Fuel Injection Generel

Fuel Injection System.
MAN B&W Diesel
L/9190-3.0/0502 (3250/NBC)
© MAN B&W Diesel

MAN B&W Diesel
© MAN B&W Diesel <2>

Overflow Valve.
MAN B&W Diesel
Valve for adjusting

the Supply Pressure.

MAN B&W Diesel
Fuel Oil Injection System.

MAN B&W Diesel

Fuel Injection.
MAN B&W Diesel
Recommended setting is to day

10 – 15 cSt.

Fuel Pump for L-MC mk I.
MAN B&W Diesel
Suction Valve.
Pump Barrel.
Plunger.
S-VIT Rack.
Fuel Setting Rack.

Suction Valve.
MAN B&W Diesel

MAN B&W Diesel Fuel Pump.
Drain from top

of Barrel.

Example of Component
MAN B&W Diesel
ID Marketing.
IMO Regulations
Fuel pump barrel
Super-Vit
Certified makings:
XXXXXXXXXXX
Part number
SXXMC/MC-C
111111-1
Marking instruction:
Number 0742843-8
To be marked with Licensee’s name/

Trademark, Part No. and Engine Type Locking Keyway for the Barrel
To check the dimensions of the certified component:
1. Remove the fuel pump top cover, see Instruction Manual VOL ll, Procedure 909-3
2. Remove the plunger/barrel assembly, see Instruction Manual VOL ll, Procedure 909-3
© MAN B&W Diesel < 10 >

Marks and Stamps on Fuel Pump
Plunger MC and MC-C Type.
MAN B&W Diesel
Marking must, as a minimum, consist of: Name and IMO id No.

Name. Manufacturer’s name/ trade mark
IMO id No.: A unique identification No. which links the

component with the design specification that was used at the time of manufacture, eg.
MAN B&W part No. or licensee’s drawing No.

Fuel Pump.
MAN B&W Diesel

Damage to Fuel Pump Plunger.
MAN B&W Diesel

Fuel Pump.
MAN B&W Diesel

Modification of Shock Absorber.
MAN B&W Diesel

MAN B&W Diesel
Fuel Pump Shock Absoeber.
50-90 cm bore MC and MCE engines

K/L45-55-67-80-80GB/GF/GFC/GFCA
In a few cases cracks have appeared in

the sealing ring groove of the housing
In certain cases the guide ring acts

as a tight sealing ring because the
high running temperature reduces
the ring gap to almost nothing
A pressure of approx. ten times the

normal working pressure is then
Built up, hence causing the cracks
The problem was solved by exchanging

the guide ring with a new ring with
larger gap

Fuel Pump.
MAN B&W Diesel
Puncture Valve.
Suction Valve.
S-VIT Actuator and

S-VIT Rack.
Fuel Setting Rack.

Fuel pump Umbrella type (50-90).
MAN B&W Diesel
Piston for
puncture valve
Puncture valve
high pressure
Drain Fuel pump top cover
High
pressure Suction valve
fuel to
fuel valve
Fuel pump barrel
Fuel pump housing
Fuel pump plunger
Fuel inlet
Lube hole
High pressure fuel Drain

Low pressure fuel
Atmospheric air

Key Components, Teglholmen Works.
MAN B&W Diesel
MC fuel pump

MAN B&W Diesel
Fuel Pump Suction Valve.
50-90MC/MC-C
Expected lifetime 40,000 hours
Modified according to SL97-344
Slide without groove and sealing ring

and with reduced clearance.
And where the slide again has been

modified with a chamfering to ensure
proper fuctioning irrespective of the fuel quality.
MBD-C Produced Valves

Always ensure to use the latest design.

