Hydraulic Cylinder Unit (Maj 2015)

purposes only
For training
Hydraulic Cylinder Unit
MAN Diesel & Turbo Author Current topic  00.00.2012 < 1 >
purposes only
For training
1) Highpressure Pipes
2) Distribution Block
3) Components:
 FIVA
 Accumulators
 Cylinder Lubricator
MAN Diesel & Turbo AAA-CPH Hydraulic Cylinder Unit 22.05.2015 < 2 >
purposes only
For training
Fuel Oil Exhaust Valve

Pressure Actuator
booster Accumulator
Overflow pipe
(de-air rating)
FIVA valve
Ball Valve
Distribution Block
ME Lubricator
purposes only
For training
High Pressure Pipe

K80ME-C6 vs K80ME-C9
Mark 6: Double wall main hydraulic pipe Mark 9: Single wall main hydraulic pipe
Safety and accumulator block Safety valve block
200 bar system 300 bar system
purposes only
For training
High Pressure Pipe

200 bar system
purposes only
For training
3) Components:
 FIVA
 Accumulators
purposes only
For training
Hydraulic Cylinder Unit,

HCU Distribution Block.
 Seen from front Side  Seen from back Side
purposes only
For training
Hydraulic Cylinder Unit, HCU

7S70ME-C8.2
Exhaust Valve
Fuel Oil Actuator
Pressure booster
Overflow pipe
Accumulator
(de-air rating)
FIVA valve
Ball Valve
Distribution Block
ME Lubricator
purposes only
For training

HCU Hydraulic Diagram, 200 bar.
Inlet Valves Drain Valves

purposes only
For training

HCU Valve Operation 200 Bar
 405 : Drain valve for FIVA valve

 406 : Drain valve for FIVA valve
 420 : Main supply valve of high pressure
oil to FIVA valve
 421 : Drain valve for distribution block
 430 : Valve for double wall pipe leakage
detection
 431 : Drain valve for outer pipe oil
560  455 : Mini-mess coupling for measurement
406 of the oil pressure (high pressure side)
421 455  560 : Supply valve of high pressure oil to
405 ME lubricator
420
430 431
Valve position during normal operation
405 406 420 421 430 431 560
Closed Closed Open Closed Open Closed Open
purposes only
For training

HCU Cautions 200 Bar
ACHTUNG ACHTUNG
HCU OVERHAULING LUBRICATION OVERHAULING
0. CHECK GAUGE WORKS! 0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO. 420, 531 1. CLOSE VALVE NO. 560
2. OPEN VALVE NO. 421, 405, 406 2. CHECK PRESSURE AT MEASURING
3.CHECK PRESSURE AT MEASURING POINT 565
POINT 455. 3. IF PRESSURE IS PRESENT, PRESS
WARNING – NEVER ’OPEN’ VALVE THE ’PRE-LUB’ BOTTON AT THE HMI
420 WHEN SYSTEM PRESSURE IS PANEL.
’ON’
purposes only
For training
Double Wall Pipe Sealing

200 bar system
Flange
Sealing rings
Outer pipe
Screws
Inner Pipe
Sealing
rings
Slide Bearings
purposes only
For training
Double Wall Pipe Leak Detection

200 bar system
1. CLOSE the valve 430 at the last but one Hydraulic Cylinder Unit.
2. OPEN the valve 431 at the last HCU to decrease the pressure in the space
between the inner and outer pipe.
3. CLOSE the valve 431 at the last HCU again.
4. Check the pressure increase in the space between at pos. 435, at the last HCU
5. If the pressure increases to system pressure level, the leakage has been found.
6. When the leakage has been eliminated, bring all the valves to their normal
position.
purposes only
For training
HCU Hydraulic Diagram

