90951 190 Grinding mandrel for holder - inside
P90951 297 Assembling tool for fuel valve
P90961 14 Fuel Valve tester, complete
Page 2 (2) When referring to this page, please quote Data D10911 Edition 0065
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
1. Fuel Valve
1.
The fuel valves must be given the utmost at-
tention and care, as the greater part of irregu-
larities that may occur during the running of the
engine can be attributed to defects in these
valves.
If the engine gives normal performance in ac-

cordance with diagrams and exhaust tempera-
tures, it is only necessary to inspect the fuel
valves after the service period stated in the
Checking and Maintenance Programme. See
Chapter 900-1.
In order to obtain reliable results during testing

of the fuel valves, all fuel valves that are dis-
mantled from the engine must be disas-
sembled, cleaned, inspected and re-assembled
before testing. See Procedure 909-11.3 and
909-12.3.
M909110240C01
Note!
In the event that the slide-type fuel valve is

pressure tested without being cleaned be-
tween the fuel nozzle and the cut-off slide,
the opening pressure value measured might 2.
be considerably lower than specified.
All fuel valves must be function-tested before

being mounted in the cylinder cover.
Pressure testing pump
Use only hydraulic oil (rust-preventing) with a

viscosity of between 7 and 10 cSt at 50°C.
For operation of the pressure testing pump,

see the supplier's instructions.
Note that the high-pressure pump should be

periodically checked in accordance with the
supplier's instructions.
2. Spring housing
To ensure that over tightening has not taken

place, check that the locking/indicating pin has
M909110240C02
not been bent or broken off.
In the event of over tightening, replace the

spring housing by a new one.
When referring to this page, please quote Procedure M90911 Edition 0240 Page 1 (13)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
3. Setting-up the fuel valve

3.
Place the fuel valve in the test rig and secure it
with the spring housings and nuts.
Tighten the nuts until the top face of the pres-

sure disc is flush with the top face of the
spring housings. Mount the oil pipe between
the pressure testing pump and the fuel valve.
Pressure testing procedure
The following functions of the fuel valve must

be checked:
M909110240C03
• Flushing and jet control

• Opening pressure
• Sealing test and sliding function
4. • Pressure test, O-ring sealing
4. Flushing and jet control
Remove air in the system and check the fuel

jet in the following way.
Slowly increase the oil pressure until straight

jets of oil are ejected from the nozzle holes (no
atomization).
Acceptance criteria:
M909110240C04
There is to be a continuous jet of oil through at

least one of the nozzle holes.
Owing to the geometry of the internal part of

the nozzle - and because of the height to
which the spindle is lifted during pressure test-
ing is lower than the height it is lifted during
normal engine operation - the fuel oil will not
necessarily flow from all of the nozzle holes.
Cause of fault:
If the jets do not fulfil the above point, the

cause may be:
Dirt in the nozzle holes
The nozzle is not mounted correctly
Page 2 (13) When referring to this page, please quote Procedure M90911 Edition 0240
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
5. Opening pressure
5.
To check the opening pressure, increase the oil
pressure until oil is admitted through the nozzle D0940
holes.
Check the opening pressure on the pressure

gauge and compare with Data D09-40 on the
datasheet.
Note!
Do NOT attempt to carry out an atomization

test on the slide type fuel valvs, as this may
damage the cut-off slide and nozzle.
Cause of fault:
If the opening pressure is higher than specified

in D09-40, the cause may be that a wrong type
of spring is used - replace the spring on the
M909110240C05
thrust spindle, if necessary, replace the com-

plete thrust spindle.
If the opening pressure is lower than specified

in D09-40, the cause may be that the spring
has sagged - replace the spring, or add a spe-
cial thin disc.
Note!
Special thin discs are available as spares.
If a spring or a disc has been changed, the

pressure testing procedure of the fuel valve
must be repeated.
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking
6. Sealing test and sliding function

6.
To check the needle valve seat for tightness
and the slide for correct closing.
Slowly increase the oil pressure to about 50

bar below the opening pressure. Maintain the
built-up pressure by closing for the oil supply.
Oil must not flow from the nozzle holes.

