S50MC-C VOLUME II

MAINTENANCE
 Instructions for Main Engines

This book forms part of a set of books consisting of three volumes entitled:

Vol. I OPERATION
Vol. II MAINTENANCE
Vol. III COMPONENTS, DESCRIPTIONS

The purpose of these books is to provide general guidance on operation and maintenance and
to describe the constructional features of a standard version of an MAN B&W main diesel en-
gine. Deviations may be found in a specific plant. In addition, the books can be used for ref-
erence purposes, for instance in correspondence and when ordering spare parts.

It is essential that the following data is stated in spare parts orders as it is used by us to ensure
the supply of the correct parts for the individual engines:

1. Name of vessel
2. Engine No. built by
3. Plate No.
4. Part No.
5. Quantity required (and description)

Example: M/S Nybo – 7730 B&W – P90201-0036 – 059

10 off (piston ring)
+ )The Plate No. may consist of either of these two sets of digits, as the pages are
in the process of being updated with new numbers: P90201-0036 or 90201-036.

To ensure optimum efficiency, reliability and lifetime of the engine and its components, only
original spare parts should be used when replacing parts on the engine.

When used in texts and illustrations, the designation “D” refers to the information given on the
data sheets inserted in the respective books.

Reliable and economical operation of the diesel engines is conditional upon its correct oper-
ation and maintenance in accordance with MAN B&W Diesel A/S’ instructions. Emissions re-
lated maintenance of the diesel engine shall be performed as specified in MAN B&W Diesel
A/S’ instructions and any additional instructions to that effect included in the Technical File.
Consequently, it is essential that the engine room personnel are fully acquainted with the con-
tents of this book and, in respect of instructions on emissions related maintenance of the die-
sel engine, also the additional instructions to that effect set out in the Technical File.

This book is subject to copyright protection, and should therefore not, in whole or in part, be
copied, reproduced, made public or in any other way made available to a third party without
the written consent of this effect from MAN B&W Diesel A/S.

MAN B&W Diesel A/S STX Engine Co.,Ltd. STX HI Co.,Ltd.

Teglholmsgade 41 MAN B&WChangwon,
80, Seongsan-dong, Diesel66-5,
A/S Sinchon-dong, Changwon,
A90023-0027

DK-2450 Copenhagen Kyungnam, Republic of Korea Kyungnam, Republic of Korea

Denmark
Teglholmsgade 41 Teleph.:+45 33 85 11 00
DK-2450 Copenhagen
Technical Service Telex :16592 manbw dk
Technical Service
Denmark
Teleph.:+82 55 282 0590
Telefax:+45 33 85 10 30
Teleph.:+45 33 85 11 00 Teleph.:+82 55 278 9651
Telex :16592 manbw dk Telefax :+82 55 282 6907 Telefax :+82 55 278 2169
CVR No. 39 66 13 14
Part Sales
Telefax: +45 33 85 10 30
Teleph.:+82 55 280 0550~6
Telefax.:+82 55 282 1388
 Cross Section through Engine Plate
P90001-0S48
Cross Section through Engine
0048
P90001

When referring to this page, please quote Plate P90001 Edition 0S48 Page 1 (1)
MAN B&W Diesel A/S
 Checking and Maintenance Schedules 900-1

Checking and Maintenance Schedules

S50MC-C
900-1 0256

The Checking and Maintenance Schedules indi- Design modifications may necessitate a revision
cate the intervals at which it is deemed appropri- of the instructions, in which case the revised in-
ate to inspect the individual components of the structions and changed overhauling intervals, if
engine and to carry out overhauls, if necessary, any, will apply and supersede those originally is-
based on the engine condition or on time criteria. sued (see e.g our Service Letters).

The stated Normal hours of service should only In addition to the checking and overhauling inter-
be used as a guide, as differences in the actual vals stated in this schedule, please note that the
service conditions, the quality of the fuel oil or lu- periodical survey requirements of the classifica-
bricating oil, the treatment of cooling water, etc. tion society may require additional checks and
will decisively influence the actual service re- overhauls to be carried out. For further informa-
sults, and thus the intervals between necessary tion please refer to the classification society.
overhauling.

The procedures are divided into three categories:

Condition checking procedures marked under the heading Normal hours of service with a C,
deal with the service condition of a number of engine compo-
nents, and form the basis for estimating whether further over-
hauling is necessary. In a number of cases the condition
checking procedures refer to Volume I of the instruction book, in
which more detailed descriptions and working procedures can be
found.

Condition-based overhauling are those procedures which under the heading Normal hours of
procedures service are marked with an O, and opposite which, under the
heading Overhaul to be based on procedure No. (column P),
a procedure number is stated.

This procedure number normally refers to one of the above con-

dition checking procedures which form the basis of the overhaul.
For this reason, the intervals stated are for guidance only.

Time-based overhauling proce- also marked with an O under the headings Normal hours of
dures service or Based on observations, are the procedures where
an actual basis for estimation is lacking. It is recommended,
therefore, to carry out these procedures at the overhauling inter-
vals stated as a basis.

Where a symbol O or C is indicated in Based on observations

(column B), this is due to the fact that special service conditions
may make checking or overhauling necessary beyond the actual
standard schedules indicated.

When referring to this page, please quote Maintenance Schedules A90050 Edition 0256 Page 1 (5)
MAN B&W Diesel A/S
 Checking and Maintenance Schedules 900-1

V : See Volume I “Operation” H : Check new/overhauled parts after 500-1500 hours

A : Adjustment to be carried out B : Based on observations
C : Check the condition P : Overhaul to be based on procedure No. or refer to
M : See maker’s instructions
O : Overhaul to be carried out
R : Parts to be replaced Normal hours of service (x1000)
No. Procedure H 2 4 6 8 16 32 B P

901 Cylinder Cover

-1 Cylinder Cover O

902 Piston with Rod and Stuffing Box

-1 Piston C C 901-1,
V

Piston rings only O

Piston complete O

-2 Piston Rod Stuffing Box C,O 902-1

903 Cylinder Liner and Cylinder Lubrication

-1 Cylinder Liner O 901-1

1000 hours and 2000 hours: C C
Inspection through scavenge ports

Measuring wear inside liner O O

-2 Cylinder Lubricators O V,M

904 Crosshead with Connecting Rod

-1 Crosshead Bearing C O

-2 Crosshead O

-3 Reciprocating Parts O

-4 Crankpin Bearing C C

-5 Connecting Rod O

905 Crankshaft, Thrust Bearing and

Turning Gear

-1 Crankshaft Deflection C C V

-2 Main Bearing C C A,C, 905-1

O V

-3 Thrust Bearing C C

-4 Journal Bearing C C A,C, 905-1

O V

-5 Axial Vibration Damper C,O

When referring to this page, please quote Maintenance Schedules A90050 Edition 0256 Page 2 (5)
0$1% :'LHVHO$6
 Checking and Maintenance Schedules 900-1

V : See Volume I “Operation” H : Check new/overhauled parts after 500-1500 hours

A : Adjustment to be carried out B : Based on observations
C : Check the condition P : Overhaul to be based on procedure No. or refer to
M : See maker’s instructions
O : Overhaul to be carried out
R : Parts to be replaced Normal hours of service (x1000)
No. Procedure H 2 4 6 8 16 32 B P

906 Mechanical Control Gear

-1 Chain C C V

-2 Chain Tightener C C A
New or overhauled chain to be checked/
retightened after 500, 1500 and 4000 hours

-3 Camshaft C C A,C

-4 Camshaft Bearings C C,O

Camshaft Coupling, Fitted Bolts C

907 Starting Air System

-1 Starting Air Distributor C C A

-2 Starting Air Valve C,O

Governor, change of oil O M

Functional check of overspeed device C M

Functional check of speed-setting system C M

(engine with bridge control system)

908 Exhaust Valve

-1 High-Pressure Pipe O

-2 Exhaust Valve

Conventional hard-faced valve seats; O

overhaul at intervals of 6000 hours

Nimonic exhaust valves; C O

check new valves after 6000 hours
subsequently, overhaul at intervals of 16000
hours

-3 Exhaust Valve Actuator O

-4 Exhaust Valve Roller Guide C C O V

-5 Exhaust Valve Cam C

-7 Exhaust Valve Special Running C

909 Fuel Oil System

-1 Fuel Pump Lead A,C V

-3 Fuel Pump Cam A 909-1

When referring to this page, please quote Maintenance Schedules A90050 Edition 0256 Page 3 (5)
0$1% :'LHVHO$6
 Checking and Maintenance Schedules 900-1

V : See Volume I “Operation” H : Check new/overhauled parts after 500-1500 hours

A : Adjustment to be carried out B : Based on observations
C : Check the condition P : Overhaul to be based on procedure No. or refer to
M : See maker’s instructions
O : Overhaul to be carried out
R : Parts to be replaced Normal hours of service (x1000)
No. Procedure H 2 4 6 8 16 32 B P
-4 Fuel Pump O

-5 Fuel Pump Top Cover O

-6 Fuel Pump Barrel Assembly O

-7 Fuel Pump Suction Valve C,O

-8 Fuel Pump Puncture Valve C,O

-9 Fuel Pump Shock Absorber C O

-11 Fuel Valve C,O

- Fuel Nozzle R R

-12 Spindle Guide R

-13 Non-return valve O

-14 Fuel Oil High-Pressure Pipes O

-15 Fuel Pump Roller Guide C,O

-16 Fuel Pump Special Running O

910 Turbocharger System

-1 Air Cooler O O V

-2 Non-Return Valve C O

-3 Auxiliary Blower O

-4 Butterfly Valves C

-5 Turbocharger Turbine O V,M

-6 Water Mist Catcher C

911 Safety Equipment

-1 Safety Valve C O

-2 Relief Valve O

Functional test of alarm system for thrust C C M

bearing and slow down /shut down system

Checking and adjustment of pressure gauge C M

Checking and adjustment of thermometers C M

Checking and adjustment of thermostats C M

Checking and adjustment of pressurestats C M

When referring to this page, please quote Maintenance Schedules A90050 Edition 0256 Page 4 (5)
0$1% :'LHVHO$6
 Checking and Maintenance Schedules 900-1

V : See Volume I “Operation” H : Check new/overhauled parts after 500-1500 hours

A : Adjustment to be carried out B : Based on observations
C : Check the condition P : Overhaul to be based on procedure No. or refer to
M : See maker’s instructions
O : Overhaul to be carried out
R : Parts to be replaced Normal hours of service (x1000)
No. Procedure H 2 4 6 8 16 32 B P
Checking and adjustment of turning gear M
switch

912 Assembly of Large Parts

-2 Holding Down and End Chock Bolts (Epoxy) C C

-3 Stay Bolts C C

913 General Tools

-1 Hydraulic Tools

-4 Standard Tightening Torques

-5 Torque Spanner

-6 Tightening Gauge

-7 Screws and Nuts

-11 Lubricating Procedures

When referring to this page, please quote Maintenance Schedules A90050 Edition 0256 Page 5 (5)
0$1% :'LHVHO$6
 General – Safety Precautions 900-2

Before maintenance work is carried out, the engine must be stopped and blocked according to the
safety precautions given on the specific Data Sheet.

SAFETY PRECAUTIONS

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 lubriating oil pumps
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Stop lubricating oil supply
X Lock the turbocharger rotors

The sketch gives the approximate location of the valves concerned:

When referring to this page, please quote Safety Precaution A90060 Edition 0002 Page 1 (1)
MAN B&W Diesel A/S
900-2 General - Safety Precautions
MAN B&W Diesel

Safety Equipment - Recommendations 1.

In order to perform maintenance in a safe and

correct way, MAN B&W Diesel A/S recommends
use of the following personal safety gear:

1. • Safety shoes.
• Hearing protection.
• Work gloves.
• Protective head wear, such as a baseball
cap with a hard protective liner.
• Safety goggles.
• Fall arrestor equipment.

A90060-0002C01
Safety shoes, hearing protection, work gloves
and protective head wear should be used when
there is a risk of falling objects, loud noises and
sharp edges or oily surfaces.
2.
Use safety goggles when working with com-
pressed air, grinders, hydraulics and when there
is a risk of getting foreign objects in the eyes.

2. We strongly recommend the use of fall

protection harness and arrestor equipment
when working in places on the engine where
there is a risk of falling or slipping.