MAN B&W Diesel
Fuel Pump for S-MC-C.
Air To fuel valve
Drain oil
Fuel oil inlet
Fuel pump barrel

Combined suction and puncture
valve on pumps without VIT
Circulating fuel oil

Fuel pump plunger
•Without VIT
Toothed rack
•VIT is an option
© MAN B&W Diesel

MAN B&W Diesel

Fuel Pump
MAN B&W Diesel

Two-Stroke Medium Bore
MAN B&W Diesel
Engines.
Fuel pump without To fuel valve

VIT with shock
absorber
Circulating fuel oil
Shock Absorber
Fuel oil inlet
© MAN B&W Diesel

MAN B&W Diesel
Engines.
Fuel pump without VIT To fuel valve

Without shock absorber
Fuel oil inlet
Circulating fuel oil outlet
© MAN B&W Diesel

Fuel Pump.
MAN B&W Diesel
Fuel Oil Inlet.
Fuel Oil Outlet.

Fuel Pump.
MAN B&W Diesel

Fuel Pump.
MAN B&W Diesel

Fuel Pump.
MAN B&W Diesel

Top of Fuel Pump.
MAN B&W Diesel

Fuel Pump Top Cover Fractures.
MAN B&W Diesel
S70MC/MC-C, 60MC/MC-C, S50MC/MC-C, S46MC-C, LS35MC
Previous New
Sharp edges
Crack initiation area
to be removed:
R1-R10 SL02-412
The fractures have been experienced on small and medium bore engines. The fractures
where initiated at the position where the inclined drillings for the high-pressure pipes
intersect with the central bore. The cause of the failure has in all cases been related to
roundings which did not fulfill our specifications.

MAN B&W Diesel
Fuel Pump.
Combined
Features: suction
Puncture valve and puncture
valve
One shock absorber per pump 90-50 cm bore K98MC
Suction and puncture valves engines K98MC-C
S90MC-C
VIT adjustment
Improvements:
• Four-hole plunger barrel design
• Two-chamber design on K98MC,
K98MC-C and S90MC-C
Verification Suction valve

• Extensive calculations of
pressure
fluctuations
• Has been tested in a test rig
© MAN B&W Diesel

Design.
MAN B&W Diesel
L90MC-C, K90MC, Combined suction and puncture valve

K90MC-C, S80MC-C K98MC-C, K98MC, S90MC-C
Puncture valve Suction valve
Peep hole

Two-Stroke Diesel Engine
and Its Prospects.
MAN B&W Diesel
Fuel pump plunger
Original design
New design

Fuel pump
MAN B&W Diesel
Umbrella type K90MC-C.
Piston for
puncture valve
Puncture valve
high pressure
Drain Fuel pump top cover
High
pressure Suction valve
fuel to
fuel valve
Fuel pump barrel
Fuel pump housing
Fuel pump plunger
Fuel inlet
Lube hole
High pressure fuel Drain

Low pressure fuel
Atmospheric air
© MAN B&W Diesel

K90MC-C Mrk. 6.
MAN B&W Diesel

K90MC-C Mrk. 6.
MAN B&W Diesel

K90MC-C Mrk. 6.
MAN B&W Diesel

Fuel Pump. K98MC-C.
MAN B&W Diesel
But installed due to the large

volume injected.

Fuel Pump Top Cover Leakage.
MAN B&W Diesel
Leakage Gasket
0.5 mm gap
Fuel inlet pressure

Fuel Pump Sealing Between Top Cover
and Fuel Pump Housing.
MAN B&W Diesel
S90-K98MC/MC-C
Viton square ring
Mild steel bushing
Mild steel plate

© MAN B&W Diesel
K98MC
MAN B&W Diesel
Protective Cap for Fuel Pump.

Fuel Pump.
MAN B&W Diesel
Pressure on both sides of

suction valve is the same.

Fuel Pump.
MAN B&W Diesel
At suction stroke,
the pressure above
the suction valve is
higher than below the
valve – the pump will
fill up with fuel oil.
Fuel Pump.
MAN B&W Diesel
Suction Valve closes.