300 bar system
purposes only
For training
HCU, Valve Operation

300 bar system
Valve position during normal operation
420 421 560
Open Closed Open
420
565 455
560
421
 420 : Main supply valve of high pressure oil to FIVA valve
 421 : Drain valve for distribution block
 455 : Mini-mess coupling for measurement of the oil pressure (high pressure side)
 560 : Supply valve of high pressure oil to ME lubricator
 565 : Mini-mess coupling for measurement of the oil pressure (high pressure side)
purposes only
For training
Hydraulic Cylinder Unit, Valves

HCU / ME Lubricator overhauling 300 Bar
Achtung Achtung
HCU OVERHAULING LUBRICATION OVERHAULING
0. CHECK GAUGE WORKS! 0. CHECK GAUGE WORKS!
1. CLOSE VALVE NO. 420, 531 1. CLOSE VALVE NO. 560
2. OPEN VALVE NO. 421, 405, 406 2. CHECK PRESSURE AT

MEASURING POINT 565
3. CHECK PRESSURE AT
MEASURING POINT 455. 3. IF PRESSURE IS PRESENT, PRESS
THE ’PRE-LUB’ BOTTON AT THE
WARNING – NEVER ’OPEN’ VALVE HMI PANEL.
420 WHEN SYSTEM PRESSURE
IS ’ON’
purposes only
For training
Hydraulic Cylinder Unit, Valves

200 bar system
Instructions
Valve No.
purposes only
For training
High Pressure Pipe

300 bar system
purposes only
For training
3) Components:
 FIVA
 Accumulators
purposes only
For training
FIVA valves
MAN FIVA Nabtesco Bosch Rexroth Curtiss Wright
purposes only
For training
FIVA valve
Fuel Injection & Valve Actuation
FIVA
Degree Crank angle
-20 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
Injection start (0)
Injection End (20)
Exhaust valve open (110)
Exhaust valve Close (270)
Approximate timing of events to be carried out by the FIVA valve

On an ME- engine the timing of injection is variable and this is just an example.
purposes only
For training
MAN FIVA valve

Two control port
Parker Pilot Valve
PCB
Pilot Spool
Valve Housing
Feedback Sensor
* LVDT
Control Spool Main Spool
L
L Tfi Cfi P Cva Tva
purposes only
For training
FIVA valve: Components and working
F.B signal
Fuel oil
CCU
Injection
Exhaust valve
1.Inductive valve
sensor
Hydraulic
oil
Ｐ
Order for
Pilot valve
Pressured oil
2.Main valve
3.Pilot valve
Components of FIVA valve 1,2,3
purposes only
For training
FIVA valve
Neutral Position BEFORE INJECTION
Fuel Pump Exhaust Valve

L
Tva
Cva
FIVA
Valve P
Cfi
Tfi
L
purposes only
For training
FIVA valve
Fuel Injection

L
Tva
Cva
P
FIVA
Valve
Cfi
Tfi
L
purposes only
For training
FIVA valve
Neutral Position AFTER COMPLETION OF INJECTION

L
Tva
Cva
FIVA
Valve P
Cfi
Tfi
L
purposes only
For training
FIVA valve
Exhaust Valve Opening

L
Tva
Cva
FIVA
Valve P
Cfi
FIVA Tfi
Valve L
purposes only
For training
Bosch Rexroth
FIVA Spool Positions
Main Spool Position

Feedback from
LVDT Sensor
purposes only
For training
Curtis Wright FIVA valve

Electric Driven FIVA valve
Couple ring Linear motor
Main Spool Bearings

purposes only
For training
FIVA operation
purposes only
For training
FIVA operation
Fuel actuation
purposes only
For training
FIVA operation
Exhaust injection
purposes only
For training
FIVA Valve Position Control
CCU
Ch. 31
2
MPC 1 Ch. 30 4-20 mA Signal
converter
Requested
position (table) ÷ Current
synchronized + Fuel ±9 ±9
amplifier
to crank shaft control V (CW) A
position
Slide pos.[mm]
+6,3
-7
Exhaust valve opening Injection