3. This is especially needed when mount-

ing eyebolts and hanging tackles inside the
crankcase, and when working on the hydrau-
lic pump station on some ME engines.
A90060-0002C02

3.
A90060-0002C03

Page 2 (2) When referring to this page, please quote Safety Precaution A90060 Edition 0002
 Cylinder Cover 101-1
Data

SAFETY PRECAUTIONS
Special
D10101 Data 0048
101-1 Edition Cylinder
S50MC-C Cover

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
Shut off lubricating oil
X Lock turbocharger rotors

Data
Ref. Description Value Unit

D01-01 Exhaust valve stud, screwing-in torque 200 Nm

D01-02 Starting valve stud, screwing-in torque 145 Nm
D01-03 Fuel valve stud, screwing-in torque 80 Nm
D01-06 Cylinder cover, complete 1670 kg
D01-08 Cooling jacket 40 kg
D01-09 Exhaust valve stud 28 kg
D13-01 Hydraulic pressure, mounting 1500
D13-02 Hydraulic pressure, dismantling 1400-1650

When referring to this page, please quote Data D10101 Edition 0S48 Page 1 (2)
MAN B&W Diesel A/S
101-1 Cylinder Cover
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 46 Grinding tool for exhaust valve seat

P90151 58 Milling and grinding wheel for fuel valve seat
P90151 60 Milling and grinding wheel for starting valve seat
P90151 83 Grinding handle
P90151 130 Lifting chains
P90151 201 Handle
P90161 Cylinder cover, tools
P91351 10 Hydraulic pump, pneumatically operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 130 9-way distributor block, complete
P91359 Torque Spanners

Page 2 (2) When referring to this page, please quote Data D10101 Edition 0S48
MAN B&W Diesel A/S
 Cylinder Cover 901-1.2
MAN B&W Diesel Dismantling

1. Set blocking device A on the main starting E

1.
valve in the BLOCKED position.

Engage turning gear B.

C

Close fuel oil inlet valve C.

D F
Close cooling water inlet valve D.
A
Close cooling water outlet valve E.

Open cooling water drain cocks F and G.

Shut off the control air and safety air sup- G

ply. Vent the manoeuvring system through
the ball valve.

Also shut off the air supply on the pressure

reduction unit for the hydraulic/pneumatic
exhaust valve, and vent the system.
M90101
0249D01

When referring to this page, please quote Procedure M90101 Edition 0249 Page 1 (10)
901-1.2 Cylinder Cover
Dismantling MAN B&W Diesel

2. Remove the cooling water inlet and outlet

2. pipes from the exhaust valve and cylinder
cover.

Remove the drain pipe from the intermedi-

ate pipe between the cylinder cover and
the exhaust valve.

Dismount the fuel oil high-pressure pipes

between fuel valves and fuel pump.
See Procedure 909-14.2.

Dismount the control air pipe from the

starting valve.
M90101
0249D02

Remove the starting air pipe.

3. Remove the exhaust valve high-pressure

pipe.
3. See Procedure 908-1.2.

Dismount the drain oil pipe between the

exhaust valve and the hydraulic activator,
the air pipe for pneumatic closing of the
exhaust valve.

4. Remove the protective jacket enclosing the

intermediate pipe between the exhaust re-
ceiver and the exhaust valve.

Dismount the screws in the flange between

the intermediate pipe and the exhaust re-
M90101
0249D03

ceiver. The four lowermost screws need not

be dismantled, just loosened.

Remove the protective caps from the cylin-

der cover nuts.
4.
M90101
0249D04

Page 2 (10) When referring to this page, please quote Procedure M90101 Edition 0249
 Cylinder Cover 901-1.2
MAN B&W Diesel Dismantling

5. Place eight spacer rings, one around each

nut, and screw the eight hydraulic jacks 5.
onto the studs.
D13
02
Connect the high-pressure pump to the
jacks by means of the distributor block and
the high-pressure hoses.

Using the vent screws of the hydraulic

jacks, vent the system and increase the
pressure as stated in Data.
For operation of the hydraulic tools, see
Procedure 913-1.

M90101
0249D05
Loosen the nuts by applying the tommy
bar through the slots in the spacer rings.

Relieve the system of pressure.

Disconnect the high-pressure hoses from 6.

the jacks.

Remove the hydraulic jacks and spacer

rings, and unscrew the nuts.

6. Hook the engine room crane on to the lift-

ing attachment on top of the exhaust valve. D01
06
Lift away the cylinder cover complete, and
land it on a couple of wooden planks.

7. Remove and discard the sealing ring be-

M90101
0249D06

tween cylinder cover and cylinder liner.

7.
M90101
0249D07

When referring to this page, please quote Procedure M90101 Edition 0249 Page 3 (10)
901-1.3 Cylinder Cover
Overhaul MAN B&W Diesel

1. Dismount all valves and pipes on the cylin-

1. der cover.
D01
09 Dismount all studs on top of the cylinder
cover.

2. Remove the four screws which secure the

cooling jacket to the cylinder cover.

Lift the cylinder cover free of the cooling

jacket and land it on a couple of planks.

If the cooling jacket sticks, use dismantling

screws to force the jacket/cover apart.
M90101
0249O01

Remove and discard the O-rings from the

cover, and carefully clean the cooling jacket
and the cylinder cover.

2. 3. Provide the cylinder cover with new O-

rings, well lubricated with oil.

4. Lift the cylinder cover and guide the jacket/

cover into position, using the guide pin as
a reference (camshaft side).

Mount and tighten the screws for the cool-

D01
08 ing jacket.
M90101
0249O02

3.
M90101
0249O03

Page 4 (10) When referring to this page, please quote Procedure M90101 Edition 0249
 Cylinder Cover 901-1.3
MAN B&W Diesel Overhaul

5. Recondition the valve bores as follows:

5.
Fuel valve bore

6. The tool consists of a common spindle with

handle, a guide, a carbon cutter, a seating
face cutter and a grinding mandrel.

Clean the fuel valve bores, using the car-

bon cutter. If required, recondition the fuel
valve seating with the appropriate cutter.

Grind the seating with the grinding mandrel

and a grinding compound (e.g.

M90101
0249O05
Carborundum No. 200).

After the milling/grinding, clean the bore

and seating carefully, and check that the
seating is not damaged.
6.
Exhaust valve bore

7. The tool consists of a spindle with handle

and a grinding disc.

After cleaning the valve bore and seating,

grind the seating with the grinding disc and
a grinding compound (e.g. Carborundum
No. 200).

After the grinding, clean the bore and seat-

ing carefully, and check that the seating is
M90101
0246O06

not damaged.

7.
M90101
0240O07

When referring to this page, please quote Procedure M90101 Edition 0249 Page 5 (10)
901-1.3 Cylinder Cover
Overhaul MAN B&W Diesel

Starting valve bore

8.
8. The tool consists of a guide, a cutter, and a
grinding disc.

Recondition the starting valve bore and

seating in the same way as described for
the fuel valve bore.

When replacing valves on a cylinder cover

that is mounted on the engine, recondition
the valve bores/seating in the same way as
described here, but without dismounting
the studs.

9. Clean the bores for safety valve/indicator

cock.
M90101
0246O08

9.
M90101
0246O09

Page 6 (10) When referring to this page, please quote Procedure M90101 Edition 0249
 Cylinder Cover 901-1.3
MAN B&W Diesel Overhaul

10. Lubricate the threads with ‘Never Seize' or

10. Molybdenum Disulphide (MoS2) and mount the
D01
01
valve studs.

D01
03 Tighten up the studs in accordance with the

screwing-in torque stated on the data sheet.

Fill up the grooves between the valve studs

and the bores for the valve studs with
permatex to prevent water or oil from entering
the bores during operation of the engine.
D01
02
Provide the water connection flanges with
new gaskets, and keep the cylinder cover
M90101
0249O10

ready for replacement.

Always fit new or overhauled valves before a

cylinder cover is mounted on the engine.

When referring to this page, please quote Procedure M90101 Edition 0249 Page 7 (10)
901-1.4 Cylinder Cover
Mounting MAN B&W Diesel

1. Place a new sealing ring on top of the cyl-

1. inder liner with the guide tabs in the fore
and aft direction.

This is to ensure that the tabs fit into the

two gas blow-out grooves milled in the cyl-
D01
06 inder cover guide recess.

2. Lift the cylinder cover by means of the

crane and carefully wipe the contact sur-
face which faces the cylinder liner.

Provide the cooling water connecting pipes

M90101
0249M01

with new O-rings and lubricate them with

grease or soft soap.

Mount a new ‘klinger’ sealing ring in the

groove of the flange of the intermediate
pipe.
2.
Lower the cover carefully into position.

During the landing, carefully check that the

cooling water connecting pipes engage
correctly with the holes in the cooling
jacket.

3. Mount the cover nuts on the studs and

screw down.

Place eight spacer rings, one around each

nut, and mount the eight hydraulic jacks on
M90101
0249M02

the studs.

Connect the high-pressure pump to the

jacks by means of the distributor block and
the high-pressure hoses.
3.
Using the vent screws of the hydraulic
D13
01 jacks, vent the system, and then increase
the pressure as stated in Data.
For operation of the hydraulic tools, see
Procedure 913-1.

Tighten the nuts by applying the tommy bar

through the slots in the spacer rings.

Relieve the system of pressure.

Finally, remove the hydraulic jacks and

M90101
0249M03

spacer rings from the nuts.

Page 8 (10) When referring to this page, please quote Procedure M90101 Edition 0249
 Cylinder Cover 901-1.4
MAN B&W Diesel Mounting

4. Mount the protective caps on the cylinder 4.

cover studs.

Align the intermediate pipe so that the

holes in the flange of the intermediate pipe
are in line with the threaded holes in the
exhaust receiver.

Mount the screws of the flange between

the intermediate pipe and the exhaust re-
ceiver.

Note!

M90101
0249M04
Lubricate the screws with anti-seize
paste containing Molybdenum Disulphide
(MoS2) before mounting.

5. Mount the insulating jacket around the in-

termediate pipe. 5.
M90101
0249M05

When referring to this page, please quote Procedure M90101 Edition 0249 Page 9 (10)
901-1.4 Cylinder Cover
Mounting MAN B&W Diesel

6. Mount the return oil pipe and the air pipe

6. for pneumatic closing of the exhaust valve.

Mount the high-pressure pipe for the hy-

draulic valve gear.
See Procedure 908-1.4.

7. Mount the starting air pipe and control air

pipe for the starting valve.

Mount the cooling water inlet and outlet

pipes on the exhaust valve.
M90101
0249M06

Mount the drain pipe on the intermediate

pipe between the exhaust valve and the
cylinder cover.

Mount the fuel oil high-pressure pipes for

the fuel valves.
7. See Procedure 909-14.4.

Connect the outlet pipe from the return oil

pipe on the fuel valves.

Shut the drain valves and open the cooling

water inlet. After venting the cylinder sec-
tion, shut the vent cocks and open the
cooling water outlet valve.

Open the fuel oil, lubricating oil and air

supplies to the alarm system.
M90101
0249M06

Note!
The air supply to the exhaust valve must
always be connected before starting the
camshaft oil pumps.

Page 10 (10) When referring to this page, please quote Procedure M90101 Edition 0249
 Cylinder Cover Panel Plate
P90151-0199
Cylinder Cover Panel
0199
P90151

When referring to this page, please quote Plate P90151 Edition 0199 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover Panel
P90151-0199

Item Item
Item Description Item Description
No. No.

010 Panel for tools

022 Name plate
046 Grinding tool for exhaust valve seat
058 Milling and grinding wheel for fuel
valve seat
060 Milling and grinding wheel for starting
valve seat
071 Dismantling tool for fuel valve seat
083 Handle for cutting and grinding tool
095 Grinding ring for starting valve
105 Grinding handle
117 Pressure tester for safety valve
130 Lifting chains
201 Handle for cutting and grinding tool

Page 2 (2) When referring to this page, please quote Plate P90151 Edition 0199
MAN B&W Diesel A/S
 Cylinder Cover - Tools Plate
P90161-0099
Cylinder Cover - Tools
0099
P90161

When referring to this page, please quote Plate P90161 Edition 0099 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Cover - Tools
P90161-0099

Item Item
Item Description Item Description
No. No.