M909110240C06
The pressure drops relatively slowly to about

15 bar, after which it drops quickly to 0 (the
slide is pressed against the conical seat and
opens for circulation oil).
Note!
Oil flows out of the leak oil outlet when the
fuel valve is full of oil.
Cause of fault:
If oil flows out of the nozzle holes, the cause is

either:
• Defective spindle guide at needle seat,
or a sticking spindle. Examine and/or
replace the spindle guide.
See Procedure 909-12.3.
• Too quick pressure drop:
- the clearances of the movable parts, both of

the spindle guide and of the non-return valve,
are too large, or the seats between the thrust
piece/spindle in the spindle guide or thrust
piece/valve slide in the non-return valve are
damaged.
Examine and/or replace both the spindle guide

and non-return valve. See Procedure 909-12.3.
If a quick pressure drop from 15 to 0 bar can-

not be registered:
• The valve slide is sticking; or
• The vent hole in the thrust piece is
blocked.
If so, disassemble and examine the spindle

guide, replace if necessary. See Procedure
909-12.3.
MAN B&W Diesel A/S
Fuel Valve 909-11.1
Checking
7. Pressure test, O-ring sealing

7. Max. 10 bar
To ensure that the leak oil (circulation oil) re-
mains in the closed system, build up a working
pressure of about max. 10 bar until oil flows
out of the leak oil outlet.
Close the leak oil outlet with a gasket and plug

screw.
Max. 100 bar
Increase the working pressure to about 100
bar.
The built-up pressure of about 100 bar should

be maintained.
Cause of fault: Max. 100 bar
If oil leaks out at the union nut, the O-ring in-

side the fuel valve head is defective, and must
be replaced.
M909110240C07
8. Atomization test
Note!
8.
Do NOT attempt to carry out an atomization
test on slide type fuel valves, as this may
damage the cut-off slide and nozzle.
The atomization test may damage the valve be-

cause it makes the needle oscillate, with a
small lift at a very high frequency. The high
pressure drop across the cut-off edge and the
high contact pressure between slide and fuel
nozzle, in combination with the poor lubricity of
the test oil, increase the risk of seizures be-
tween cut-off slide and nozzle.
M909110240C08
All of these conditions involve the risk of sei-

zure between the cut-off slide and the nozzle.
MAN B&W Diesel A/S
909-11.2 Fuel Valve
Dismantling
1. Close the fuel oil inlet and outlet valves,

1. and drain the high-pressure pipe and the
fuel valve.
Dismantle and remove the fuel oil high-

pressure pipe.
Disconnect the return oil pipe from the fuel

valve.
2. Remove the nuts and the spring housings.

M909110240D01
3. Take out the valve. If the valve is sticking,

use the fuel valve dismantling tool to pull
the fuel valve clear of the top cover.
If the valve is not to be overhauled immedi-

2. ately, the valve should be placed immersed
in diesel oil until overhauling.
M909110240D02
3.
D0943
M909110239D03
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
When fuel valves are overhauled, all parts

should be handled carefully and be kept clean. 1.
Use only clean, non-fluffy rags for wiping pur-

poses. Make sure to remove all liquid or solid
impurities. Whenever fuel valves are over-
hauled, all sealing rings should be discarded
and replaced by new, faultless sealing rings be-
fore reassembly.
1. Measure the length A of the protruding part

of the nozzle, and write down the result for
correct re-assembling of the valve. A
M909110240O01
2. Place the valve holder in a machine vice,
mount the fuel valve in the holder and fit
the valve with the guide disc from the
grinding tool.
3. Compress the fuel valve and the spring in- 2.

side, by means of a drilling machine, to
avoid seizures in the union thread. Hold the
fuel valve compressed and unscrew the
union nut with a hook spanner.
Remove the valve from the valve holder.

M909110240O02
3.
M909110240O03
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
Pull the valve head clear of the valve housing.