Camshaft Arrangement of
L/S 60 and 70MC-C.
MAN B&W Diesel
Fuel To
exhaust
pump
valve
Design Features
• Bearings located between roller guides

• Camshaft with shrunk-on cams
• Reversing of fuel pump only
• Hydraulic activated exhaust valve
L/72316-5.0/1101 (2600/RØL)

MAN B&W Diesel
Design Features.
Fuel pump with ’umbrella’ sealing
Standard design on MC engines

No separate camshaft lubricating oil system
Lower installation costs
Less maintenance
Clean drain fuel oil for recycling
Fuel Pump Roller Guide –
'Umbrella’.
MAN B&W Diesel
Fuel
oil
drain
Lubrication hole
Bronze bushing
Roller
Steel bushing
guide
neck
Reversing Mechanism.
MAN B&W Diesel

Manually Lift of Roller Guide.
MAN B&W Diesel

Reversing Link
MAN B&W Diesel
for Fuel Pump Roller Guide.
Design and Experience
A Cracks B Cracks

Fuel Valve.
MAN B&W Diesel

Fuel Valve.
MAN B&W Diesel

Fuel Valve.
MAN B&W Diesel

MAN B&W Diesel
Venting Hole.
Adjustment Shims.

Fuel Valve.
MAN B&W Diesel
Function of
Standard Fuel Valve.

MAN B&W Diesel
Fuel injection valve

MAN B&W Diesel
Return Oil
Venting Venting
Closed. Closed.
Venting
open. When opening
Pressure
building pressure is reached,
up.
Atomizing takes place.

Fuel Injection.
MAN B&W Diesel

Nozzel Layout.
MAN B&W Diesel

Fuel Injection.
MAN B&W Diesel

Over Heating.
MAN B&W Diesel
Wrong Nozzel.

Banana Burnings.
MAN B&W Diesel
Wrong Nozzel.

Overheated Ringpack due
MAN B&W Diesel
to wrong nozzels.

Fuel Injection.
MAN B&W Diesel
Typical
Blow-By
Crack.

Poor Maintenance!!!!!!!!!!!
MAN B&W Diesel

Non-original Fuel Nozzels.
MAN B&W Diesel

Poor qualitycontrol at sub.
MAN B&W Diesel supplier
The root of the nozzle tip with wrong rounding.

Supplied by OMT. Spec: (OMT-TSK90MC4185)
Nozzle tip supplied by MAN B&W with correct rounding.

Spec (with MAN B&W logo stamp 12388117.0x185)

Marks and Stamps on Fuel Valve
Nozzle MC and MC-C Type.
MAN B&W Diesel
Marking must, as a minimum, consist of: Name, IMO id No. and nozzle size.
Name: Manufacturer’s name/ trade mark
IMO id No.: A unique identification No. which links the component
with the design specification that was used at the time of
manufacture, eg. MAN B&W part No. or licensee’s drawing No.
Nozzle size: Diameter of nozzle hole.
Example of marking:
The example shows how to mark a nozzle with hole
diameter Ø 1.5 mm. with Part No. 1261573-1

MAN B&W Diesel
Hand Pump for

Pressure testing
Fuel Valves.

Opel P Pump.
MAN B&W Diesel

Fuel Valve, Spring Housing.
MAN B&W Diesel

Fuel Injection.
MAN B&W Diesel
Pressure from Spring Houses.
When pressure testing

the condition as in the
Cylinder Head has to be
establised.
Landing surface in Cylinder Head.

Fuel Injection.
MAN B&W Diesel

Fuel Valve, Conventional Type.
MAN B&W Diesel

MAN B&W Diesel
Fuel Valve.
80, 90 and 98 bore 17,500 N → 21,000 N

MC and MC-C
engines Increased safety 65 → 70
Against leakage

L60MC Original Fuel Valve.
MAN B&W Diesel
+ 25 bar
Opening pressure 300 bar
- 0 bar

MAN B&W Diesel
L60MC Slide Fuel Valve.
+ 30 bar
Opening pressure 350 bar
- 0 bar

Performance.
MAN B&W Diesel
Conventional fuel valve Mini-sac valve Slide-type fuel valve