015 Wooden box

027 Hydraulic jack, complete
039 Support
040 Support
052 O-ring with back-up ring
064 O-ring with back-up ring
090 Key, hexagon socket screw
100 Tommy bar
111 Stud setter
206 Hydraulic jack - cylinder cover, com-
plete
218 Hydraulic jack - cylinder cover, com-
plete

Page 2 (2) When referring to this page, please quote Plate P90161 Edition 0099
MAN B&W Diesel A/S
 Piston 102-1
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
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Stop lubricating oil supply
X Lock the turbocharger rotors

Data

Ref. Description Value Unit

D01-05 Cylinder cover stud, check distance 128-129 mm

D02-01 Test pressure 7 bar
D02-02 Piston rod/crosshead, tightening torque 430 Nm
D02-03 Piston rod/crown, tightening torque 300 Nm
D02-05 Piston skirt, tightening torque 80 Nm
D02-06 Cooling oil pipe, tightening torque 80 Nm
D02-07 Piston rod/crosshead, tightening torque+angle 100/30 Nm/°
D02-08 Piston ring new, radial width 17.2 mm
D02-09 Piston ring worn, min. radial width 14.2 mm
D02-10 Groove No.1, max. vertical height 13.2 mm
D02-11 Groove Nos. 2, 3 and 4, max. vertical height 10.2 mm
D02-12 Piston top, max. permissible burn-away 15 mm
D02-13 Piston ring new, height of ring No. 1 12.4 mm
D02-14 Piston rings new, height of ring Nos. 2, 3 and 4 9.4 mm
D02-15 Minimum free ring gap ( before dismantling ) 28 mm
D02-16 Minimum ring gap, ring No. 1 ( new ring in new liner ) 3.4 mm
D02-17 Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) 2.4 mm
D02-18 Vertical clearance, new parts 0.38 mm
D02-19 Vertical clearance, worn parts, max. 0.87 mm
D02-20 Piston complete 1000 kg
D02-21 Piston crown 220 kg
D02-22 Piston rod 580 kg
D02-23 Piston skirt 60 kg
D02-24 Piston cooling pipe 22 kg
D02-25 Lifting tool, tightening torque 100 Nm
D02-46 CPR ring CL groove, min. depth 1.1 mm

When referring to this page, please quote Data D10201 Edition 0109 Page 1 (2)
102-1 Piston
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

P90251 040 Lifting tool for piston rod foot

P90251 075 Template for piston top
P90251 087 Distance piece for stuffing box
P90251 099 Cover for stuffing box hole
P90251 110 Pressure test tool for piston
P90251 134 Piston ring expander
P90251 158 Guide screw for piston crown

P90261 Piston and Piston Rod - Tools

P90265 Piston and Piston Rod - Support Tools
P90266 Piston - Lifting Tools

P90451 118 Rubber cover for crosshead

Page 2 (2) When referring to this page, please quote Data D10201 Edition 0109
 Piston 902-1.1
MAN B&W Checking

Scavenge Port Inspection

1.
To detect possible leakages from the piston
or cylinder cover, keep the cooling water
and cooling oil circulating during the scav-
enge port inspection.

1. The scavenge port inspection is carried out

from the scavenge air receiver. An addition-
al view of the rings is possible through the
cleaning cover on the manoeuvring side.

Turn the engine at least ½ a revolution, and

M90201
0280C01
begin with a unit arriving downwards, just
above the scavenge air ports. Inspect the
piston rod and the lower part of the cylin-
der wall.

While the piston is passing downwards,

inspect the piston skirt, all the piston rings, 2.
the ring lands and the piston top.

2. Ring inspection:
Inspect the rings, one at a time, and note
down the results. See Volume I, Operation,
Chapter 707.

3. Ring tension:
Check the tension of the piston rings, by
pressing against them with a wooden stick.
M90201
0280C02

3.
M90201
0280C03

When referring to this page, please quote Procedure M90201 Edition 0286 Page 1 (20)
902-1.1 Piston
Checking MAN B&W

4. Ring grooves:
4. Measure the total clearance between the
D02
18 piston ring and the ring groove. The total
clearance must not exceed the value stated
in Data.
D02
19 Measure the clearance at the top (E) and
E
bottom (F) of the piston ring groove.
Total clearance = E + F.

F 5. Uppermost piston ring:

If possible, measure the depth of the pres-
sure relief grooves with a calliper. The
piston rings must be replaced if the radial
M90201
0280C04

Max. 2mm
depth of the grooves has worn down to
less than stated in Data D02
46.

Checking, in connection with piston

overhaul
5.
D02
46 6. Piston support:

Remove the piston from the cylinder and

place it on the piston support.
See Procedure 902
1.2. For evaluation of
the rings, see Volume I, Chapter 707.

Note!
It is recommended to replace all the pis-
ton rings whenever a piston is removed
M90201
0280C05

from the engine.

6.
M90201
0285C06

Page 2 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.1
MAN B&W Checking

7. Free ring gap:

Before dismantling the piston rings, mea- 7.
sure the free ring gap of all the piston
rings.
D02
15
For dismantling the piston rings, see Proce-
dure 902
1.3.

8. Radial ring width:

Measure the radial width of the rings. Note
down the results See Volume I, Operation,
Chapter 707.

9. Ring grooves:

M90201
0285C07
Clean the ring grooves and check them for
burn marks or other deformation.

Measure the ring grooves with a calliper

gauge, see Data D02
10 and D02
11.
8.
Clearance in piston ring grooves:
The maximum vertical height in a worn ring
groove must not exceed the value stated
in Data. The groove is also worn out if
there is no chromium layer.
D02
08 New
If the ring grooves are worn out, the piston
crown must be reconditioned, contact MAN
B&W Diesel A/S for advice.
M90201
0280C08

D02
09 Worn

9.
D02-10
D02-11

Max 2mm
M90201
0280C09

When referring to this page, please quote Procedure M90201 Edition 0286 Page 3 (20)
902-1.1 Piston
Checking MAN B&W

10. Piston crown top:

10. Clean the piston crown and check the
burn
away by means of the template.
D02
12
For maximum permissible burn away value,
see Data.

Check the burn
away on the whole circum-

ference of the piston crown top.

If the burn
away exceeds the values given

in Data, contact MAN B&W for advice.

Note down the results for later reference.

M90201
0285C10

Page 4 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.2
MAN B&W Dismantling

Preparations in the crankcase

1.
1. Access:
Open the crankcase door to the cylinder
concerned.

Turn the crosshead down far enough to

give access to the piston rod stuffing box
and the piston rod/crosshead connection.

2. Stuffing box:
Release the stuffing box by removing the
innermost screws from the stuffing box
flange.

M90201
280D01
On engine models where the drain pipe is
connected directly to the stuffing box:

Disconnect the stuffing box drain pipe.

2.
Note!
Do NOT remove the outermost screws
from the flange.

3. Loosen the piston rod
crosshead connec-

tion:
Remove the screws from the piston rod.
M90201
0280D03

3.
M90201
0284D04

When referring to this page, please quote Procedure M90201 Edition 0286 Page 5 (20)
902-1.2 Piston
Dismantling MAN B&W

4. Stuffing box distance pieces:

4.
Mount the two distance pieces on the pis-
ton rod foot to protect the lower scraper
ring and to guide the stuffing box.

Preparations on the cylinder top

5. Cylinder cover:
Remove the cylinder cover. See Procedure
901
1.2.

Make a scratch mark in liner and pis-

ton cleaning ring to ensure correct
re
mounting. Remove the piston cleaning
ring.

Carefully remove any wear ridges at the top

of the cylinder liner. See Procedure 903
1.3.
M90201
0280D05

5.
M90201
0285D06

Page 6 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.2
MAN B&W Dismantling

6. Piston lifting tool:

Turn the piston to TDC. The top of the pis- 6. D02
25
ton is now free of the cylinder liner.

Clean the lifting groove of the piston crown

and mount the lifting tool.

Note!

Make sure to mount the lifting tool cor-

rectly, so that the claws of the lifting tool
enter the lifting grooves of the piston
crown.

M90201
0285D07
If the engine not is equipped with long dis-
tance pieces, remove one or two cylinder
cover studs, using a stud setter.

When referring to this page, please quote Procedure M90201 Edition 0286 Page 7 (20)
902-1.2 Piston
Dismantling MAN B&W

Piston lift
7.
7. Lift the piston out of the cylinder liner and
guide the piston rod foot through the stuff-
ing box flange.

If the engine is equipped with long distance

pieces for the stuffing box, the piston rod
foot can pass between two cylinder cover
studs.

Place the two halves of the support around

one of the openings in the platform. Low-
er the piston rod foot and stuffing box
through the opening in the platform. Secure
the two support halves with screws and
lower the piston on the support. Check the
piston is resting on the piston rod flange.

Limited Lifting height:

If the piston rod foot can not be lifted clear

of the liner top with the standard lifting
D02
20 tool, contact MAN Diesel for instructions
for tilted lift.
M90201
0285D08

Page 8 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.2
MAN B&W Dismantling

8. Protect the crosshead bearing:

8.
Place a cover over the opening for the pis-
ton rod stuffing box in the bottom of the
cylinder unit.

Turn the crosshead down far enough to

permit mounting of the protective rubber
cover on the crosshead bearing cap. The
protective rubber cover is found on tool
panel 904.

The covers must remain in place to protect

the crosshead bearing journal from impuri-
ties until the piston is remounted.

Clean, measure and recondition the cylin-

der liner. See Procedure 903
1.
M90201
0283D09

When referring to this page, please quote Procedure M90201 Edition 0286 Page 9 (20)
902-1.3 Piston
Overhaul MAN B&W

1. Piston support:
1. Place the piston in the support and remove
the piston lifting tool.
D02
20 See Procedure 902
1.2.

Clean the piston top and the piston rings.

Check the free ring gap and the burn
off

on the piston top. See Procedure 902
1.1.

Remove the stuffing box. See Procedure

902
2.3.

2. Piston ring dismantling:

M90201
0285O01

Take off the piston rings by means of the

ring expanders. If the engine is equipped
with two ring expanders, the short ring ex-
pander is for the uppermost ring.

2. First remove the uppermost ring, then ring

No. two, three and four.

Clean and inspect the rings and the ring

grooves. See Procedure 902
1.1.

3. Piston crown dismantling:

Remove the locking wire and the innermost
screws between the rod and the piston
crown.

Lift the piston crown and skirt clear of the

piston rod.
M90201
0285O02

3.

D02
21
+
D02
23
M90201
0284O03

Page 10 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.3
MAN B&W Overhaul

4. Piston rod and cooling pipe:

Remove the screws from the cooling oil 4.
pipe flange.

Mount the eye bolts and lift out the cooling D02
24
oil pipe.

Clean and inspect the cooling oil pipe and D02
06

the piston rod, then remount the cooling oil
pipe, see Data.

Check that the surfaces of the O
ring D02
22

groove is clean and smooth.

M90201
0280O04
Mount a new O
ring on the piston rod
flange.

5. Unhook the crane from the piston lifting

tool, and connect the lifting tool and the
crane hook by means of a wire rope. Lift 5.
up the piston crown.

Fit two eyebolts in the piston skirt and a

wire rope between the bolts as shown in
the sketch.

Install a tackle in a suitable place with suf-

ficient space below for the piston crown.
Attach the tackle to the wire rope on the
piston crown and carefully turn the piston
crown upside down. Use both cranes if the
engine room is equipped with two cranes.
M90201
0286O05

Land the piston lifting tool and the piston

crown on a sufficient support of wood
pieces. Loosen the piston lifting tool and
lift the piston crown clear of the tool.

6. Piston crown dismantling and cleaning: 6.

Place the piston crown with skirt on a D02
23
wooden support as shown.

Remove the locking wire and the screws in

the skirt. If necessary use two dismantling
screws to pull the skirt out of the piston
crown. Mount two eye bolts in the skirt. Lift
the skirt and land it on a couple of planks.

Discard the sealing ring on the piston skirt.

M90201
0284O05

When referring to this page, please quote Procedure M90201 Edition 0286 Page 11 (20)
902-1.3 Piston
Overhaul MAN B&W

Thoroughly clean and inspect all parts of

7. the crown and skirt. If coke deposits are
found in the cooling spaces of the piston
D02
05 crown, they should be washed clean with
Carbon Remover or a similar cleaning fluid.
When all coke deposits have been dis-
solved, clean and inspect the piston crown
again.