4.
Remove the:
• Non return valve
• Thrust spindle parts
• Thrust foot
• Spindle guide and fuel nozzle
from the valve housing.
Remove and discard all the O-rings.

M909110240O04
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
4. Carefully clean and examine all surfaces of

the: D0942
• Fuel valve housing
• Fuel valve head
• Thrust spindle
If necessary, grind the seating surfaces by

means of the grinding mandrels supplied and a
fine-grain abrasive (such as Carborundum No.
500).
This grinding must only be carried out manu-

ally.
After the grinding, wash the parts in gas oil

and blow clean by means of compressed air to
remove any remains of the grinding compound.
In the event of more serious damage to the

seating surface for the high-pressure pipe in
the valve head, the milling tool can be used.
Normally, the milling tool is turned by hand, but

it may be fitted in the chuck of a column-type
drilling machine provided that the number of
revolutions is kept at a minimum (not exceed-
ing approx. 100 r/min). An ample supply of cut-
ting emulsion must be used.
Note!
Take care not to exceed the maximum dia-
meter of the seat, see Data.
M909110239O04
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
5. The complete spindle guide, including the

5. fuel nozzle, should be sent to an
authorised MAN B&W repair shop for over-
haul. If this is not possible, the spindle
guide may be overhauled on board.
Note!
Do not attempt to remove the fuel nozzle

from the spindle guide unless the spindle
guide has been dismantled. Otherwise the
M909110240O05
cut-off slide on the spindle may be dam-

aged.
6. The non-return valve should be sent to an

authorised MAN B&W repair shop for over-
haul. If this is not possible, the non-return
6.
valve may be overhauled on board.
7. Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.
Carefully slide the spindle guide down into

the valve holder, and turn the nozzle until
the spindle guide engages correctly with
the guide pin. Check that distance A corre-
M909110240O06
sponds to the measurement taken before

the valve was disassembled.
Note!
Make sure that the fuel nozzle and

7.
spindle guide engage correctly with the
guide pin in the fuel valve housing. This
can be ascertained by attempting to turn
the nozzle after mounting. It must not be
possible to turn the nozzle.
M908020253D05
MAN B&W Diesel A/S
Fuel Valve 909-11.3
Overhaul
8. Mount:
8.
• the thrust foot
• the parts of the thrust spindle
• the non-return valve
in the fuel valve housing.
Mount a new O-ring in the uppermost

groove of the fuel valve housing.
Lubricate the thread of the valve head with
M909110240O08
molybdenum disulphide (MoS2).
For the correct use of this lubricant, see

Procedure 913-11.
Fit the valve head with new O-rings. 9.
9. Make sure that the guide pin between

valve housing and valve head is intact, and
press the valve head down into the valve
housing.
See that the guide pin between valve hous-

ing and valve head engages correctly so as
to prevent relative turning of the parts.
M909110240O09
MoS 2
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
10. Assemble the valve by means of the union

10. nut.
Place the valve in the valve holder in a drill-

ing machine.
Compress the fuel valve and the spring in-

side. Keep the valve compressed and
tighten the union nut with a hook spanner.
After overhaul, the fuel valve must be

tested in the test rig.
11. If the fuel valve is not to be mounted in the

engine immediately after the overhaul,
cover all openings of the valve with plastic
to prevent dirt from entering the valve dur-
ing storage.
M909110240O10
MAN B&W Diesel A/S
Fuel Valve 909-11.4
Mounting
1. Before mounting the fuel valve, thoroughly

clean the valve bore in the cylinder cover 1.
and check the seating in the bore for
marks which, if any, must be eliminated.
(For reconditioning of the valve bores in the D0943
cylinder cover, see Procedure 901-1.3).
If not already done, mount new O-rings on

the fuel valve. Lubricate the valve with mo-
lybdenum Disulphide (MoS2). MoS 2
2. Mount the valve in position in the cylinder

cover.
M909110239M01
Mount the spring housings and the nuts.
Tighten the nuts until the top face of the
pressure disc is flush with the top face of
the spring housing. This must be done with
great care, as the spring tension in the
housing determines the correct tightening 2.
of the fuel valve to the cylinder cover as
well as the correct compression of the fuel
valve.
3. Lubricate the thread on the union nipple of