C.A.
FIVA Valve
purposes only
For training
Supervision of Feedback
FIVA signal
purposes only
For training
FIVA signal & Plunger Position
The FIVA is immediately set to exhaust valve open position: (Safe position) if:
1
 The FIVA valve feed back signal is not valid, i.e. outside 4-20 mA
 The FIVA valve feed back signal indicates a too high (not physical possible) speed
 The FIVA valve feed back signal indicates a position not allowed outside a window
around TDC
 The fuel booster position feed back signal indicates that the fuel booster is moving
during the compression stroke.
Reset by resetting CCU in question, or invalid / valid these 2 inputs Ch. 30 & 31
purposes only
For training
FIVA signal & Plunger Position
Injection start
angle trig Injection
TDC Injection control

Injection preparation
2
Fuel booster position
supervision
1
FIVA valve feed-back
signal supervision
ECS reads Feedback

Signals from FIVA &
Fuel Plunger 1 time
per 0.5ms
purposes only
For training
FIVA valve
Safe Position Identified
purposes only
For training
3) Components:
 FIVA
 Accumulators
purposes only
For training
Accumulator
Diaphragm, Working Principle
purposes only
For training
Accumulator
Nitrogen Check, SL06-469
The accumulator charge pressure should be

checked within the first week of service.
Next check should be made around 4
months 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

working servo oil pressure as well as the
accumulator temperature.
For the 300 bar HPS accumulator charging

pressures are:
136 bar +/-5 @ 20°C

154 bar +/-5 @ 50°C
purposes only
For training
3) Components:
 FIVA
 Accumulators
 ME Lubricator
purposes only
For training
Cylinder Lubrication System
purposes only
For training
Cylinder Liners
Injection nozzle
Injection nozzle
with non-return Cylinder liner
valve
purposes only
For training
ME Lubricator
Cylinder lub. Inductive proximity sensor

oil inlet for feed-back signal to
control of piston movement
Signal for
lubrication from
controller
Level sensor for
cylinder oil in lubricator
Outlets for
cylinder liner Injection plunger
lub. oil
injectors
Spacer for
basic setting of
pump
stroke
Drain 200 bar system oil supply
Non-return valve Stroke oil
adjusting outlet Actuator
screw piston
Sealingring
purposes only
For training
ME Lubricator
Distribution Block
Level sensor
Cylinder Lubricator
purposes only
For training
Auxiliaries : Cylinder Lubrication
purposes only
For training
Cylinder Lubrication Demands
The purposes of cylinder lubrication are as follows:
1. To create a hydrodynamic oil film separating the piston rings from the liner
The optimum is kept safely down to a feedrate of 0.60 g/kWh.
2. To clean the piston rings, lands and ring grooves
All approved cylinder oils fullfils the requirements, even at a feed rate as low as 0.60
g/kWh.
3. To control corrosion, i.e. control the neutralisation af sulphuric acid
According to latest Service Letter (SL14-587) ACC factor and Minimum Feedrate have
to be adjusted to ACC factor (g/kWh*S%) x S% and 0.60 g/kWh
purposes only
For training
Optimizing Cylinder Condition
Liner wear rate as a function of lube oil dosage
High wear due to oil starvation

0,9
(boundary lubrication)
0,8
0,7
Liner Wear (mm/1000h) 0,6
0,5
0,4
0,3
0.10 mm/1000h
0,2
0.05 mm/1000h
0,1 0.02 mm/1000h
0
0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3 1,4 1,5 1,6
Lube Oil Dosage (g/kWh)
purposes only
For training
Total Base Number (TBN)
purposes only
For training
Optimising the ACC factor

Two ways to optimize ACC factor
1: ACC familiarization.
Adjust according to piston ring and liner wear.
Use oil analysis to evaluate.
2: Adjust according to Feed Rate Sweep, SL14-587

Adjust according to oil analysis.
purposes only
For training
Latest Service Letter regarding cylinder

Lubrication
Please familiarize your self with the latest Service letter regarding cylinder
lubrication, before we go through the service letter in details
purposes only
For training
Optimising the ACC factor