Note!

Coke deposits reduce heat transfer from

the piston crown to the cooling oil. The
deposits must be removed as a routine
M90201
0284O06

procedure when a piston is overhauled.

7. Piston crown assembly:

Mount a new O
ring on the piston skirt.
8. Check that the surfaces of the O
ring
groove are clean and smooth. Coat the ring
with lubricating oil before mounting.

Mount the piston skirt on the piston crown.

Tighten the screws to specified torque, see
data D02
05. Lock the screws with locking
wire, see Procedure 913
7.

8. Piston crown and skirt mounting:

Mount the guide screw to ensure the cor-
rect positioning of the piston rod in relation
to the piston crown.

Lubricate the O
ring on the piston rod

flange with lubricating oil.

Land the overhauled piston crown and skirt

on the piston rod.

Remove the guide screw.

D02
03
M90201
0284O07

Mount and tighten the screws between the

piston rod and the piston crown, see Data.

Page 12 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.3
MAN B&W Overhaul

Sealing ring and pressure test

9.
According to current class rules, the piston
must be pressure tested hydraulically. It is
possible to carry out a test of the sealing
rings with compressed air before filling the
piston with oil. The sealing ring test can
also be carried out when the piston is rest-
ing in the support tool.

9. Sealing ring test:

Mount the pressure
testing tool on the
piston rod foot. Connect compressed air
to the testing tool and fill the piston to 4
5

M90201
0277O16
bar. Close the valve on the testing tool and
remove the air connection. The piston must
now hold the pressure for minimum 30
minutes.

Spray a little soap water on to the surface 10.

joints between piston rod/crown/skirt and D02
01
around the bolt heads to detect leaks.

Dry off all soap water.

10. Pressure test:

For this test, the piston must be turned oil
upside down (see next step to turn a com-
plete piston).

Fill the piston and piston rod with lubricat-

ing oil. Mount the pressure
testing tool
M90201
0277O17

on the piston rod foot. Pressure
test the

piston at the pressure stated on the Data
Sheet. Check the contact surfaces of the
piston and the sealing rings for tightness.
Check that there are no cracks in the pis-
ton crown.

Turn the piston upside up and drain out the

piston oil.

When referring to this page, please quote Procedure M90201 Edition 0286 Page 13 (20)
902-1.3 Piston
Overhaul MAN B&W

11. Piston turning:

11. Lift the piston with the normal lifting tool.
Lower the piston rod foot until it is close to
the platform. Land the foot on a wooden
block.

Lower the piston crown to the platform and

land it on a wooden block in such a way
that it is possible to remove the lifting tool.

Attach the lifting bracket to the bottom of

the piston rod foot. Hook the crane on to
the lifting bracket. Lift the piston rod foot
clear of the wooden block. Keep lifting until
the piston rod is in a vertical position.

Note!
During the lift, follow with the crane
to keep the crane positioned vertically
above the lifting point. The stuffing box
must be removed.
M90201
0283O10

Page 14 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.4
MAN B&W Mounting

12. Piston completion:

Fit the new piston rings (alternately 12.
right
hand and left
hand cuts, with the ring A
gaps staggered 180° and with the TOP
mark upwards), using the ring expander. B
When mounting the piston rings, use the
ring expanders to prevent unintended de- A C
formation of the rings.

Do not expand the rings more than neces- D

sary. The uppermost ring (CPR
ring) must
be mounted with the short ring expander, B
if the engine is equipped with two ring ex-
panders

Mount the piston rod stuffing box.

See Procedure 902
2.3. C

D
M90201
0285O11

When referring to this page, please quote Procedure M90201 Edition 0286 Page 15 (20)
902-1.4 Piston
Mounting MAN B&W

Preparation of piston
1.
1. Check the piston rings and piston crown in
accordance with Procedure 902
1.1, if not
already done.

Mount the lifting tool on the piston crown.

See Data D02
25.

2. Stuffing box position:

Ensure that the stuffing box is correctly po-
sitioned over the distance pieces mounted
on the piston rod foot. Both the holes for
the flange and the drain hole for the drain
pipe must be positioned correctly.
M90201
0285M01

2.
M90201
0277M02

Page 16 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.4
MAN B&W Mounting

Preparation of cylinder liner

3.
3. Mount the guide ring:
Mount the guide ring in the top of the cyl-
inder liner. The cut outs for the lifting tool
must be turned to fit the piston lifting tool.

4. Stuffing box cover:

Remove the cover from the piston rod
stuffing box opening in the bottom of the
cylinder unit.

Clean the stuffing box flange.

M90201
0283M03
5. Crosshead position:
Turn the crosshead to a position 45° from
TDC (crank web pointing towards exhaust
side).

4.
M90201
0277M05

5.
M90201
0277M06

45°

When referring to this page, please quote Procedure M90201 Edition 0286 Page 17 (20)
902-1.4 Piston
Mounting MAN B&W

Mounting of piston
6. D02
20
6. Coat the O
rings of the stuffing box and
the piston rod with oil. Coat the piston
rings and cylinder liner with cylinder lubri-
cating oil.

Lower the piston into the cylinder liner

– while guiding the piston rod foot through
the cut
out in the stuffing box flange – until
the piston rings are inside the liner.

7. Protective cover:
Remove the protective rubber cover from
M90201
0285M06

the crosshead.

8. Crosshead alignment:
Turn the crosshead almost to TDC, while
checking that the guide ring of the cross-
7. head enters the centre hole in the piston
rod.

After turning the crosshead fully to TDC,

and ensuring that the piston rod has full
contact with the crosshead, unscrew the
lifting tool and remove the lifting tool and
the guide ring for piston rings.
M90201
0283M07

8.
M90201
0284M08

Page 18 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston 902-1.4
MAN B&W Mounting

9. Stuffing box:
Turn down and land the stuffing box on the 9.
stuffing box flange. Check that the holes in
the stuffing box and stuffing box flange are
correctly centered.

Tighten the piston rod stuffing box by

means of the screws through the inner
holes in the stuffing box flange. For Data,
see Procedure 902
2.

On engine models where the drain pipe is

connected directly to the stuffing box:

M90201
0280M09
• Mount the stuffing box drain pipe.

Remove the distance pieces from the pis-

ton rod foot.

10. Tightening of the piston rod
crosshead 10.

connection:
Mount and tighten the piston rod screws.
D02
02
Tighten the screws to the specified torque or
and lock with locking wire. D02
07
See Data. Use either Data D02
02 or Data
D02
07.

11. Piston cleaning ring:

Mount the piston cleaning ring in accor-
dance with the scratch mark. If the PC
ring
is damaged (broken or cracked), it must be
replaced by another ring.
M90201
0284M10

See Procedure 903
1.

11.
M90201
0285M12

When referring to this page, please quote Procedure M90201 Edition 0286 Page 19 (20)
902-1.4 Piston
Mounting MAN B&W

12. Cylinder cover studs:

12. If the cylinder cover studs have been re-
moved, remount them. Carefully clean the
surfaces around the base of the studs and
check the O
rings on the studs.

Mount the cylinder cover studs with the

stud setter. Screw the stud down to con-
tact and half a revolution back.

13. Cylinder cover:

Land the cylinder cover on the liner and
check the distance that the stud is protrud-
ing from the cylinder cover. If necessary,
M90201
0277M15

adjust the distance D01
05 by turning the

stud.

Tighten the cylinder cover nuts and mount

the necessary pipes.
13. See Procedure 901
1.4.

14. Running
in:
Smear the piston rod with molybdenum di-
sulphide, and turn the crankshaft a couple
of revolutions.

At the first opportunity, start the engine

and keep it running for about 15 minutes
at a speed corresponding to “Dead Slow”
D01
05 Ahead.

Then stop the engine and inspect the pis-

M90201
0280M14

ton rod and stuffing box.

Page 20 (20) When referring to this page, please quote Procedure M90201 Edition 0286
 Piston Rod Stuffing Box 102-2
Data

SAFETY PRECAUTIONS
Special
D10202 Data 0048
102-2 Edition PistonS50ME-C
Rod Stuffing Box

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D02-26 Stuffing box flange, outer screws tightening torque 80 Nm

D02-27 Stuffing box flange, inner screws tightening torque 80 Nm
D02-28 Stuffing box halves, tightening torque 80 Nm
D02-29 Uppermost rings, ring-end clearance 4x6 mm
D02-30 Lowermost rings, ring-end clearance 3x3 mm
D02-33 Check length for the six uppermost springs:
D02-34 – F 0 = 0 N.........…....... L 0 = 639 mm
D02-35 – F 1 = 153 +/– 7 N....... L 1 = 763 mm
D02-36 – F 2 = 163 +/– 10 N..... L 2 = 835 mm
D02-37 Check length for the four lowermost springs:
D02-38 – F 0 = 0 N......….......... L 0 = 496 mm
D02-39 – F 1 = 150 +/– 7 N....... L 1 = 646 mm
D02-40 – F 2 = 200 +/– 10 N..... L 2 = 714 mm
D02-44 Stuffing box complete 63 kg
D02-45 Stuffing box half 19 kg

When referring to this page, please quote Data D10202 Edition 0S48 Page 1 (2)
MAN B&W Diesel A/S
102-2 Piston Rod Stuffing Box
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

P90251 109 Mounting tool for stuffing box spring

P90251 122 Worktable for stuffing box
P90451 118 Rubber cover for crosshead

Page 2 (2) When referring to this page, please quote Data D10202 Edition 0S48
MAN B&W Diesel A/S
 Piston Rod Stuffing Box 902-2.1
Checking
0221 Rod Stuffing Box
Piston S46MCC
Checking
902-2.1

1.
1. After the piston rod stuffing box has been
dismantled, check the following clearanc-
es:.
See Procedure 902-2.2. D02-29

Uppermost scraper ring and sealing rings

A
Clearance at ring ends (scraper ring).
Total clearance (scraper ring). (D02-29) D02-30

Clearance at ring ends (sealing rings).

Total clearance (sealing rings). (D02-29)

Lowermost scraper rings

Clearance at ring ends.

Total clearance. (D02-30) B
The ring clearances stated in Data apply to A B
new rings.

As a general guide, it is recommended –

depending on the overhauling intervals and
one’s own experience – to replace sealing D02-29 D02-30
rings and scraper rings when the specified
NB902-2.1 216 01

clearance values D02-29 and D02-30 have

been halved.

2. Check the length of the springs at different

loads. Adjust the loads to achieve the
2.
lengths stated in Data. D02-33
If the loads necessary are outside the limits
stated in Data, the springs must be discard-
ed.

It is recommended to renew the springs for

the sealing rings when the rings are re-
newed.
D02-37
HM902-5.0 70 02

When referring to this page, please quote Procedure M90202 Edition 0221 Page 1 (9)
0$1% :'LHVHO$6
902-2.2 Piston Rod Stuffing Box
Dismantling
Dismantling
902-2.2

1. In connection with dismantling of the piston,

only the innermost screws in the stuffing box
flange should be removed.

If, in the period between piston overhauls, it be-

comes necessary to inspect the piston rod
stuffing box, proceed as follows:

1. Turn the crosshead to about 90° from TDC.

Mount the rubber cover around the piston

rod to protect the crosshead bearing from
impurities.
GN902-2.2 203 01

2. Remove the drain oil pipe and all innermost

screws and all outer screws except for two
screws placed diametrically opposite in the
stuffing box flange, longitudinally to the en-
2. gine.

3. Mount the worktable around the piston rod

so that the two remaining screws in the
stuffing box flange can be loosened through
the holes.
DM902-5.2 108 02

3.
DM902-5.2 108 03

Page 2 (9) When referring to this page, please quote Procedure M90202 Edition 0221
0$1% :'LHVHO$6
 Piston Rod Stuffing Box 902-2.2
Dismantling

4. Remove the two long dismantling screws 4.

from the worktable.

Mount them in the stuffing box through the

holes in the worktable.

Remove the remaining two screws from the

stuffing box.

5. Turn the piston to BDC, thereby withdraw-

ing the stuffing box from the cylinder frame
bottom.

DM902-5.2 108 04
6. Remove the two long dismantling screws
from the stuffing box and mount them in the
worktable.

