Air Cooler Element 110-1

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
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
X Engage turning gear
X Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D10-04 Air cooler element, complete with covers, up to 1700 kg

D10-06 Reversing chamber 215 kg
D10-07 Water inlet/outlet cover 300 kg

When referring to this page, please quote Data D11001 Edition 0059 Page 1 (2)
110-1 Air Cooler Element
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

P91063 Air Cooler - Tools

P91064 Travelling Trolley
P91066 Air Cooler - Lifting Tools
P91356 Lifting Tools, Etc.

Page 2 (2) When referring to this page, please quote Data D11001 Edition 0059
 Air Cooler Element 910-1.1
Checking
Air Cooler Element
S42MC
0231
Checking
910-1.1

1.
1. For the day-to-day checking of the scav-
enge air cooler, measure the drop in pres-
sure and temperature of the scavenge air
across the cooler while the engine is run-
ning.

Compare these measurements with the

testbed data. For further evaluation of the
measurements, see the instruction book
Volume I, OPERATION, Chapter 706.

2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of

GN910-1.1 207 01
the air side of the cooler.

A decrease in the air temperature drop

across the scavenge air cooler indicates
fouling of the water side of the cooler.
4.
3. If the measurements indicate fouling of the
water side of the air cooler element, the el-
ement must be dismantled and overhauled/
cleaned.

If the measurements indicate fouling of the

air side of the air cooler element, it is rec-
ommended to inspect the air cooler ele-
ment as follows:

4. Remove the inspection cover from the air

cooler.
GN910-1.1 207 04

5. Visually inspect the air cooler element

through the opening.

If the air side of the element is fouled, clean

the element using the spray pipe arrange- 5.
ment fitted above the air cooler element.
See Procedure 910-1.3.
GN910-1.1 207 05

When referring to this page, please quote Procedure M91001 Edition 0231 Page 1 (7)
MAN B&W Diesel A/S
910-1.2 Air Cooler Element
Dismantling
Dismantling
910-1.2

2. 1. Close the cooling water inlet and outlet

valves. Open the drain cocks to drain off the
cooling water.

2. Dismount the cooling water inlet and outlet

pipes from the end cover.

Remove and discard the gaskets.

3. Dismantle the screws and pull out the cool-

er element approx. 10 cm, using the dis-
mantling screws.
GN910-1.2 207 01

2.
GN910-1.2 207 02

3.
GN910-1.2 207 03

Page 2 (7) When referring to this page, please quote Procedure M91001 Edition 0231
MAN B&W Diesel A/S
 Air Cooler Element 910-1.2
Dismantling

4. Mount the lifting bracket on the front end 4.

cover.

Attach two tackles to the lifting bracket, one

horizontally and one vertically.

Using the vertical tackle, lift the air cooler

element approx. 2-3 mm.

Using the horizontal tackle, pull out the air

cooler element approx. half a metre.

5. Mount the two guide rails on the frame

EN910-1.2 222 04
around the air cooler element.

6. Using the horizontal tackle, pull out the air

cooler element far enough to gain access to
the aft end cover.
5.
Mount two shackles in the upper corners of
the aft end cover.

Mount lifting wire ropes between the two

shackles and the lifting bracket, and hook
the engine room crane on to the lifting wire
ropes.

Remove the two tackles and lift the air cool-

er element away. Land the element on a
couple of wooden planks.
EN910-1.2 222 05

Note!

During the lift, take care not to damage

the air cooler element.
6.
D10-04
EN910-1.2 222 06

When referring to this page, please quote Procedure M91001 Edition 0231 Page 3 (7)
MAN B&W Diesel A/S
910-1.3 Air Cooler Element
Overhaul
Overhaul
910-1.3

1. Cleaning the air side:

1. The air side of the cooler is cleaned by in-

jecting a chemical fluid through the spray
pipe arrangement fitted to the air chamber
above the cooler element.

It is recommended to use one of the follow-

ing cleaning fluids, or a similar product.

