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Diesel Customer Information No. 324
MAN Diesel & Turbo – a member of the MAN Group
MAN Diesel & Turbo SE
Head offi ce (& postal address)
Stadtbachstraße 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 0
Fax: +49 (0) 821 322 3382
www.mandieselturbo.com
PrimeServ
After Sales Augsburg
Stadtbachstraße 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 3509
Fax: +49 (0) 821 322 1530
PrimeServ
After Sales Technical
Stadtbachstraße 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 1499 (24-h-hotline)
Fax: +49 (0) 821 322 3838
PrimeServ
After Sales Commercial
Stadtbachstraße 1
86153 Augsburg
Germany
Phone: +49 (0) 821 322 1799 (24-h-hotline)
Fax: +49 (0) 821 322 3574
Evaluation of FuelInjection Pump
DCI / 324 - August 2013
Concerns
MAN Diesel & Turbo four-stroke
engines 48/60B, 51/60DF
Summary
Information regarding fuel injection
pump evaluation
Filing Advice
Assembly group / work card 200
Background
Fuel injection pumps of MAN Diesel & Turbo’s medium
speed engines are high loaded engine components.
The pump elements are subjected to high stresses
caused by pressure changes. Due to this plunger and
barrel are affected by cavitation.
Facts
Wear due to cavitation is a typical process in fuel
injection pumps, which begins already with the fi rst
engine operating period. Wear typically occurs on the
spill port hole of the monoblock cylinder and the
plunger crown above the control edge. Cavitation is well
known as a physical phenomenon in high pressure fl uid
systems. The severity of cavitation attack is very much
associated with the viscosity and in particular with the
quality of fuel, e.g. water content and the load of the
engine.
Prevention
In order to reduce the cavitation attack to the fuel pump
element the so-called baffl e screw, a sacrifi cial
component, had been a standard of our injection
pumps for years.
For your information you will fi nd attached our Diesel Customer Information No. 280, describing maintenance
interval for nose-type and fl at baffl e screws
However it is important to observe specifi ed parameters such as fuel pressures, temperatures, water content
inside fuel oil and viscosities to minimize the cavitation effect. Anyhow development of cavitation cannot be
avoided and is directly connected to engine load and related injection pressure.
Recommendation
For your continuous service inspections of the pump elements, we like to support you with attached working
cards “Check and evaluation of pump element”, in order to give you a proper overview of possible occurring
abrasion wear and cavitation and how to realize and evaluate these fi ndings.
Contact
Should you have any queries, our Technical Service will be pleased to be of assistance:
MAN Diesel & Turbo SE
86224 Augsburg
Tel.: +49 (0) 821 322-2514
Fax: +49 (0) 821 322-3838
E-mail: [email protected]
Please forward this information to your technical operating personnel and
remember to inform us of the current operating hours of your MAN Diesel & Turbo engines.
Jörn Holst
Senior Manager
After Sales Technical
Stefan Eefting
Vice President
After Sales
DCI / No. 324 - August 2013
Diesel Customer Information »Evaluation of the fuel injection pump« - Page 2 of 2
Fuel injection pumpCheck and evaluation of pump element
SummaryCarry out the work in good time in accordance with the maintenance sched-ule,check the components’ quality/wear conditionprevent operational problems/damage.The pump element of the fuel injection pump must be checked or replacedat the times stipulated in the maintenance schedule at the latest.
The work/working steps include:Check/Assessment of parts/components.