Familiarization of the ACC factor
purposes only
For training
Drain oil analysis
Used oil taken from the engine

Cylinder
through the scavenge bottom drain
Oil
can be used for cylinder condition
evaluation.
Drain oil analysis is also a strong

tool for judging the engine wear
condition. Drain oil samples taken in
active ACC operation will show if the
oil feed rate can be optimized while
Drain keeping the BN between 10-25
Oil mgKOH/kg and the iron (Fe) content
below 200 mg/kg in the drain oil.
System
Oil
purposes only
For training
Drain oil analysis
Cylinder
Oil
Drain Oil
System
Oil
purposes only
For training
Drain Oil Evaluation
Onboard Laboratory
purposes only
For training
Cylinder Lubrication Back up
 In case of CCU failure, where

the CCU cannot be changed
immediately, the cylinder
lubrication can be achieved by a
temporary cable from one of the
ECU units, plug 52, to the
solenoid valve on the lubricator
on the unit in question.
 The lubrication will be with

random timing.
purposes only
For training
purposes only
For training
purposes only
For training
Alpha Lubricator Mk. II
Level sensor
purposes only
For training
Alpha Lubricator MK II
Main components - design description
4/3-way
Control valve
Nonreturn valves
300 bar 300 bar
A B Lube oil points
Position sensor
Main piston Return piston Injection plungers Lube oil inlet
purposes only
For training
Disclaimer
All data provided in this document is non-binding.

This data serves informational purposes only and is especially
not guaranteed in any way. Depending on the subsequent
specific individual 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 project, especially specific
site and operational conditions.

Hydraulic Cylinder Unit (Maj 2015)

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purposes only

Hydraulic Cylinder Unit

Hydraulic Cylinder Unit

Hydraulic Cylinder Unit

Fuel Oil Exhaust Valve

High Pressure Pipe

High Pressure Pipe

Hydraulic Cylinder Unit

Hydraulic Cylinder Unit,

 Seen from front Side  Seen from back Side

Hydraulic Cylinder Unit, HCU

Hydraulic Cylinder Unit,

Inlet Valves Drain Valves

Hydraulic Cylinder Unit,

 405 : Drain valve for FIVA valve

Hydraulic Cylinder Unit,

Double Wall Pipe Sealing

Double Wall Pipe Leak Detection

HCU Hydraulic Diagram

HCU, Valve Operation

Valve position during normal operation

420 421 560

Open Closed Open

Hydraulic Cylinder Unit, Valves

1. CLOSE VALVE NO. 420, 531 1. CLOSE VALVE NO. 560

2. OPEN VALVE NO. 421, 405, 406 2. CHECK PRESSURE AT

Hydraulic Cylinder Unit, Valves

High Pressure Pipe

Hydraulic Cylinder Unit

MAN FIVA Nabtesco Bosch Rexroth Curtiss Wright

Degree Crank angle

Injection start (0)

Injection End (20)

Exhaust valve open (110)

Exhaust valve Close (270)

Approximate timing of events to be carried out by the FIVA valve

MAN FIVA valve

Parker Pilot Valve

FIVA valve: Components and working

Components of FIVA valve 1,2,3

Fuel Pump Exhaust Valve

Fuel Pump Exhaust Valve

Fuel Pump Exhaust Valve

Fuel Pump Exhaust Valve

Main Spool Position

Curtis Wright FIVA valve

Couple ring Linear motor

Main Spool Bearings

FIVA Valve Position Control

Exhaust valve opening Injection

TDC Injection control

ECS reads Feedback

Hydraulic Cylinder Unit

The accumulator charge pressure should be

A minor leakage from the accumulators is

The charge pressure is dependent on

For the 300 bar HPS accumulator charging

136 bar +/-5 @ 20°C

Hydraulic Cylinder Unit

Cylinder Lubrication System

Cylinder lub. Inductive proximity sensor

Auxiliaries : Cylinder Lubrication

Cylinder Lubrication Demands