• Product: ACC 9, produced by

Drew Chemical Corp., New York, USA
GN910-1.3 207 01

• Product: 80B, produced by

Vecom Int., Maassluis, Holland

2. Do not start cleaning until the engine has

3. been at a standstill for about 30 minutes.
Do not disconnect the compressed air sup-
ply to the exhaust valve.

Remove the covers on the scavenge air re-

ceiver to let vapours escape.

3. Follow the detailed cleaning instructions

displayed at the cleaning pipe on the en-
gine. To ensure satisfactory spraying of the
cleaning fluid, the circulating pump pres-
sure must be at least 0.7 bar.

4. Continue the cleaning process for at least

30 minutes. The time required depends on
DG910-5.1 62 01

the frequency with which cleaning is carried

out and on the chemical product used.

5. After cleaning, flush the cooler with clean

water until the water in the sight glasses ap-
pears clean and pure.

6. Inspect the air cooler element by removing

the cover of the scavenge air cooler hous-
ing.
See Procedure 910-1.2.

Page 4 (7) When referring to this page, please quote Procedure M91001 Edition 0231
MAN B&W Diesel A/S
 Air Cooler Element 910-1.3
Overhaul

Cleaning the water side 2.

1. Dismantle the air cooler element and re-

move it from the engine.
See Procedure 910-1.2.

2. Dismantle the front end cover of the air

cooler element. Remove and discard the
gasket.

3. Dismantle the aft end cover of the air cooler

element. Remove and discard the gasket.

4. Clean the water side of the cooler element

GN910-1.3 207 02
(the inside of the tubes) using the cleaning
brush mounted on a drilling machine. Flush D10-07
the tubes with clean fresh water.

In the event of a leaking tube, plug both 3.

ends of the tube using a brass or copper
plug.

In the event of leakages between a tube

and the tube plate, roll the tube using the
tube expander.

5. Clean and check the inside of the front end

and aft end covers. If necessary replace the
corrosion blocks.

Note!
GN910-1.3 207 03

If damaged, the coating inside the covers D10-06

is to be repaired with the original coating
or a similar product.
4.
6. When cleaning is complete, mount new
gaskets and re-mount the front end and aft
end covers of the air cooler element.

7. Re-mount the air cooler element in the

scavenge air cooler housing.
See Procedure 910-1.4.
GN910-1.3 207 04

When referring to this page, please quote Procedure M91001 Edition 0231 Page 5 (7)
MAN B&W Diesel A/S
910-1.4 Air Cooler Element
Mounting
Mounting
910-1.4

1. 1. Lift the air cooler element and land the aft

end of the element on the guide rails
mounted on the air cooler housing.

Hook a tackle on to the bracket at the front

of the air cooler element.

Remove the lifting wire ropes and shackles.

2. Push the air cooler element inwards ap-

prox. one metre.

Remove the guide rails from the air cooler

housing.
EN910-1.2 222 06

D10-04
3. Clean the frame around the air cooler ele-
ment and the contact surface of the front
end cover.
2.
Apply a thin layer of silicone paste to the
frame around the air cooler element and the
contact surface of the front end cover.

Push the air cooler element fully into the air

cooler housing.
EN910-1.4 222 02

3.
EN910-1.4 222 03

Silicone

Page 6 (7) When referring to this page, please quote Procedure M91001 Edition 0231
MAN B&W Diesel A/S
 Air Cooler Element 910-1.4
Mounting

4. Mount and tighten all the screws of the front 4.

end cover.

Remove the tackle and the lifting bracket

from the front end cover.

5. Mount the cooling water inlet and outlet

pipes on the front end cover.

6. Close the drain cocks and open the cooling

water inlet and outlet valves.

Note!

EN910-1.4 222 04
Remember to vent trapped air from the
air cooler element.

GN910-1.2 207 02 5.