the fuel oil pipe with a heat resistant anti
seize grease before mounting.
Note!
It is recommended to overhaul the fuel oil

high-pressure pipe before mounting.
M909110240M02
As a minimum, the distance between

the fuel oil pipe ends and the thrust
bushings must be checked and, if nec-
essary, adjusted. 3.
Mount the overhauled fuel oil high-pressure

pipe and the return oil pipe.
Note!
All fuel valves must be function-tested

before being mounted in the cylinder
cover, see Procedure 909-11.1.
M909110240M03
MAN B&W Diesel A/S
Spindle Guide 109-12
Data
Stopped engine
Shut 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 lubricating oil pumps
Engage turning gear
Shut off fuel oil
Data
D09-70 Nozzle spray hole cleaning tool table
Nozzle Cleaning
spray hole drill Test pin
1.40 1.35 1.44
1.45 1.40 1.49
1.50 1.45 1.54
1.55 1.50 1.59
1.60 1.55 1.65
1.65 1.60 1.70
1.70 1.65 1.74
1.75 1.70 1.80
1.80 1.75 1.85
1.85 1.80 1.89
1.90 1.85 1.94
1.95 1.90 1.99
2.00 1.95 2.05
D09-71 Nozzle spray hole diameter 1.65 mm

MAN B&W Diesel A/S
109-12 Spindle Guide
Data
P90966 Fuel Valve Nozzle - Tools

P90968 Probe light with magnifier, complete
P90974 Fuel Valve Nozzle - Cleaning Tools
MAN B&W Diesel A/S
Spindle Guide 909-12.3
Overhaul
Spindle Guide
K98MC-C
0227
Overhaul
909-12.3
2.
Note!
This instruction is only valid for spindle

guides of the slide valve design.
Extreme care and accuracy should be

exercised when carrying out this opera-
tion.
Based on service experience it is recom-

mended to replace the complete spindle
guide after 16000 hours of operation.
1. Clean the outside of the spindle guide in pure

gas oil or similar. The individual parts of the
spindle guide are not interchangeable, there-
fore only one guide is to be disassembled at
a time.
Note!
MA909-6.2 111 02
The spindle guide, thrust piece and spin-

dle are matched parts and may not be re-
placed individually.
2. Place the spindle guide in a bench vice pro- 4.

vided with “soft” jaws, and use the brass
mandrel as shown to disassemble the spin-
dle guide.
3. Mount the pulling tool around the fuel noz-

zle on the spindle guide. Turn the nut to pull
the fuel nozzle off the spindle guide.
Note!
The pulling tool is not standard for all

engines, but may be delivered as an
optional extra.
4. If no pulling tool is available, the fuel nozzle

can be dismantled from the spindle guide
using two screwdrivers.
Place the screwdrivers opposite each other

in the small gap between the fuel nozzle
and the spindle guide and very carefully
MA909-6.2 111 03
force the fuel nozzle off the spindle guide.
MAN B&W Diesel A/S
909-12.3 Spindle Guide
Overhaul
5. 5. Clean all the parts of the spindle guide in

gas oil and wipe dry with a clean piece of
cloth.
Clean all parts again in gas oil or ‘Electro-

cleaner’ and wipe dry with a clean piece of
cloth.
Place all the parts on a clean, soft, lint-free

cloth and examine them through an 8-10
times magnification magnifying glass and
an inspection lamp.
During the examination, pay special atten-

tion to the seating surfaces and sliding sur-
faces of the parts.
6. Remove any deposits or very fine scratches

by placing the spindle, thrust piece or spin-
dle guide respectively in a lathe, as shown,
and polishing with a very fine conventional
polishing linen ‘grade 360’.
MA909-6.2 111 04
Use also a little oil for the polishing (a

coarser polishing linen must absolutely
not be used).
6.
Note!
The sliding surface of the cut-off slide

may only be polished VERY carefully.
The sliding surface must not be dam-
aged.
After polishing, clean the parts again and

re-check the seat on thrust piece/spindle,
the seat on slide valve/spindle, and the seat
on spindle/guide. Use an inspection lamp
and an 8-10 times enlargement magnifying
glass.
MA909-6.2 111 05
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
MAN B&W Diesel A/S
Overhaul
7. Clean any carbon deposits from the central 7.