By means of the four short screws in the

worktable, press the stuffing box out of the 5.
flange.
For overhauling the stuffing box, see Pro-
cedure 902-2.3.
DM902-5.2 108 05

6.
EN902-2.2 221 06

When referring to this page, please quote Procedure M90202 Edition 0221 Page 3 (9)
0$1% :'LHVHO$6
902-2.3 Piston Rod Stuffing Box
Overhaul
Overhaul
902-2.3

Normally, overhaul of the piston rod stuffing box

is carried out by routine methods in connection
with the dismantling (pulling) of the pistons.

During such overhauls, the piston rests on a

support placed over one of the cut-outs in the
top platform.

Work on the stuffing box is then carried out

from the platform below.

Overhaul inside the engine is carried out in the

same way as outside the engine.
GM902-5.1 90 01

1. Mount two eye bolts in the stuffing box

flange, and hook on two tackles.

Lift the stuffing box a little up the piston rod,

1. and mount the worktable round the piston
rod at a suitable working height.

Land the stuffing box on the worktable, and

remove the tackles and eye bolts.
D02-44 2. Remove the O-ring of the stuffing box. If the
O-ring is intact and is to be used again,
D02-44
move it up the piston rod and secure it in
this position, for example with tape.

Remove the nuts from the stuffing box as-

sembling bolts.
2222041a

2.
2222042a

Page 4 (9) When referring to this page, please quote Procedure M90202 Edition 0221
0$1% :'LHVHO$6
 Piston Rod Stuffing Box 902-2.3
Overhaul

3. Take out the six bolts, and pull away one 3.

stuffing box half.

Mount two eye bolts on the stuffing box half D02-45

and remove it from the worktable.

4. Using a feeler gauge, measure the vertical

clearance of the rings.
See Procedure 902-2.1.

5. Remove the remaining stuffing box half and

press all sealing rings and scraper rings
down against the worktable.

6. Measure the clearance between the ring

2222043a
segments to determine whether replace-
ment is necessary.
See Procedure 902-2.1.
7.
Dismantle and stack the rings in the same D02-33
order as when fitted in the stuffing box.

Carefully clean all the ring segments.

Inspect and assess the surface quality of

the sealing rings. If their sliding surfaces
have scratches or marks, replace the rings.
D02-37
7. Check the lengths of the springs.
See Procedure 902-2.1.

8. Inspect the surface of the piston rod. If

HM902-5.0 70 02

small longitudinal scratches have occurred

(caused by poorly adapted stuffing box
rings), smooth the piston rod surface care-
fully with a fine grained carborundum stone.
In the case of coarse scratches, it may 8.
prove necessary to machine-grind the sur-
face in a workshop.

9. Clean the halves of the stuffing box hous-

ing.
HC902-5.1 98 07

When referring to this page, please quote Procedure M90202 Edition 0221 Page 5 (9)
0$1% :'LHVHO$6
902-2.3 Piston Rod Stuffing Box
Overhaul

10. 10. Lubricate the piston rod (in the area where
all the ring units in the stuffing box will be
positioned) with molybdenum disulphide
(MoS 2).

Assemble all the stuffing box ring units

round the piston rod, on the worktable, in
the following way:

• Place the lowermost scraper ring seg-

ments on the worktable.

• Place the spring round the segments,

and hook the spring ends together.
NB902-3 217 10

Repeat this procedure for the remaining

scraper rings.

11. On top of the scraper rings, assemble the

two sealing ring units (each consisting of a
4-part and an 8-part ring).

Assemble the 8-part sealing ring so that the

two guide pins face upwards, place the
spring round the segments and, hook the
spring ends together.

Assemble the 4-part sealing ring above the

8-part sealing ring. Push the two rings to-
gether in such a manner that the guide pins
in the lower sealing ring engage with the
two holes in the upper sealing ring.
HC902-5.1 98 11

Finally, assemble the uppermost ring unit

(consisting of a 4-part scraper ring and an
8-part sealing ring).

11. Use the stuffing box half on the worktable

to adjust the height of all the assembled
ring units on the piston rod until the ring
units are opposite the corresponding
grooves in the stuffing box housing. Subse-
quently, push the stuffing box half into con-
tact with the piston rod, round the ring units.

Note!

If the stuffing box is assembled inside the

engine, place two pieces of plywood of
the same thickness as the flange on the
worktable, to ease the assembling.

Page 6 (9) When referring to this page, please quote Procedure M90202 Edition 0221
0$1% :'LHVHO$6
 Piston Rod Stuffing Box 902-2.3
Overhaul

12. Check the ring clearance again. 12.

Then place the other half of the stuffing box

housing on the worktable, pushing it into D02-28
place round the rings.

Mount and tighten up the fitted bolts to the

torque specified on the Data Sheet.

Mount the O-ring in the stuffing box groove.

13. Mount eye bolts and wire ropes, and lift the
stuffing box a little.

HC902-5.1 98 12
Remove the worktable and lower the stuff-
ing box until it rests against the distance
pieces on the piston rod foot.

Remove wire ropes and screws. 13.

D02-44
22320313

When referring to this page, please quote Procedure M90202 Edition 0221 Page 7 (9)
0$1% :'LHVHO$6
902-2.4 Piston Rod Stuffing Box
Mounting
Mounting
902-2.4

1. 1. In connection with mounting of the piston,

only the innermost flange screws are to be
mounted and tightened, see data.

After overhauling the stuffing box inside the

engine, assemble the stuffing box halves on
top of the four screws.

Mount the two long screws from the workta-

ble in the stuffing box.

Turn down the short screws so that the

stuffing box lands on the flange.

2. Turn the piston upwards until the stuffing

22420416

box is in place in the cylinder frame.

2. Note!

Make sure that the two guide pins in the

flange enter the guide holes in the bottom
of the cylinder frame.

3. Mount two screws in the flange through the

holes in the worktable.
DM902-5.2 108 08

3.
DM902-5.2 108 09

Page 8 (9) When referring to this page, please quote Procedure M90202 Edition 0221
0$1% :'LHVHO$6
 Piston Rod Stuffing Box 902-2.4
Mounting

4. Remove the long screws from the stuffing 4.

box and mount them in the worktable.

Remove the worktable from the piston rod.

5. Mount and tighten all the inner and outer

screws for the stuffing box. See Data.

6. Remove the protecting rubber cover from

the piston rod/crosshead.

Smear the piston rod with molybdenum di-

sulphide.

DM902-5.2 108 10
Then turn the crankshaft a couple of revo-
lutions.

Start up the engine and keep it running for

about fifteen minutes at a number of revo- 5.
lutions corresponding to very slow or idle
speed.

Then stop the engine and inspect the piston

rod and stuffing box.

D02-26
DM902-5.2 108 11

D02-27

6.
GN902-2.2 203 01

When referring to this page, please quote Procedure M90202 Edition 0221 Page 9 (9)
0$1% :'LHVHO$6
 Piston and Piston Rod Panel Plate
P90251-0237

When referring to this page, please quote Plate P90251 Edition 0237 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod Panel
P90251-0237

Item Item Description Item Item Description

No. No.

014 Panel for tools

026 Name plate
040 Lifting tool, piston rod foot
051 Lifting tool, cylinder liner
075 Template, piston top
087 Distance piece, stuffing box
099 Cover, stuffing box hole
109 Mounting tool, stuffing box spring
110 Pressure test tool, piston
122 Worktable, stuffing box
134 Expander, piston ring
158 Guide screw, piston crown
160 Guide screw, piston crown

Page 2 (2) When referring to this page, please quote Plate P90251 Edition 0237
MAN B&W Diesel A/S
 Piston and Piston Rod - Tools Plate
P90261-0108

When referring to this page, please quote Plate P90261 Edition 0108 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Tools
P90261-0108

Item Item Description Item Item Description

No. No.

019 Guide ring for piston

Page 2 (2) When referring to this page, please quote Plate P90261 Edition 0108
MAN B&W Diesel A/S
 Piston and Piston Rod - Support Tools Plate
P90265-0001

When referring to this page, please quote Plate P90265 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston and Piston Rod - Support Tools
P90265-0001

Item Item Description Item Item Description

No. No.

010 Support iron for piston

Page 2 (2) When referring to this page, please quote Plate P90265 Edition 0001
MAN B&W Diesel A/S
 Piston - Lifting Tools Plate
P90266-0002

When referring to this page, please quote Plate P90266 Edition 0002 Page 1 (2)
MAN B&W Diesel A/S
Plate Piston - Lifting Tools
P90266-0002

Item Item Description Item Item Description

No. No.

016 Lifting tool for piston

Page 2 (2) When referring to this page, please quote Plate P90266 Edition 0002
MAN B&W Diesel A/S
 Cylinder Liner 103-1
Data

SAFETY PRECAUTIONS
Special Edition
D10301
103-1 Data 0056 Cylinder
S50ME-C Liner

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D03-01 Lifting tool screws, tightening torque 150 Nm

D03-03 Cylinder diameter, new 500 mm
D03-04 Piston cleaning ring diameter, new 498.3 mm
D03-05 Cylinder liner, complete 1820 kg
D03-06 Cooling jacket 170 kg
D03-16 Piston cleaning ring radial width, new 38.8 mm
D03-17 PC-ring/Liner max. wear deviation 0.5 mm
D03-18 PC-ring replacement criteria:

Liner diameter: 500 mm

Liner wear: Install:
0 – 0.50 mm Standard PC-ring
(new or max. wear of diameter 0.50 mm)
0.50 – 1 mm Oversize PC-ring
> 1 mm Dummy ring

When referring to this page, please quote Data D10301 Edition 0056 Page 1 (2)
MAN B&W Diesel A/S
103-1 Cylinder Liner
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

P90251 51 Lifting tool for cylinder liner

P90361 Measuring tool for cylinder liner
P90362 Cylinder Liner - Extra Tool
P90366 Cylinder Liner - Lifting Tools

Page 2 (2) When referring to this page, please quote Data D10301 Edition 0056
MAN B&W Diesel A/S
 Cylinder Liner 903-1.1
Checking
Cylinder Liner
S50MC
0253
Checking
903-1.1

1.
1. Dismount the cylinder cover, piston and
PC-ring.
See Procedure 901-1.2. D03-03
See Procedure 902-1.2.

Clean the cylinder liner and scavenge air

ports.

2. Position the cylinder liner measuring tool.

Measure the cylinder liner with an inside

micrometer at the positions indicated on the
measuring tool. See Data.

3. Take measurements in the fore-and-aft and

athwartship directions.

4. Check and assess the condition of the cyl-

inder liner according to the description giv-
en in Volume I, Chapter 707.
DM903-2.0 90 01

5. Carefully scratch over any scores or marks

on the cylinder liner running surface, and
grind away the wear ridges. See Procedure
903-1.3. 2.
6. Check the lubricating points of the cylinder
by pumping cylinder oil to each individual
lubricating point.

Clean any blocked lubricating duct.

GN903-1.1 203 03

4.
GM903-1.1 253 04

When referring to this page, please quote Procedure M90301 Edition 0253 Page 1 (10)
MAN B&W Diesel A/S
903-1.1 Cylinder Liner
Checking

7. 7. Piston cleaning (PC) ring:

The PC ring is to be regarded as an inte-

grated part of the liner and it is intended to
follow the service life of the liner.

During inspection of the piston and liner,

the PC ring must also be inspected.

When the piston is removed, the PC-ring

must always be taken up before the piston.
See Procedure 902-1.2.
GW903-1.1 247 07

8. Measure the PC ring radial width B, and

find the most worn place. Compare with
data D03-16 and calculate the wear of the
PC ring. Multiply the wear by 2 to get the
8. PC ring diameter wear.

Measure the liner in the fore-and-aft and

athwartship directions at piston skirt TDC
position, corresponding to measuring point
No. 5 on the liner measuring tool. Compare
the measurements with the diameter of a
new liner as stated in data. Calculate the
wear of the liner.

Compare the PC ring diameter wear with

the wear of the liner. If wear of the two com-
DM903-1.1 237 08

ponents does not deviate more than D03-

17, then reinstall the PC ring.

If the deviation between PC ring wear and

liner wear is more than D03-17, or if the PC
ring is broken or cracked, replace the ring
with a new PC ring, an oversize ring or a
dummy ring according to the table in D03-
18 on the Data sheet.

If it is needed to install an oversize PC ring,

contact MAN B&W Diesel for advice.