6.
GN910-1.4 207 06

When referring to this page, please quote Procedure M91001 Edition 0231 Page 7 (7)
MAN B&W Diesel A/S
 Non-Return Valve 110-2
MAN B&W 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
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

When referring to this page, please quote Data D11002Edition 0009 Page 1 (2)
110-2 Non-Return Valve
Data MAN B&W

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

Page 2 (2) When referring to this page, please quote Data D11002 Edition 0009
 Non-Return Valve 910-2.3
Overhaul
Non-Return Valve
0211
Overhaul
910-2.3

1.
This procedure includes both the main non-re-
turn valve and the non-return valve for the aux-
iliary blowers.

Both sets of non-return valves are accessed via

the scavenge air receiver.

Note!

Access to the scavenge air receiver must

not be attempted until the air in the
receiver is clean.

BM910-2.3 208 01
Main Non-Return Valve

1. The main non-return valve consists of four

valve flaps located inside the scavenge air
cooler housing. 2.

2. Remove the screws holding the valve flap.

Remove the valve from the engine.

3. Remove the spring pin from the valve shaft

and knock the valve shaft out of the valve
flap.

Clean the valve shaft and the slide bearings

inside the valve flaps. Lubricate the valve
shaft and the slide bearings with molybde-
num disulphide (MoS 2).

After the overhaul, it must be possible to

move the valve flap by the light touch of a
finger.

4. Assemble the valve and re-mount it in the

scavenge air cooler housing.
BM910-2.3 208 02

3.
BM910-2.3 208 03

When referring to this page, please quote Procedure M91002 Edition 0211 Page 1 (2)
0$1% :'LHVHO$6
910-2.3 Non-Return Valve
Overhaul

5. Non-Return Valve for Auxiliary Blowers

5. Inside the scavenge air cooler housing, lift

up the valve flap of the valve to be over-
hauled.

6. Remove the screws behind the valve flap.

Remove the valve from the engine.

7. Remove the spring pins from the valve shaft

and knock the valve shaft out of the valve
flap.
BM910-2.3 208 05

Clean the valve shaft, the slide rings and

the slide bearings inside the valve flaps. Lu-
bricate the valve shaft, the slide rings and
the slide bearings with molybdenum disul-
phide (MoS 2).
6.
After the overhaul it must be possible to
move the valve flap by the light touch of a
finger.

8. Assemble the valve and re-mount it in the

scavenge air cooler housing.
BM910-2.3 208 06

7.
BM910-2.3 208 07

Page 2 (2) When referring to this page, please quote Procedure M91002 Edition 0211
0$1% :'LHVHO$6
 Auxiliary Blower 110-3
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
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D10-09 Weight of blower unit, complete * up to 770 kg

*) Depending on electric motor type and number of
cylinders of engine (size and capacity of auxiliary blower)
D10-12 Electric motor, impeller and motorplate 235 kg

When referring to this page, please quote Data D11003 Edition 0030 Page 1 (2)
110-3 Auxiliary Blower
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

P91356 Lifting Tools, Etc.

Page 2 (2) When referring to this page, please quote Data D11003 Edition 0030
 Auxiliary Blower 910-3.3
Overhaul
Auxiliary Blower
S42MC
0215
Overhaul
910-3.3

2.
1. Depending on the type of overhaul, discon-
nect the cable connections from one or both
blower motors.

The overhaul can be carried out either by

dismantling the complete blower unit or just
dismantling the individual blower wheel
which is to be replaced/overhauled.

2. Complete Blower Unit

Hook a shackle and a tackle to the lifting

bracket in the top of the blower unit. It may
be necessary to remove one or more of the
gallery plates.

Remove all screws in the outlet flange of

the blower unit.
D10-09
Remove all screws in the lower inlet flange
of the blower unit.
GN910-3.3 206 02

Remove all screws in the upper inlet flange

of the blower unit.

Lift away the blower unit and land it on

wooden planks for further dismantling/over-
haul.

When referring to this page, please quote Procedure M91003 Edition 0215 Page 1 (2)
MAN B&W Diesel A/S
910-3.3 Auxiliary Blower
Overhaul

3. 3. Blower Wheel

Remove the safety guard and the driving

belt.