bore of the fuel nozzle by means of the spe-
cial brass brush. Clean the fuel nozzle with
gas oil and wipe dry with a clean cloth.
8. See Data for nominal spray hole size, and

compare with the sketch for correct hole po-
sition. Find correct drill size and matching
test pin in the table, D09-70, on the data
sheet, via the nominal hole size.
9. Clean the spray holes, using gas oil and the

special drills supplied.
MN909-12.3 225 07
Note!
During this operation be very careful not

to push the drill too far to avoid scratch- D09-71 D09-75
8.
ing the snug-fit surface on the inside of
the fuel nozzle.
Then test the spray holes with the test pin.

If the test pin is able to enter just one of the D09-72
holes, the fuel nozzle must be discarded.
This also applies to nozzles with oval holes D09-74

(can be ascertained with a magnifying
glass).
D09-73
Check the fuel nozzle before mounting on
MN909-12.3 225 08
the spindle guide, the cut-off slide must be

able to move freely inside the nozzle.
Note!
It is recommended that the fuel nozzle is 9.

changed whenever the spindle guide is
being overhauled or at maximum 8000
running hours.
MN909-12.3 225 09
MAN B&W Diesel A/S
909-12.3 Spindle Guide
Overhaul
11. 10. Lubricate the spindle and the thrust piece

with the cut-off slide with a little Molybde-
num Disulphide (MoS2), see Procedure
913-11.
11. Assemble the thrust piece, the spindle and

the spindle guide and carefully knock the
parts together using a soft hammer.
12. Shake the spindle guide back and forth.

The spindle with the cut-off slide must be
able to slide freely back and forth inside the
spindle guide, with a ‘clicking’ sound.
MN909-12.3 215 09
12.
MN909-12.3 215 10
MAN B&W Diesel A/S
Overhaul
13. Lubricate the sliding surfaces of the nozzle 13.

and the spindle with a little Molybdenum Di-
sulphide (MoS2). See Procedure 913-11.
Mount the nozzle on the spindle guide.
Make sure that the half-circle shaped

groove on the nozzle and the spring pin are
in line. Spring pin
If nozzle and spindle guide are provided

with scratch marks opposite the spring pin,
they must be in line.
Place the parts on the plane of a drilling

machine or hydraulic press and position the
mounting tool over the parts. Make sure
that all the parts are perfectly aligned.
Scratch marks
Press the nozzle on to the spindle guide.
HN909-12.3 221 11
Note!
The mounting tools are not standard for

all engines but may be delivered as
optional extras.
If no mounting tools are available, the noz-

zle can be mounted on the spindle guide
using a short piece of pipe.
Place the pipe around the nozzle, so that

the lower end of the pipe rests on the ‘foot’
of the fuel nozzle. Then press the parts to-
gether the same way as when using the
mounting tools.
Check that the spindle inside the spindle

guide is able to move freely as in step 10.
14. If the spindle guide is not to be mounted in a

fuel valve immediately after the overhaul, cov-
er all openings of the spindle guide with plas-
tic to prevent dirt from entering the spindle
guide during storage.
MAN B&W Diesel A/S
Non-return Valve 109-13
Data
Stopped engine
Shut off star ting air supply – At star ting air receiver
Block the main star ting valve
Shut off star ting 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 fuel oil
Data
MAN B&W Diesel A/S
109-13 Non-return Valve
Data
P90951 153 Flange for dismantling of non return valve

P90968 Fuel Valve - Inspection Tools
MAN B&W Diesel A/S
Non-return valve 909-13.3
Overhaul
Non-return valve
K98MC-C
0206
Overhaul
909-13.3
1.
Note!
Extreme care and accuracy should be

exercised when carrying out this opera-
tion.
1. Clean the outside of the non-return valve

with pure gas oil. The individual parts are
not interchangeable, therefore only one
guide is to be disassembled at a time.
Note!
Except for the slide valve spring, defec-

tive parts cannot be replaced individually

by new ones.