When a new liner is installed, also a new

PC ring must be installed. When a new liner
is ordered, also a new PC ring must be or-
dered.

Page 2 (10) When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
 Cylinder Liner 903-1.2
Dismantling
Dismantling
903-1.2

1. Dismount the cylinder cover. 1.

See Procedure 901-1.2.

Discard the sealing ring from the top of the

cylinder liner.

Turn the piston down far enough to make it

possible to remove the wear ridges at the
top of the liner.
See Procedure 903-1.3. D03-01
Dismount the piston and the PC-ring.
See Procedure 902-1.2.

Mount the two lifting screws in the cylinder

liner.

Note! GN903-1.2 224 01

Tighten the lifting screws to the torque

stated in Data.

Check with a 0.05 mm feeler gauge that 2.

there is no clearance between the screws
and the cylinder liner.

This must be done whenever the lifting

tools are mounted on the liner.

2. Disconnect – at the exhaust side of the cyl-

inder – the oil pipes leading from the cylin-
der lubricator to the non-return valves.

Dismount the four cooling water pipes – be-

tween the cooling jacket and cylinder cover
GN903-1.2 224 02

– and clean them carefully.

When referring to this page, please quote Procedure M90301 Edition 0253 Page 3 (10)
MAN B&W Diesel A/S
903-1.2 Cylinder Liner
Dismantling

3. 3. Remove the screws of the cooling water in-

let pipe.

4. Attach the crane hook to the lifting cross-

bar.

Hook the chains from the lifting tools on to

the crossbar and lift the cylinder liner with
the cooling jacket out of the cylinder frame.

Note!

Low lifting height in the engine room may

EN903-1.4 205 03

require the removal of one or more cylin-

der cover studs before dismantling the
cylinder liner.

4. Land the cylinder liner vertically on, for in-

D03-05 stance, a couple of planks.

Clean the cylinder frame internally, taking

special care with the contact surfaces for
the cylinder liner at the top of the cylinder
frame.

Discard the O-rings on the cooling water

pipes.

Clean the pipes carefully.

GN903-1.2 224 04

Page 4 (10) When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
 Cylinder Liner 903-1.2
Dismantling

5. The lifting screws are also used for trans- 5.

porting the cylinder liner.

D03-05

HN903-1.2 244 05

When referring to this page, please quote Procedure M90301 Edition 0253 Page 5 (10)
MAN B&W Diesel A/S
903-1.3 Cylinder Liner
Overhaul
Overhaul
903-1.3

1. 1. Unscrew the nuts on the non-return valves

and remove the valves.

Clean and inspect the non-return valves.

2. Attach two tackles to the crossbar, as

shown.

Mount two lifting eye bolts in the cooling

jacket.

Hook the tackles on to the lifting eye bolts

on the cooling jacket and haul tight.
GN903-1.3 224 01

Remove the two lifting screws from the cyl-

inder liner.

Remove the four clamps which fix the cool-

2. ing jacket to the cylinder liner.

3. Lift the cooling jacket away by means of the

tackles, and land it on the wooden planks.
EN903-1.3 237 02

3.

D03-06
EN903-1.3 237 03

Page 6 (10) When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
 Cylinder Liner 903-1.3
Overhaul

4. Check and assess the condition of the cyl- 4.

inder liner according to the description giv-
en in Volume I, Chapter 707.

Carefully scratch over any scores or marks

on the cylinder liner running surface, by
means of a rough grindstone held in the
hand.

Check in the top of the liner for a wear ridge

(where the piston rings reverse direction). If
there is any sign of a wear ridge, it is nec-
essary to create a groove by grinding.The
groove serves to prevent the build-up of a
new wear ridge.

5. It is recommended to use a wear ridge mill-

ing machine to create the groove. For use
of the milling machine, see supplier’s in-
struction.

6. Alternatively, place an old piston ring on the

HN903-1.3 221 04

top of the piston and turn to a position that

enables the grinding disc to rest on the old
piston ring while removing the wear ridge.
Use a grinding disc with a round edge.
5.
Check the distance C before grinding to as-
certain that the wear ridge was caused by
the top ring at TDC.
MB903-1.3 231 04

The maximum depth of the groove is calcu-

lated as S max. = D x 0.0045.

Note!
6.
It is of the utmost importance that the
groove is made with a regular rounding
as shown in the sketch.

D
R=4-5 mm
C
C
MN903-1.3 229 05

When referring to this page, please quote Procedure M90301 Edition 0253 Page 7 (10)
MAN B&W Diesel A/S
903-1.3 Cylinder Liner
Overhaul

7. 7. Replace the two uppermost O-rings on the

cylinder liner.

8. Lower the cooling jacket on to the cylinder

liner.

Note!

Make sure that the scratch marks in the

fuel pump side of the cylinder liner and
cooling jacket coincide.
GN903-1.3 203 04

9. Mount the four clamps in the groove of the

liner, and tighten the screws.

Remove the tackles from the lifting cross-

bar and the cooling jacket lifting eye bolts.
8.
10. Mount the non-return valves for cylinder lu-
brication. Tighten the nuts and connect the
lubricating oil pipes.

D03-06
EN903-1.3 237 08

9.
EN903-1.3 237 09

Page 8 (10) When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
 Cylinder Liner 903-1.4
Mounting
Mounting
903-1.4

1. Loosen the water connections on the cool- 1.

ing jacket.

Mount the two lifting screws in the cylinder

liner. See Data D03-01.

Hook the chains from the lifting crossbar on

to the lifting screws, and lift the jacket/liner
assembly.

Mount the lowermost O-ring and apply a lit-

tle lubricating oil on the ring.
D03-01
2. Check that the joint surfaces on the cylinder
frame and cylinder liner are completely
clean.

Coat the joint surfaces with permatex or a

similar liquid sealing compound.

Mount the cylinder liner in the cylinder

frame. Replace the O-rings on the water
connections and mount the water connec-
DM903-1.4 237 01

tions on the cooling jacket.

2.
GN903-1.4 224 02

When referring to this page, please quote Procedure M90301 Edition 0253 Page 9 (10)
MAN B&W Diesel A/S
903-1.4 Cylinder Liner
Mounting

3. 3. Fit a new gasket between the cooling water

inlet pipe and the cooling jacket. Mount and
tighten the screws.

4. Connect and tighten the oil pipes for the

cylinder lubrication.

Vent the cylinder lubricating system until

oil, without air bubbles, comes out from the
non-return valves. Check that there is no
leakage from the system.

When this is in order, check that each indi-

EN903-1.4 205 03

vidual lubricating point functions correctly.

5. Lubricate the upper part inside of the cylin-

der liner with cylinder lubricating oil and
mount the piston and the PC ring.
4. See Procedure 902-1.4.

6. Mount the sealing ring and the cylinder cov-

er.
See Procedure 901-1.4.

Tighten the upper water connections on the

cooling jacket as soon as the cylinder cover
is correctly positioned.
GM903-1.4 253 04

6.
GN901-1.4 203 01

Page 10 (10) When referring to this page, please quote Procedure M90301 Edition 0253
MAN B&W Diesel A/S
 Cylinder Lubricators 103-2
Data

SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10302
103-2 Data 0026 Cylinder Lubricators

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D03-22 Minimum crankthrow angle 103 °

D03-23 Maximum crankthrow angle 114 °
D03-24 Optimum crankthrow angle 108 °

When referring to this page, please quote Data D10302 Edition 0026 Page 1 (2)
MAN B&W Diesel A/S
103-2 Cylinder Lubricators
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 D10302 Edition 0026
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.1
Checking
Cylinder Lubricators
S46MC-C
0240
Checking
903-2.1

1.
1. Further information concerning other than Last lubrication point Lubrication point No. 1
nominal feed rates, feed rates for running-
in and for part load operation, and recom-
mended oil types, is given in instruction
book Volume I, OPERATION.
No. 2 lubricator No. 1 lubricator

2. The cylinder lubricators are mounted on the

front end of the engine.

GN903-2.1 227 01
For lubricator number. See the sketch.

3. Each cylinder has six injection points.

Check that the pumps for all injection points
are activated during one revolution of the 4.
engine.

4. Turn the engine in AHEAD direction until the

mark on No. 1 lubricator housing is in line
with the mark on the scale at the lead-in
shaft. This indicates that the pump stroke is
completed for lubricating point No. 1.

5. Check that the crankthrow for cylinder No.

1 is positioned between D03-22 and D03-
23 degrees past BDC.

Use the numbers on the turning wheel to

GN903-2.1 203 04

determine the exact position of the crank-

throws.

5.

D03-22
D03-23
GN903-2.1 203 05

Cyl. No. 1

When referring to this page, please quote Procedure M90302 Edition S240 Page 1 (4)
MAN B&W Diesel A/S
903-2.1 Cylinder Lubricators
Checking

6. 6. Turn the engine further in AHEAD direction

until the mark on the second lubricator
housing is in line with the mark on the scale
at the lead-in shaft. This indicates that the
pump stroke is completed for the last lubri-
cating point on No. 2 lubricator.

7. Check that the crankthrow for the aftmost

cylinder is positioned between D03-22 and
D03-23 degrees past BDC.

8. If one of the crankthrows is not in the cor-

rect position, adjust the lubricators.
GN903-2.1 203 04

See Procedure 903-2.3.

7.

D03-22
D03-23

Aftmost
GN903-2.1 203 05

Cylinder

Page 2 (4) When referring to this page, please quote Procedure M90302 Edition S240
MAN B&W Diesel A/S
 Cylinder Lubricators 903-2.3
Adjustment
Adjustment
903-2.3

1.
Note!

Any adjustment of lubricator No. 1 will

alter the setting of lubricator No. 2.

Therefore, any adjustment of lubricator

No. 1 must be followed by a re-adjust-
ment of lubricator No. 2.

1. Remove the guards over the couplings.

Loosen the set screws in the couplings and

pull the coupling wheels out of contact with

DM903-4.0 62 04
the planet wheels.

2. For adjustment of lubricator No. 1, turn the

crankshaft in AHEAD direction until the
crankthrow for cylinder No. 1 is D03-24 de- 2.
grees past BDC for lubricator No. 1.

If necessary, turn the lubricator shaft in

AHEAD direction.

Push the coupling wheels in to contact with

the planet wheel for lubricator No. 1 and
fasten the screws.

For adjustment of lubricator No. 2, turn the D03-24

crankshaft in AHEAD direction until the
crankthrow for the aftmost cylinder is D03-
24 degrees past BDC.

Use the numbers on the turning wheel to

determine the exact position of the crank-
throws.
GN903-2.3 203 02

When referring to this page, please quote Procedure M90302 Edition S240 Page 3 (4)
MAN B&W Diesel A/S
903-2.3 Cylinder Lubricators
Adjustment

3. 3. Turn the pump shaft slowly in AHEAD direc-

tion until the mark on the scale at the lead-
in shaft is in line with the mark on the lubri-
cator housing.

4. Re-engage the coupling wheel and tighten

the set screw.

Re-check the setting.

See Procedure 903-2.1.

Mount the guard over the coupling.

DM903-4.0 62 06

4.
DM903-4.0 62 07

Page 4 (4) When referring to this page, please quote Procedure M90302 Edition S240
MAN B&W Diesel A/S
 Cylinder Liner - Tools Plate
P90361-0084
Cylinder Liner - Tools
0084
P90361

When referring to this page, please quote Plate P90361 Edition 0084 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Tools
P90361-0084

Item Item
Item Description Item Description
No. No.

036 Cylinder gauge, complete

Page 2 (2) When referring to this page, please quote Plate P90361 Edition 0084
MAN B&W Diesel A/S
 Cylinder Liner - Lifting Tools Plate
P90366-0007
Cylinder Liner - Lifting Tools
0007
P90366

When referring to this page, please quote Plate P90366 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
Plate Cylinder Liner - Lifting Tools
P90366-0007

Item Item
Item Description Item Description
No. No.