4. Remove the screws in the blower flange

and lift away the blower flange complete
with blower wheel and bearing housing.

For overhaul of blower wheel and bearings,

see blower manufacturer’s instructions.
GN910-3.3 206 03

5. Electric Motor

The electric motors can be dismantled with-

out removing the blower housing.
4.
Remove the safety guard and the driving
belt.

Hook a shackle and a tackle to the motor.

It may be necessary to remove one or more
of the gallery plates.

Remove all screws in the flange of the mo-

tor.
GN910-3.3 206 04

Lift away the motor and land it on wooden

planks for further dismantling/overhaul.

Page 2 (2) When referring to this page, please quote Procedure M91003 Edition 0215
MAN B&W Diesel A/S
 Turbocharger Turbine 110-5
Data
SAFETY PRECAUTIONS 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 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 oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

When referring to this page, please quote Data D11005 Edition 0010 Page 1 (2)
MAN B&W Diesel A/S
110-5 Turbocharger Turbine
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

Page 2 (2) When referring to this page, please quote Data D11005 Edition 0010
MAN B&W Diesel A/S
 Turbocharger Turbine 910-5.3
MAN B&W Diesel Cleaning

The dry cleaning method employs com-

pressed air to blow dry, solid, granules
through the turbocharger, thus removing
most of the deposits which may have
formed on the nozzle vanes and turbine
blades.

On account of their hardness, nut-shells, or

broken or artificially shaped pieces of acti-
vated charcoal with a size of between 1.0
and max. 1.5 mm are particularly suited as
blasting agents.

Note!
We do not recommend the use of rice or
grain as cleaning materials, as these
may possibly stick in the exhaust gas
boiler.

It is not always possible to remove thick

deposits with this dry cleaning method.

Therefore, in order to prevent the build-up

of thick deposits, the turbine must be
cleaned after every 24 to 50 hours of op-
eration.

Generally, turbocharger cleaning can be

carried out without, or with very little, re-
duction of the engine load.

More detailed information regarding the

amount of granules to be used is stated on
the instruction plate located close to the
turbocharger.

Note!
Regarding water washing of turbo-
charger turbine, see turbine manu-
facturer’s instructions.
See also Volume I, Chapter 706.

When referring to this page, please quote Procedure M91005 Edition 0212 Page 1 (2)
910-5.3 Turbocharger Turbine
Cleaning MAN B&W Diesel

Cleaning Procedure:

1. Carry out cleaning for every 24 to 50 hours

of operation, based on observations.
Amount
TC type
dm3 2. Preferably clean the turbocharger at full
TCA 33 0.5 load. Do not clean below half load.
TCA 44 0.5
3. Close valve A.
TCA 55 1.0
TCA 66 1.5 4. Open valves B and C, to blow out any de-
TCA 77 2.0 posits and/or condensate in the connecting
pipe.
TCA 88 2.5
M91005
0212O01

TCA 99 3.0 After about two minutes, close valves B

and C.

5. Slowly open valve A to relieve the pressure

in the tank.

6. Fill the tank with the quantity of granules

specified in the table.

A C 7. Close valve A.

8. Open valves B and C, to blow-in the gran-

B ules. After one to two minutes, close valves
B and C.

9. Slowly open valve A to relieve the pressure

in the tank.
M91005
0211O01

Caution!
1. The drain openings in the gas cas-
ings must remain closed while dry
cleaning the turbine.

2. It is possible that during dry cleaning

of the turbine, some of the blown-in
solid particles or sparks will escape
through the funnel.

Page 2 (2) When referring to this page, please quote Procedure M91005 Edition 0212
 Water Mist Catcher 110-6
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
Shut off air supply to exhaust valve – Only with stopped lubricating oil pumps
Engage turning gear
X Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D10-11 Water mist catcher 158 kg

When referring to this page, please quote Data D11006 Edition 0038 Page 1 (2)
110-6 Water Mist Catcher
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

P91356 Lifting Tools, Etc.