&
Place the non-return valve as shown in Fig. 0
1 in a bench vice provided with “soft” jaws,

A
and disassemble the non-return valve, us- 2.
ing the disassembling tool and a hammer
as shown.
2. Clean all the parts for the spindle guide in

gas oil and wipe them dry with a clean B C D
piece of cloth.

Finally, clean in either gas oil, kerosene or

‘Electrocleaner', and wipe the parts dry with

%
1
a clean piece of cloth.
3. Now place the parts on clean, lint-free rags 3.

and examine with an 8-10 times enlarge-
ment magnifying glass, and an inspection
lamp with magnifying glass as shown in Fig.
3.

&
0
0$1% :'LHVHO$6
909-13.3 Non-return valve
Overhaul
4. 4. Examine the slide faces of movable parts

for coating. Vent slide B/housing A will be
too tight if there is a coating. (The letters A-
D refer to the letters/parts in Fig. 2).
Fix vent slide B and, subsequently, housing

A in a lathe as shown in Fig. 4 and remove
the coating by means of very fine conven-
tional polishing linen ‘grade 360'.
Also a little oil should be used (a coarser

polishing linen must absolutely not be
used).
MC909-6.2 69 04
5. Check spring C for the thrust piece for out-

side wear marks. If defective, it should be
exchanged.
5. Check the seat on thrust piece D/vent slide,

and the seat on vent slide/housing. Use an
inspection lamp and an 8-10 times enlarge-
ment magnifying glass.
If the seats are not in order, i.e. if there are

pressing-in marks or similar on the seats,
the complete spindle guide must be dis-
carded.
NA909-13.3 205 05
6. Mount the non-return valve as follows:
• Lubricate all movable parts with molyb-

denum disulphide (MoS2).
6.
• Place the loosely-assembled non-return
valve on the plane of a drilling machine,
with the tool positioned as shown in Fig.
6.
• Make sure that the thrust piece and the

other parts are perfectly aligned and that
the thrust piece is guided in the vent
slide.
• Press the handle until the housing and

thrust piece meet.
7. If the non-return valve is not to be mounted

in a fuel valve immediately after the over-
haul, cover all openings of the non-return
valve with plastic to prevent dirt from enter-
MC909-6.3 69 06
ing the valve during storage.
0$1% :'LHVHO$6
Fuel Oil High-Pressure Pipe 109-14
Data
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
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
X Engage turning gear
X Shut off fuel oil
X Stop lubricating oil supply
Data
D09-47 Fuel oil high-pressure pipe, tightening torque 300 Nm

D09-50 Union nuts, tightening torque 55 Nm
D09-52 Fuel oil pipe 25 kg
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipe
Data
P90951 104 Milling tool for fuel oil pipe

P90951 116 Crowfoot spanner
P90951 128 Crowfoot spanner
MAN B&W Diesel A/S
Fuel Oil High-Pressure Pipe 909-14.2
Dismantling
High-Pressure Pipe with Double Pipe 2.
1. Close the fuel oil inlet and outlet valves.
2. Unscrew the union nut at the fuel valve end

of the high-pressure pipe.
Pull the union nut clear of the union nipple.
Unscrew the union nipple from the fuel

valve.
3. Unscrew the union nut at the fuel oil pres-
M909140242D02
sure booster end of the high-pressure pipe.
Pull the union nut clear of the union nipple.
Unscrew the union nipple from the fuel

pump. 3.
4. Lift the pipe ends clear of the fuel valve/

fuel pump, and remove the high-pressure
pipe from the engine.
Note!
It is recommended always to overhaul
the high-pressure pipe before remount-
ing it on the engine.
M909140242D03
The overhaul should preferably take

place immediately after the high-pres-
sure pipe has been dismantled.
4.
D0952
M909140242D04
MAN B&W Diesel A/S
909-14.3 Heading
Overhaul
Whenever the fuel oil high-pressure system has

1.
been dismantled, it is necessary, before re-
mounting the high-pressure pipes, to carefully
inspect the tapered contact surfaces of the
pipe ends, together with their seats in fuel
valves and fuel oil pressure booster top cover.
If the pipe ends require reconditioning, proceed

as follows:
1. If not already done, unscrew the union nuts

from the union nipples.
M909140242O01
2. Fasten the pipe in a vice with soft jaws.