Safety requirements▪ Engine secured against starting up
▪ Engine stopped
Personnel and time required
Number Qualification Duration in h
1 Technician 0,1
Tools/aids required
Qty Designation Number Status
1 Paper towels - Inventory
1 Cleaning medium (wool) - Inventory
1 Magnifying glass - Inventory
Corresponding Work CardWork Card Work Card Work Card
200.04
Preliminary remarksPump elements of fuel injection pumps are subjected to high stressescaused by pressure changes in the flowing fuel. Wear due to cavitation is atypical process in a fuel injection pump, which begins already with the firstengine run. Wear due to cavitation is a typically occurring on process on thepump piston crown. The cavitation process directly depends on the watercontent in fuel and develops much faster with increasing water content. Thewear is not a problem until the control edge is not affected. Therefore it isimportant to observe the specified parameters, such as fuel pressures, tem-peratures and viscosities to minimise these effects. Moreover, foreign mattermay damage the fuel injection pump or seating surfaces of the injectionvalves. Observance of the fuel specification and careful fuel treatment aredecisive for a long service life of the fuel injection system components. Weardue to cavitation of the pump piston crown is minimised by the design of fuel
2013
-06-
12 -
de
Fuel
inje
ctio
n pu
mp
6682
200
.08-
01Ge
nera
l
MAN Diesel & Turbo 200.08
6682 200.08-01 EN 1 (4)
injection pumps and by using baffle screws. In this case it is important tocheck and replace pump elements and baffle screws at the intervals speci-fied in the maintenance schedule at the latest. The following assessment cri-teria must be helpful for the decision on possible further use of the pump ele-ment.
Figure 1: Cleaned pump plunger of the fuel injection pump
No or little Wear. Continued Use
Cleaned pump plunger displays no signsof wear.
Assessing: Continued Use
1 Pump plunger
2 Pump plunger crown
3 Control edge
Table 1: No wear
Cleaned pump plunger displays slightsigns of wear.
Assessing: Continued Use
4 Flow pattern through the suction holesuperimposed by first signs of cavitation
Table 2: Slight wear
Fuel
inje
ctio
n pu
mp
6682
200
.08-
01Ge
nera
l
2013
-06-
12 -
de
200.08 MAN Diesel & Turbo
2 (4) 6682 200.08-01 EN
Progressed wear Continued Use
Pump plunger displays progressed signsof wear.
Control edge is not damaged.
Wear condition is normal and does notaffect the function of the fuel injectionpump. The particles removed are smallerthan the clearance of the pump plunger(particle size in nanometer range)
No polishing of the cavitation zone.
Assessing: Continued Use
Table 3: Progressed wear
Pump plunger displays further pro-gressed signs of wear.
Control edge is not damaged.
Depth of signs of wear looks out doubt-ful, however does not affect the engineoperation. (No drop of the ignition pres-sure or exhaust gas temperature withinthe load range)
Assessing: Continued Use
3 Control edge
5 Main cavitation ranges
Table 4: Further progressed wear
Wear limit achieved. Replace a pump element
Pump plunger has achieved the wearlimit.
Control edge is damaged. Main cavitationranges has achieved the control edge.
Assessing: Replace the pump element
3 Control edge
5 Main cavitation ranges
Table 5: Wear limit achieved
2013
-06-
12 -
de
Fuel
inje
ctio
n pu
mp
6682
200
.08-
01Ge
nera
l
MAN Diesel & Turbo 200.08
6682 200.08-01 EN 3 (4)
Baffle screw
Baffle screw displays slight signs of wear.
Assessing: Continued Use
Table 6: Baffle screw with signs of cavitation
Fuel
inje
ctio
n pu
mp
6682
200
.08-
01Ge
nera
l
2013
-06-
12 -
de
200.08 MAN Diesel & Turbo
4 (4) 6682 200.08-01 EN
MAN Diesel SE • 86224 Augsburg • Germany
Tel. +49 821 322-0 • Fax +49 821 322-3838 • E-Mail: [email protected] 1 - 3
Maintenance interval for baffle screws
Engine 48/60B
CUS 280 • 10/09
General instructions The continuous development of our engines and engine
components also results in the optimisation of maintenance intervals
and ease of maintenance. One such optimisation comes with the
change of our baffle screw production to a new flat version, which
results in both a reduction in operating and maintenance costs.
The new optimised design consists of a combination of the flat, type
-0292 baffle screw and a type -1386 or -1485 pump element.