Page 2 (2) When referring to this page, please quote Data D11006 Edition 0038
 Water Mist Catcher 910-6.2
Dismantling
Water Mist Catcher
S42MC-C
0217
Dismantling
910-6.2

2.
1. Normally it is not necessary to remove the
water mist catcher element from the scav-
enge air cooler housing. If, however, the
water mist catcher element has been fouled
or damaged, it must be dismantled for
cleaning or repair.

2. To dismantle the water mist catcher, dis-

mantle the water mist catcher cover to give
access to the air cooler housing.

3. Loosen the screws which fasten the water

mist element to the cooler frame, through

DG910-5.3 62 01
the small end cover.

4. Pull the water mist catcher half way out and

screw a lifting eye bolt into the top of the
water mist catcher.
3.
Attach a tackle to the eye bolt and tighten
up the tackle.

5. Pull the water mist catcher fully out of the

scavenge air cooler housing and land it on
a couple of wooden planks.
DG901-5.3 62 02

4.

D10-11
DG901-5.3 62 03

When referring to this page, please quote Procedure M91006 Edition 0217 Page 1 (3)
0$1% :'LHVHO$6
910-6.4 Water Mist Catcher
Mounting
Mounting
910-6.4

1. 1. Lubricate the two supports on the under-

side of the water mist catcher with plenty of
grease.
D10-11
Apply a thin layer of silicone paste to the
frame of the water mist catcher on the side
which will face toward the sealing frame of
the cooler housing.

Note!

Make sure to mount the water mist

catcher correctly. See the sketch.
EN910-6.4 214 01

Air flow 2. Slide the water mist catcher into the scav-
enge air cooler housing.

2. When the water mist catcher is half-way in,

remove the tackle and the eye bolt, and
push the water mist catcher fully into the
scavenge air cooler housing.

3. Tighten the two screws at the front end of

the water mist catcher. Mount the cover.
GN910-6.4 205 02

3.
DG901-5.3 62 02

Page 2 (3) When referring to this page, please quote Procedure M91006 Edition 0217
0$1% :'LHVHO$6
 Water Mist Catcher 910-6.4
Mounting

4. Tighten the two screws at the aft end of the 4.

water mist catcher. Clean the water mist
catcher cover and apply a thin layer of sili-
cone paste along the edges of the cover.
Mount the cover.

DG901-5.3 62 01

When referring to this page, please quote Procedure M91006 Edition 0217 Page 3 (3)
0$1% :'LHVHO$6
 Turbocharger System - Tools
Tools Plate
MAN B&W Diesel P91061-0071

When referring to this page, please quote Plate P91061 Edition 0071 Page 1 (2)
Plate
Turbocharger System - Tools
Tools
P91061-0071 MAN B&W Diesel

Item Item Description Item Item Description

No. No.

014 Pulling tool

026 Lifting eye bolt

Page 2 (2) When referring to this page, please quote Plate P91061 Edition 0071
 Air Cooler - Tools Plate
P91063-0017

When referring to this page, please quote Plate P91063 Edition 0017 Page 1 (2)
MAN B&W Diesel A/S
Plate Air Cooler - Tools
P91063-0017

Item Item Description Item Item Description

No. No.

015 Guide rail, air cooler fore end

027 Guide rail, air cooler fore end

Page 2 (2) When referring to this page, please quote Plate P91063 Edition 0017
MAN B&W Diesel A/S
 Air Cooler - Lifting Tools Plate
MAN B&W P91066-0001

When referring to this page, please quote Plate P91066 Edition 0001 Page 1 (2)
Plate
Air Cooler - Lifting Tools
P91066-0001 MAN B&W

Item Item Description Item Item Description

No. No.

011 Lifting attachment air cooler fore end,

complete
023 Screw

Page 2 (2) When referring to this page, please quote Plate P91066 Edition 0001