Mount the miller on the pipe end.
Note!
The two pipe ends are of different de-

2. signs – see sketch.
A
Turn the upper tightening ring (A) until the
miller presses against the pipe end.
Turn the miller with, for instance, a tap

wrench while lightly tightening the upper
tightening ring (A) to provide a suitable
pressure between the miller and the pipe
end.
During the milling process, add drilling oil

A emulsion liberally.
M909140242O02
3. On both pipe ends a small groove has

been ground to indicate the maximum al-
lowable grinding of the pipe ends.
3. The pipe ends may only be ground until the

ground surface is flush with the bottom of
Max. grindaway the groove.
If the pipe ends are still not in order, the

pipe must be discarded.
After completing the milling, carefully clean

the high-pressure pipe, and blow through
the bore with compressed air.
M909140242O03
MAN B&W Diesel A/S
Heading 909-14.3
Overhaul
4. Lift up the union nuts and the union 4.

nipples.
Remove the spring rings from the two-part

sleeves. Remove the sleeves.
5. Remove the union nipple and union nut

from the pipe ends. Clean all parts and re-
place the O-rings. Remount the union
nipple and union nut on both pipe ends.
6. Mount the two-part sleeves and lock the

sleeves with the spring rings.
M909140242O04
Screw the union nuts losely (approx. 2
revolutions) on to the union nipples.
5.
M909140242O05
6.
M909140242O06
MAN B&W Diesel A/S
909-14.4 Fuel Oil High-Pressure Pipe
Mounting
1. Check that the sealing surfaces on both

4.
D0952 pipe ends are in order without scratches or
pressing-in marks.
2. Ensure that the fuel valve is fitted with a

new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.
3. Ensure that the union nipple at the fuel oil

pressure booster end of the high-pressure
pipe is fitted with a new O-ring. Lubricate
the thread on the union nipple with a heat
resistant grease.
M909140242M04
4. Mount the high-pressure pipe between the

fuel valve and the fuel oil pressure booster.
Screw the union nipples onto the fuel valve
and into the fuel oil pressure booster top
cover, by hand.
5.
Note!
D0950 The nipples must be screwed by hand,
as the threads of the union nipples, fuel
valve or fuel oil pressure booster top
cover might otherwise be damaged.
Tightening with a crowfoot wrench
should only be done after both of the
union nipples have been screwed into
position.
5. If not already done, screw the union nut

M909140242M05
D0947 loosely (approx. 2 revolutions) on to the

union nipple screwed into the fuel valve.
Using a crowfoot wrench and torque

wrench, tighten the union nipple, then the
6. union nut, to the torques stated in data.
D0950 6. Repeat step 5 on the union nipple screwed
into the fuel oil pressure booster.
If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet
and outlet valves.
M909140242M06
D0947
MAN B&W Diesel A/S
Fuel Valve - Tools Plate
P90961-0069
When referring to this page, please quote Plate P90961 Edition 0069 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve - Tools
P90961-0069
Item Item Description Item Item Description

No. No.
014 High-pressure pump

026 Table
038 Rig fuel oil valve
040 High-pressure hose
051 Connection piece, M42x2
063 Test rig, complete
075 Cover
087 Angle union
099 Gasket
109 Plug screw
122 Hose
Page 2 (2) When referring to this page, please quote Plate P90961 Edition 0069
MAN B&W Diesel A/S
Fuel Valve Nozzle - Tools Plate
P90966-0007
Fuel Valve Nozzle - Tools
0007
P90966
For ordering new

cleaning tool;
please state the number
on the fuel nozzle.
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Tools
P90966-0007
Item Item
Item Description Item Description
No. No.
011 Tool box, empty