Sac volume 1690 mm3 Sac 520 mm3 Sac volume 0 mm3
© MAN B&W Diesel
Slide Fuel Valves.
MAN B&W Diesel
Large bore
Small bore
Medium bore

MAN B&W Diesel
Cut-off Shaft.
Present New

New Short Slide-Type Fuel Valve Nozzle
vs. Previous Long Type.
MAN B&W Diesel
© MAN B&W Diesel

Nozzle for Slide Fuel Valve.
MAN B&W Diesel

Spindle Guide for Slide Valve.
MAN B&W Diesel

MAN B&W Diesel
Fuel Slide Valve.
Closed Open
K90MC

MAN B&W Diesel
Slide Valve Pressure Testing.
Risk of seizure
Avoid atomisation test because of:

1. Small lift
2. Large pressure drop
4 3. High contact pressure
4. High frequency
3-5
5. Thin oil
1-2
© MAN B&W Diesel

Performance.
MAN B&W Diesel
Exhaust valve cylinder 2

Before installation of slide valve

Service Experience.
MAN B&W Diesel
exhaust valve, cylinder 2
Conventional valve
Slide valve
(890 h after installation)

MAN B&W Diesel
Compound Fuel Valve Nozzle.

MAN B&W Diesel
High
Pressure
Pipes.

MAN B&W Diesel
High
Pressure
Pipes.

MAN B&W Diesel
High
Pressure
Pipes.

High Pressure Pipes.
MAN B&W Diesel

High Pressure Pipes.
MAN B&W Diesel

MAN B&W Diesel

Design and Experience.
MAN B&W Diesel
Fuel pump

Genuine Spare Part.
MAN B&W Diesel
Fuel oil high pressure pipe

Double-pipe design
• Easy installation
• Less risk of damaging the seat during the installation
• 20% cheaper
Fuel Injection (Very Low Load).
MAN B&W Diesel
Standard fuel valves Air

sw
Poor smoke performance irl
Poor HC performance
Fuel valve Fuel valve
© MAN B&W Diesel

Fuel Injection (Very Low Load).
MAN B&W Diesel
Air
Slide fuel valve sw
irl
Smokeless performance
Low HC performance
Fuel valve Fuel valve
© MAN B&W Diesel

MAN B&W Diesel
8S60MC – total 43,000 h

Slide fuel valves – 13,000 h
Max. 2mm burning

MAN B&W Diesel
8S60MC – total 43,000 h

Slide fuel valves – 13,000 h
Max. 2mm burning

Combustion Chamber
MAN B&W Diesel
Exhaust valve assembly

Cylinder cover
for K98MC
Inconel coating
is applied to
aviod hot
corrosion

MAN B&W Diesel

Super -
MAN B&W Diesel

MAN B&W Diesel
0bar – 5,5bar – ca. 3bar.
0% 100% load.

MAN B&W Diesel
Position Servo.

Position Servo.
MAN B&W Diesel
Pilot Signal. Venting. Control Air(Power Air).

MAN B&W Diesel
Upper Break Point Pressure

P max(with S-VIT)
P max (without S-VIT)
P comp.
Lower Break Point
p scav.
Load
0% ~45% ~85% 100%
Following takes place in the Pump:
MAN B&W Diesel
From 0% Load to Lower Break Point (ca 45%) : S-VIT not activ.
From Lower Break Point to Upper Break Point (ca 85%) : S-VIT activ – Barrel lowered – S-VIT index increases.
From Upper Break Point to 100% Load : S-VIT activ – Barrel raised – S-VIT index decreases.
Barrel lowered : Higher pmax. Barrel raised : Lower pmax.
From ca 85% Load, - pmax is constant due to the increase in pcomp.
Barrel
Position
S-VIT Index
Load
0% ~45% ~85% 100%
Barrel Position.
MAN B&W Diesel
S-VIT Signal. Upper Break Point Pressure