Previous version:
nose-type baffle screw -0264
The nose-type baffle screw -0264 represents the previous version. It
must be replaced after 3000 hours at the latest and must be
checked for condition every 1000 hours and replaced if necessary.
New version:
flat baffle screw -0292
The flat baffle screw -0292 has been the current serial-production
component since May 2009. In future, it must only be replaced
when the pump element is renewed.
Diesel Customer InformationDiesel Customer InformationDiesel Customer InformationDiesel Customer Information CUS CUS CUS CUS 222280808080 • 10101010/09/09/09/09
MAN Diesel SE • 86224 Augsburg • Germany
Tel. +49 821 322-0 • Fax +49 821 322-3838 • E-Mail: [email protected] 2 - 3
Advantages of the new
version
Low maintenance effort:
Checking the baffle screws every 1000 hours is no longer required.
In accordance with the new maintenance schedule, the baffle
screws are replaced after 15,000 to 18,000 hours together with the
pump element.
Reduced maintenance costs:
Ø Components are approximately of the same price (pump
element and flat baffle screw)
Ø Labour costs reduced by approx. 90 %
Ø No additional engine downtimes due to baffle screw
inspection or replacement
Conversion to flat baffle
screws
Whether or not you can convert to flat baffle screws immediately
depends upon the installed pump elements.
Pump elements which can be fitted with the flat baffle screws are
listed in the following table.
Pump element Pump element Pump element Pump element
versionversionversionversion
Type of Type of Type of Type of Baffle screwBaffle screwBaffle screwBaffle screw
----1386138613861386 Can be installed with flat baffle screw Can be installed with flat baffle screw Can be installed with flat baffle screw Can be installed with flat baffle screw ----0292029202920292
----1485148514851485 Can be installed with flat baffle screw Can be installed with flat baffle screw Can be installed with flat baffle screw Can be installed with flat baffle screw ----0292029202920292
Pump elements which should be fitted with the nose-type baffle
screws are listed in the following table.
Pump element Pump element Pump element Pump element
versionversionversionversion
Type of Baffle screwType of Baffle screwType of Baffle screwType of Baffle screw
----1356135613561356 NoseNoseNoseNose----type type type type baffle screwbaffle screwbaffle screwbaffle screw recommendedrecommendedrecommendedrecommended
----1395139513951395 NoseNoseNoseNose----type type type type baffle screwbaffle screwbaffle screwbaffle screw recommendedrecommendedrecommendedrecommended
If pump elements with other serial numbers are installed in the
engines, we offer you the option of ordering a conversion kit
consisting of matching pump element and flat baffle screw. We
would be pleased to provide you with a cost estimate.
Important note Please note that the replacement of flat baffle screws in non-
compatible pump elements, leads to an exponential increase in
pump element wear.
Diesel Customer InformationDiesel Customer InformationDiesel Customer InformationDiesel Customer Information CUS CUS CUS CUS 222280808080 • 10101010/09/09/09/09
MAN Diesel SE • 86224 Augsburg • Germany
Tel. +49 821 322-0 • Fax +49 821 322-3838 • E-Mail: [email protected] 3 - 3
Determining the pump
element version
For identification of the pump element version, four digits are
stamped into the pump element.
In the following example sketch this is the number ----1111386386386386::::
Contact address Should you have any queries, our Technical Service will be pleased
to be of assistance:
MAN Diesel SE
86224 Augsburg,
Tel.: +49 (0) 821 322-1499
Fax: +49 (0) 821 322-3838
E-mail: [email protected]
Please forward this information to your technical operational personnel and remember to inform us of the
current operating hours of your MAN Diesel engines.
----1386138613861386
IMO 1312IMO 1312IMO 1312IMO 1312
Identification oposite pin:Identification oposite pin:Identification oposite pin:Identification oposite pin:
4 digits 4 digits 4 digits 4 digits ----1386 and IMO 13121386 and IMO 13121386 and IMO 13121386 and IMO 1312
-- -- 1
38
61
38
61
38
61
38
6
IMO
13
12
IMO
13
12
IMO
13
12
IMO
13
12