023 Extractor for fuel nozzle
035 Drift for fuel nozzle
047 Cleaning brush
202 Cleaning tool for fuel valve nozzle,
complete
MAN B&W Diesel A/S
Fuel Valve - Inspection Tools Plate
P90968-0001
Fuel Valve - Inspection Tools
0001
P90968
MAN B&W Diesel A/S
Plate Fuel Valve - Inspection Tools
P90968-0001
Item Item
No. No.
012 Probe light with magnifier, complete
MAN B&W Diesel A/S
Cleaning Tools - Fuel Valve Nozzle Plate
P90974-0001
Cleaning Tools - Fuel Valve Nozzle
0001
P90974
MAN B&W Diesel A/S
Plate Cleaning Tools - Fuel Valve Nozzle
P90974-0001
Item Item
No. No.
015 Drill*
027 Test mandrel*
039 Pin vice*
206 Cleaning tool set, complete
Note:
* When ordering new cleaning tool,
please state P/N on fuel nozzle.
MAN B&W Diesel A/S
Mounting Tools - Top Cover Seals Plate
P90981-0001
MAN B&W Diesel A/S
Plate Mounting Tools - Top Cover Seals
P90981-0001
Item Item Description Item Item Description

No. No.
013 Cone
025 Pushing tool
037 Compression tool
049 Spacer ring
MAN B&W Diesel A/S

909 - Fuel Oil System: Documents in This Chapter

Uploaded by

Copyright:

Available Formats

909 - Fuel Oil System: Documents in This Chapter

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

909 - Fuel Oil System: Documents in This Chapter

Uploaded by

Copyright:

Available Formats

909 - Fuel Oil System

Documents in this Chapter

10911 0065 Fuel Valve, Data

MAN B&W Diesel A/S

Ref. Description Value Unit

D09-40 Fuel valve opening pressure 300 - 380 bar

Plate Item No. Description

P90151 71 Dismantling tool for fuel valve

If the engine gives normal performance in ac-

In order to obtain reliable results during testing

In the event that the slide-type fuel valve is

All fuel valves must be function-tested before

Pressure testing pump

Use only hydraulic oil (rust-preventing) with a

For operation of the pressure testing pump,

Note that the high-pressure pump should be

To ensure that over tightening has not taken

not been bent or broken off.

In the event of over tightening, replace the

3. Setting-up the fuel valve

Tighten the nuts until the top face of the pres-

Pressure testing procedure

The following functions of the fuel valve must

• Flushing and jet control

4. Flushing and jet control

Remove air in the system and check the fuel

Slowly increase the oil pressure until straight

There is to be a continuous jet of oil through at

Owing to the geometry of the internal part of

If the jets do not fulfil the above point, the

Dirt in the nozzle holes

The nozzle is not mounted correctly

Check the opening pressure on the pressure

Do NOT attempt to carry out an atomization

If the opening pressure is higher than specified

thrust spindle, if necessary, replace the com-

If the opening pressure is lower than specified

Special thin discs are available as spares.

If a spring or a disc has been changed, the

6. Sealing test and sliding function

Slowly increase the oil pressure to about 50

Oil must not flow from the nozzle holes.

The pressure drops relatively slowly to about

If oil flows out of the nozzle holes, the cause is

- the clearances of the movable parts, both of

Examine and/or replace both the spindle guide

If a quick pressure drop from 15 to 0 bar can-

If so, disassemble and examine the spindle

7. Pressure test, O-ring sealing

Close the leak oil outlet with a gasket and plug

The built-up pressure of about 100 bar should

Cause of fault: Max. 100 bar

If oil leaks out at the union nut, the O-ring in-

The atomization test may damage the valve be-

All of these conditions involve the risk of sei-

1. Close the fuel oil inlet and outlet valves,

Dismantle and remove the fuel oil high-

See Procedure 909-14.2.

Disconnect the return oil pipe from the fuel