P max(with S-VIT)
P comp.
Lower Break Point
p scav.
Load
0% ~45% ~85% 100%
Function of Super-VIT.
MAN B&W Diesel
When the compression pressure is of a value corrosponding to

app 45% of load, the Super-Vit start to change the Lead Angel for the
FO-injection so the injection starts earlier. The change in lead angel for
FO-injection to earlier injection continues until the pressure differense
between combustion pressure and compression pressure is max 35bar at
app. 85% of load. At 85% of load, the max pressure is now 100%.
When increasing the Load to 100%, the Super-Vit retard the injection
again, so the combustion pressure during the increase in load is kept at 100%,
even when retarding the injection, wich should lower the combustion pressure.
The increase in compression pressure compensates for the retarded injection
and keeps the combustion pressure constant at 100%.
MAN B&W Diesel
Adjustments
for low Pmax.

MAN B&W Diesel
Engines.
Fuel pump without VIT To fuel valve
Shims
Fuel oil inlet
Circulating fuel oil outlet
© MAN B&W Diesel

MAN B&W Diesel
Pressure
P comp.
p scav.
Load
0% 100%
MAN B&W Diesel
Shim(s) Taken out Pressure
Shim(s) inserted P comp.
p scav.
Load
0% 100%
Adjustment of pmax
MAN B&W Diesel
If pmax is low: Take out shim(s) accordingly
Barrel Lowered Higher pmax Earlier injection
If pmax is High: Insert shim(s) accordingly
Barrel Raised Lower pmax Later injection

Fuel Pump
MAN B&W Diesel
Shims

Fuel Injection Generel

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Available Formats

Fuel Injection Generel

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Copyright:

Available Formats

Fuel Injection System.

MAN B&W Diesel

© MAN B&W Diesel

© MAN B&W Diesel <2>

Valve for adjusting

© MAN B&W Diesel <3>

© MAN B&W Diesel <4>

© MAN B&W Diesel <5>

Recommended setting is to day

© MAN B&W Diesel <6>

Fuel Setting Rack.

© MAN B&W Diesel <7>

© MAN B&W Diesel <8>

Drain from top

© MAN B&W Diesel <9>

To be marked with Licensee’s name/

To check the dimensions of the certified component:

© MAN B&W Diesel < 10 >

Marking must, as a minimum, consist of: Name and IMO id No.

IMO id No.: A unique identification No. which links the

© MAN B&W Diesel < 11 >

© MAN B&W Diesel < 12 >

© MAN B&W Diesel < 13 >

© MAN B&W Diesel < 14 >

© MAN B&W Diesel < 15 >

50-90 cm bore MC and MCE engines

In a few cases cracks have appeared in

In certain cases the guide ring acts

A pressure of approx. ten times the

The problem was solved by exchanging

© MAN B&W Diesel < 16 >

S-VIT Actuator and

Fuel Setting Rack.

© MAN B&W Diesel < 17 >

Fuel pump barrel

Fuel pump housing

Fuel pump plunger

High pressure fuel Drain

© MAN B&W Diesel < 18 >

© MAN B&W Diesel < 19 >

Expected lifetime 40,000 hours

Modified according to SL97-344

Slide without groove and sealing ring

And where the slide again has been

MBD-C Produced Valves

© MAN B&W Diesel < 20 >

Fuel oil inlet

Fuel pump barrel

Circulating fuel oil

© MAN B&W Diesel

© MAN B&W Diesel < 22 >

© MAN B&W Diesel < 23 >

Fuel pump without To fuel valve

© MAN B&W Diesel

Fuel pump without VIT To fuel valve

Fuel oil inlet

Circulating fuel oil outlet

© MAN B&W Diesel

Fuel Oil Inlet.

Fuel Oil Outlet.

© MAN B&W Diesel < 26 >

© MAN B&W Diesel < 27 >

© MAN B&W Diesel < 28 >

© MAN B&W Diesel < 29 >

Standard design on MC engines