021 Crossbar for cylinder liner

Page 2 (2) When referring to this page, please quote Plate P90366 Edition 0007
MAN B&W Diesel A/S
 Crosshead Bearing 104-1
Data

SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10401
104-1 Data 0048 Crosshead Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D02-02 Piston rod/crosshead, tightening torque 430 Nm

D02-07 Piston rod/crosshead, tightening torque+angle 100/30 Nm/°
D02-20 Piston complete 921 kg
D04-01 Crosshead bearing, top clearance max. 0.55 mm
D04-02 Crosshead bearing, top clearance min. 0.15 mm
D04-03 Oil wedge length, L 10 mm
D04-04 Crosshead bearing cap 160 kg
D04-05 Crosshead bearing shell, upper 13 kg
D04-06 Crosshead bearing shell, lower 28 kg
D04-07 Crosshead bearing cap with bearing shell 173 kg
D04-21 Crosshead complete 1100 kg
D04-51 Connecting rod complete 1400 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 -1650 bar

When referring to this page, please quote Data D10401 Edition 0S48 Page 1 (2)
MAN B&W Diesel A/S
104-1 Crosshead Bearing
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

P90451 47 Wire guide

P90451 59 Lifting attachment - connecting rod
P90451 72 Chain for suspending piston
P90451 96 Bracket for support, crosshead
P90451 106 Bracket for support, crosshead
P90461 Connecting Rod - Hydraulic Tools
P91351 10 Hydraulic pump, pneumatically operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 117 5-way distributor block, complete
P91356 Lifting Tools, Etc.
P91359 Torque Spanners
P91366 50 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10401 Edition 0S48
MAN B&W Diesel A/S
 Crosshead Bearing 904-1.1
Checking
Crosshead Bearing
S50ME-C
0239
Checking
904-1.1

2.
Tin-Aluminium bearings

The top clearance between the journal and a

new bearing shell is the result of a summation
of the production tolerances of the bearing as-
sembly components.

The top clearance for a new bearing will nor-

mally be in the range stated in Data. Note that
the figures are to be used for guidance only.

For the top clearance of a specific bearing, see

the measurement in the Adjustment Sheet in

GW904-1.1 239 02
Volume I, OPERATION.

1. Open the crankcase door at the relevant

cylinder.

2. Turn the crankthrow concerned to BDC. 3. D04-01

D04-02
3. Measure the clearance in the crosshead
bearing by inserting a feeler gauge be-
tween the bearing cap and the crosshead
journal at the top of the upper bearing shell,
at both sides and fore and aft. See Data.

4. The difference between the actual clear-

ance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
DM904-1.1 232 03

later) must not exceed 0.1 mm. If so, the

crosshead bearing must be disassembled
for inspection.
See Procedure 904-1.2.

For evaluation of the bearing shell, see

Chapter 708, ‘Bearings’ in the instruction 5.
book, Volume I, OPERATION.

5. The wear limit for a crosshead bearing shell

is confined to a 50% reduction of the oil
wedge length L.

If the wear limit exceeds the 50% reduction,

(Oil Wedge)
the bearing shell must be replaced by a
new one.

D04-03
DM904-1.1 232 05

When referring to this page, please quote Procedure M90401 Edition 0239 Page 1 (10)
0$1% :'LHVHO$6
904-1.2 Crosshead Bearing
Dismantling
Dismantling
904-1.2

1. This procedure applies to the following two dis-

mantling situations:

• with piston mounted

• with piston removed

With piston mounted:

1. Turn the crankshaft down far enough to give

access to the nuts and screws on the piston
rod.
GW 904-1.1 239 02

2. Mount two chains in the inner screw holes

in the top of the crankcase, in the athwarth-
ship direction, for suspending the piston
rod.

2. 3. Loosen and remove the locking wire from

the screws on the piston rod foot. Remove
the screws.
HN904-1.2 222 02

3.
HN904-1.2 222 03

Page 2 (10) When referring to this page, please quote Procedure M90401 Edition 0239
0$1% :'LHVHO$6
 Crosshead Bearing 904-1.2
Dismantling

4. Mount a lifting eye bolt on each side of the 4.

piston rod.

5. Turn the crosshead to TDC.

Hook the chains to the lifting eye bolts in

the piston rod.

Turn the crosshead downward, and the pis-

ton rod will then remain suspended from
the two chains.

With piston removed:

HN904-1.2 222 04
6. Turn to BDC.

7. Place the spacer rings around the nuts and

screw the hydraulic jacks on to the studs.
5.
Loosen the crosshead bearing cap nuts.
For operation of the hydraulic jacks, see
Procedure 913.

Remove the hydraulic jacks and the spacer

rings, and unscrew the nuts.
HN904-1.2 222 05

7.

D13-02
HN904-5.2 217 01

When referring to this page, please quote Procedure M90401 Edition 0239 Page 3 (10)
0$1% :'LHVHO$6
904-1.2 Crosshead Bearing
Dismantling

8. 8. Mount the lifting attachments on the head

of the connecting rod.

9. Suspend two tackles from the lifting brack-

ets, in the athwarthship direction.

10. Mount the wire guide at the top of the

crankcase door frame to prevent damage.

Mount two eye bolts in the top of the cross-

head bearing cap.

Hook the tackles on to the eye bolts, and re-

move the bearing cap from the engine.
JN904-1.2 227 08

Check the upper part of the journal.

9.
JN904-1.2 227 09

10.
D04-07
JN904-1.2 227 10

Page 4 (10) When referring to this page, please quote Procedure M90401 Edition 0239
0$1% :'LHVHO$6
 Crosshead Bearing 904-1.2
Dismantling

11. Place the bearing cap on one side on a 11. D04-07

couple of wooden planks.

Check the bearing shell, see Procedure

904-1.1.

12. Fasten tackles to the fixed lifting brackets

on the frame box wall.

HG904-1.2 238 11
13. Turn the crosshead upwards until the piston
rod lands on the crosshead. Ensure that the
guide ring in the crosshead fits correctly in D04-05
the centre hole of the piston rod.

Do not remove the chains or lifting eye 12.

bolts.

HG904-1.2 238 12

13.
GN904-1.2 203 13

When referring to this page, please quote Procedure M90401 Edition 0239 Page 5 (10)
0$1% :'LHVHO$6
904-1.2 Crosshead Bearing
Dismantling

14. 14. Turn to TDC and attach the tackle hooks to

the lifting attachments. Haul the tackles
tight.

15. Mount the four supports for guide shoes on

the crosshead guides.

Carefully turn the crank down towards the

exhaust side, until the guide shoes rest on
the supports.

Adjust the support brackets to the guide

shoes so that the weight of the crosshead
HG904-1.2 238 14

is evenly distributed on the four supports.

Haul the tackles tight.

16. Turn the crankthrow carefully towards BDC

15. while ‘following’ with the tackles, thus con-
tinuously supporting the connecting rod.

17. With the crosshead resting on the supports,

check the lower part of the crosshead jour-
nal and the lower bearing shell.

Regarding checking of journal and bearing

shells, see Volume I, OPERATION, Chap-
ter 708, ‘Bearings’.
JN904-1.2 227 15

16.
17. D04-21
D02-20
JN904-1.2 227 16

Page 6 (10) When referring to this page, please quote Procedure M90401 Edition 0239
0$1% :'LHVHO$6
 Crosshead Bearing 904-1.2
Dismantling

18. In cases where it is necessary to remove 18.

the lower bearing shell, tilt the connecting
rod towards the doorway on the fuel pump
side, using the tackles.
D04-06

Dismount the locking screws, and turn the

bearing shell so far up that an eye bolt can
be mounted.

Lift the bearing shell out of the engine.

JN904-1.2 227 18

When referring to this page, please quote Procedure M90401 Edition 0239 Page 7 (10)
0$1% :'LHVHO$6
904-1.4 Crosshead Bearing
Mounting
Mounting
904-1.4

1. With piston mounted/

With piston removed:
D04-06
1. Mount and secure the bearing shell in the
bearing housing.

The excess height X is to ensure the cor-

rect tightening-down of the bearing shell
and must not be eliminated.

2. Raise the connecting rod to an upright po-

sition.

Turn to TDC while ‘following’ with the tack-

JN904-1.4 227 01

les, for assembling the crosshead and the

connecting rod.

Take care that the guide shoes do not dam-

2. age the bearing shell.

D04-21 3. Remove the supports from the crosshead

guides.

Remove the tackles from the crosshead.

Turn the crank throw to BDC.

If the piston is mounted, slowly turn down

until it is fully suspended from the chains.
JN904-1.4 227 02

3.
JN904-1.4 227 03

Page 8 (10) When referring to this page, please quote Procedure M90401 Edition 0239
0$1% :'LHVHO$6
 Crosshead Bearing 904-1.4
Mounting

4. Lift the bearing cap into the engine. Lower 4. D04-07

the bearing cap onto the crosshead and re-
move the tackles. Remove the lifting attach-
ments from the connecting rod and the wire
guide from the door frame.

Note!

Take care that the bearing studs do not

damage the crosshead.

5. Tighten all four crosshead bearing cap nuts

JN904-1.4 227 04
simultaneously. See Data.
For operation of hydraulic jacks, see Sec-
tion 913.

6. Mount the piston.

See Procedure 902-1.4. 5.

With piston mounted:

7. Turn the crosshead upwards until the piston

rod lands on the crosshead. Ensure that the
guide ring in the crosshead fits correctly in
the centre hole of the piston rod.

D13-01
HN904-5.2 217 01

7.
GN904-1.4 203 07

When referring to this page, please quote Procedure M90401 Edition 0239 Page 9 (10)
0$1% :'LHVHO$6
904-1.4 Crosshead Bearing
Mounting

8. 8. Unhook the chains from the lifting eye bolts

in the piston rod. Remove the chains and
eye bolts from the top of the crankcase,
from the piston rod and from the crosshead
bearing cap.

9. Turn down to BDC, tighten the screws in the

piston rod, and lock with locking wire. See
Data.

Mount the locking wire in such a way that

GN904-1.2 203 19

the wire is tightened if a screw works loose.

See Procedure 913-7.

9. D02-02
D02-07
HN904-1.4 222 09

Page 10 (10) When referring to this page, please quote Procedure M90401 Edition 0239
0$1% :'LHVHO$6
 Crosshead 104-2
Data

SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10402
104-2 Data 0050 Crosshead

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
X Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D04-04 Crosshead bearing cap 160 kg

D04-08 Cooling oil outlet pipe, tightening torque 50 Nm
D04-12 Guide strip screws, tightening torque 100 Nm
D04-13 Guide plate, tightening torque 135 Nm
D04-15 Telescopic pipe, tightening torque 50 Nm
D04-19 Telescopic pipe, tightening angle 25 °
D04-21 Crosshead complete 1100 kg
D04-22 Guide shoe 159 kg
D04-23 Cooling oil outlet pipe 9 kg
D04-50 Connecting rod, without bearing caps 1020 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 -1650 bar

When referring to this page, please quote Data D10402 Edition 0S50 Page 1 (2)
MAN B&W Diesel A/S
104-2 Crosshead
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

P90451 47 Wire guide

P90451 59 Lifting attachment - connecting rod
P90451 60 Lifting tools - crosshead
P90451 72 Chain for suspending piston
P90451 84 Retaining tool telescopic pipe
P90451 214 Torque wrench offset tool
P90462 11 Guide shoe extractor, complete
P90463 Crosshead - Hydraulic Tools
P91351 10 Hydraulic pump, pneumatically operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 117 5-way distributor block, complete
P91356 Lifting Tools, Etc.
P91359 Torque Spanners
P91366 50 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10402 Edition 0S50
MAN B&W Diesel A/S
 Crosshead 904-2.2
Dismantling
Crosshead
S50ME-C
0239
Dismantling
904-2.2

2.
1. Dismount the piston.
See Procedure 902-1.2.

2. Dismount the main bearing lubricating oil

pipes.

3. Dismount the cooling oil outlet pipe from

the guide shoe and the drain oil slotted
pipe.

Loosen and remove the screws which se-

cure the telescopic pipe to the guide shoe.

GN904-2.2 203 02
In order to reach the screw in the corner be-
hind the telescopic pipe, use the offset tool
along with a socket wrench.

4. Mount the retaining tool for the telescopic

pipe on the stuffing box housing for the tel- 3.
escopic pipe.

Turn the crosshead to TDC.

Suspend the telescopic pipe by means of

the tool.

Turn the crosshead to gain access to the

nuts on the crosshead bearing studs.

Mount two eye bolts in the top of the crank-

case in the fore-and-aft direction.
GN904-2.2 204 03

Mount the spacer rings and the hydraulic

jacks for loosening the nuts on the cross-
head bearing studs.

For operation of the hydraulic tools, see 4.

Section 913.
D13-02
Loosen the nuts, remove the hydraulic jacks D04-23
and unscrew the nuts.
HN904-2.2 223 04

When referring to this page, please quote Procedure M90402 Edition 0239 Page 1 (7)
0$1% :'LHVHO$6
904-2.2 Crosshead
Dismantling

5. 5. Mount eye bolts in the crosshead bearing

cap and hook the tackles on to the lifting
brackets in the top of the crankcase.

Dismount the bearing cap and lift it out of

the engine.

6. Mount the special lifting tool on the cross-

head.

Mount the lifting attachments for fixing the

connecting rod, on the head of the connect-
ing rod.
HN904-2.2 223 05

Fasten tackles to the lifting brackets on the

frame box wall and attach the tackle hooks
to the lifting attachments. Haul the tackles
tight.
6.
Attach the flat-plaited wire strap to the en-
gine room crane.

D04-21 Hook the engine room crane on to the lifting

tool on the crosshead, and lift the cross-
head.

7. Using the tackles, tilt the connecting rod to-

wards the exhaust side, while turning the
crankthrow towards the camshaft side.

Transfer the tackles from one lifting attach-

ment to another as necessary.
GN904-2.2 232 06

When the crankthrow is 90° after BDC, stop

turning.

7. By alternate use of the tackles, tilt the con-

necting rod until it rests against a couple of
D04-50 wooden planks in the bottom of the bed-
plate.
HN904-2.2 223 07

Page 2 (7) When referring to this page, please quote Procedure M90402 Edition 0239
0$1% :'LHVHO$6
 Crosshead 904-2.2
Dismantling

8. Lower the crosshead to a position just 8.

above the main bearing caps.

Remove the guide strips and both guide

plates from the guide shoes.

Mount lifting eye bolts in both guide shoes.

9. Suspend two tackles from the eye bolts in

the top of the crankcase, in the fore-and-aft
direction, and attach the tackles to the
guide shoes.

Push one of the guide shoes against the

GN904-2.2 232 08
middle of the crosshead. If necessary, use
the guide shoe extractor tool.

10. Pull the “free end” of the crosshead into the

neighbouring cylinder unit. 9.

Mount the guide shoe extractor on the op- D04-22

posite guide shoe.

Pull off the guide shoe, remove the extrac-

tor, and lift up the guide shoe.
GN904-2.2 232 09

10.

D04-22
GN904-2.2 232 10

When referring to this page, please quote Procedure M90402 Edition 0239 Page 3 (7)
0$1% :'LHVHO$6
904-2.2 Crosshead
Dismantling

11. 11. Pull the crosshead with guide shoe into the
opposite neighbouring cylinder unit.

Mount the guide shoe extractor tool on the

remaining guide shoe.

Pull off the guide shoe, remove the extrac-

tor tool and lift up the guide shoe.

12. Turn the crosshead 90°.

13. Mount the wire guide tool in the framebox

door opening.
GN904-2.2 232 11

Remove the crosshead from the engine, us-

ing wire rope and tackles.

Protect the crosshead, for instance with

12. thick or corrugated paper, and land it out-
side the engine.

If necessary, remove the guide shoes from

the engine.
HN904-2.2 223 11

13.
HN904-2.2 223 12

Page 4 (7) When referring to this page, please quote Procedure M90402 Edition 0239
0$1% :'LHVHO$6
 Crosshead 904-2.4
Mounting
Mounting
904-2.4

1. Attach the flat-plaited wire strap to the en- 1.

gine room crane. D04-22 D04-21
Lift the crosshead into the engine, using
wire rope, tackles, and the engine room
crane.

2. Turn the crosshead 90°. Pull the crosshead

to one side under the web plates between
the cyliners.

3. Lower one guide shoe in the other side of

the crosshead and mount the guide shoe

HN904-2.2 223 11
extractor tool.

Use the guide shoe extractor tool to pull the

crosshead so far through the guide shoe
that the other guide shoe can be lowered.
3.
Follow the movement of the crosshead with
the engine room crane.

4. Lower the other guide shoe.

Use the guide shoe extractor tool to push

the crosshead towards the second guide
shoe.

Remove the extractor tool and adjust the

position of the opposite guide shoe.
GN904-2.4 232 03

4.
GN904-2.4 232 04

When referring to this page, please quote Procedure M90402 Edition 0239 Page 5 (7)
0$1% :'LHVHO$6
904-2.4 Crosshead
Mounting

5. 5. Mount the guide plates on the side of the

D04-12
D04-13 guide shoes.

Tighten the screws and lock them with lock-

ing wire.
See Procedure 913-7.

Using the engine room crane, lift the cross-

head to a working position and mount the
guide strips on the side of the guide shoes.

Tighten the screws and lock them with lock-

ing wire.
HN904-2.4 223 05

See Procedure 913-7.

6. Using the tackles, lift the connecting rod to

a vertical position while turning the crank-
throw to BDC.
6.
7. When the connecting rod is in a vertical po-
D04-50 sition, lower the crosshead and land it on
the connecting rod.

Remove the lifting attachments from the

connecting rod head.

Remove the lifting tool from the crosshead.

HN904-2.4 223 06

7.
EN904-2.4 237 07

Page 6 (7) When referring to this page, please quote Procedure M90402 Edition 0239
0$1% :'LHVHO$6
 Crosshead 904-2.4
Mounting

8. Lift the crosshead bearing cap into the en- 8.

gine. D04-04

9. Mount the spacer rings and the hydraulic

jacks for tightening the nuts on the cross-
head bearing studs.

For operation of the hydraulic tools, see

Procedure 913.

Mount the drain oil slotted pipe and the

cooling oil outlet pipe on the guide shoe.

HN904-2.2 223 05
Turn the crankshaft to TDC.

Land the telescopic pipe on the guide shoe.

10. For tightening the bolt in the corner behind

the telescopic pipe, use the offset tool 9.
along with the torque wrench. D13-01 D04-15
D04-19
11. Mount the lubricating oil pipes on the main
bearing caps.
D04-08
12. Mount the piston.
See Procedure 902-1.4.
HN904-2.2 223 04

10.
D04-15
D04-19
GN904-2.2 204 03

When referring to this page, please quote Procedure M90402 Edition 0239 Page 7 (7)
0$1% :'LHVHO$6
 Reciprocating Parts 104-3
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
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
X Stop lubricating oil supply
X Lock the turbocharger rotors

Data

Ref. Description Value Unit

Acceptance criteria with piston in centre (F-A direction)

D04-25 PF+PA, N max. 0.5 mm
D04-26 PF+PA, O max. 0.7 mm
D04-28 E+G, H+F, N max. 0.5 mm
D04-29 E+G, H+F, N min. 0.2 mm
D04-30 E+G, H+F, O max. 0.8 mm
D04-34 J+C, L+D, K+C, M+D, N max. 0.9 mm
D04-35 J+C, L+D, K+C, M+D, N min. 0.5 mm
D04-36 J+C, L+D, K+C, M+D, O max. 1.1 mm
D04-40 ZF/ZA O max. 5.0 mm
D04-41 ZF/ZA O min. 4.0 mm
D04-67 Crankshaft position (after BDC). 70 °
D04-68 Piston inclination R1-R2, O max. 0.35 mm
N: New and cold engine with staybolts tightened
(less than 100 running hours).
O: Engine in service.

When referring to this page, please quote Data D10403 Edition 0052 Page 1 (2)
104-3 Reciprocating Parts
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

P91366 058 Feeler gauge

P91366 073 Dial gauge and stand tool

Page 2 (2) When referring to this page, please quote Data D10403 Edition 0052
 Reciprocating Parts 904-3.1
MAN B&W Checking

In order to achieve uniform measuring condi-

1.
tions on board, the ship’s trim must be as
close as possible to 0°.

1. Mount a transparent plastic tube along the

length of the bedplate. T S S

Bend each end approx. 250 mm up the

framebox side. See T.

Fill the tube with water (preferably co-

loured) until the water level is approx. 100 Bedplate
mm from the end of the tube.

M90403
0219C01
Trim the ship until the difference between
the water level S fore and aft is less than
1.5 mm per 1000 mm.

Measurements are to be taken with a ruler.

2. Fore Aft
2. Turn the crankshaft in ASTERN direction to
D04-67 (see data) degrees after BDC (the
guide shoe must rest against the cross-
head guide).

Check the centering of the piston in the

cylinder liner by measuring the clearance
(use a long feeler gauge from the scavenge
air space) between the piston skirt and the
cylinder liner in the Fore and Aft positions
(PF
PA).
M90403
0220C02

PA
Make sure that the piston is clear of the
cylinder liner in the fore and aft directions.
D0
4
6 PA
7

When referring to this page, please quote Procedure M90403 Edition 0220 Page 1 (8)
904-3.1 Reciprocating Parts
Checking MAN B&W

3. Fit a dial gauge in the bottom of the scav-

3. enge air space to the front of the piston rod
with the tip of the dial gauge against the
piston rod.

Note down the reading of the dial gauge

R1.

4. Turn the crankshaft in ASTERN direction to

35° before TDC.

R1

Aft

Fore
M90403
0220C03

D04
68

4. C
TD
fore
° Be
3 5
M90403
0220C04

Page 2 (8) When referring to this page, please quote Procedure M90403 Edition 0220
 Reciprocating Parts 904-3.1
MAN B&W Checking

5. Note down the reading of the dial gauge

5.
R2.

Calculate the piston inclination R1-R2.

6. Turn in astern direction until the bottom of

the guide shoe is 50 mm above the top of
the cut-out in the web plate.

R2

Aft

Fore
M90403
0220C05

D04
68

6.

50
EXH CAM

E 1
2 G 1
2
50

F 1
2
H 1
2
M90403
0219C03

When referring to this page, please quote Procedure M90403 Edition 0220 Page 3 (8)
904-3.1 Reciprocating Parts
Checking MAN B&W

7. Measure the fore and aft clearances ZF

7. and ZA between the crankthrow and the
connecting rod.

8. Measure the clearance C, between the

foremost stop plate and the crosshead.

Fore Aft
M90403
0220C07

ZA

ZF D04
41

8.
C

Fore
M90403
0220C08

Page 4 (8) When referring to this page, please quote Procedure M90403 Edition 0220
 Reciprocating Parts 904-3.1
MAN B&W Checking

9. Measure the clearance D, between the aft-

most stop plate and the crosshead. 9.
D
10. Measure the clearances E1 and E2 be-
tween the top of the foremost guide shoe
and the exhaust-side crosshead guide.

11. Measure the clearances E3 and E4 be-

tween the top of the aftmost guide shoe
and the exhaust-side crosshead guide. Aft

M90403
0220C08
10. E1 E2

Aft
M90403
0220C10

11. E3 E4

Fore
M90403
0220C11

When referring to this page, please quote Procedure M90403 Edition 0220 Page 5 (8)
904-3.1 Reciprocating Parts
Checking MAN B&W

12. Measure the clearances G1 and G2 be-

12.
J G2 G1 tween the top of the foremost guide shoe
and the manoeuvring-side crosshead guide.

Measure the clearance J between the

top of the foremost guide strip and the
Fore manoeuvring-side crosshead guide.

13. Measure the clearances G3 and G4 be-

tween the top of the aftmost guide shoe
and the manoeuvring-side crosshead guide.

Measure the clearance L between the

top of the aftmost guide strip and the
M90403
0220C12

manoeuvring-side crosshead guide.

14. Measure the clearances F1 and F2 between

the bottom of the foremost guide shoe and
the exhaust-side crosshead guide.
13.
G4 G3 L

Aft
M90403
0220C13

14.

Fore
M90403
0220C14

F1 F2

Page 6 (8) When referring to this page, please quote Procedure M90403 Edition 0220
 Reciprocating Parts 904-3.1
MAN B&W Checking

15. Measure the clearances F3 and F4 between

15.
the bottom of the aftmost guide shoe and
the exhaust-side crosshead guide.

16. Measure the clearances H1 and H2 be-

tween the bottom of the foremost guide
shoe and the manoeuvring-side crosshead Aft
guide.

Measure the clearance K between the bot-

tom of the foremost guide strip and the
manoeuvring-side crosshead guide.

17. Measure the clearances H3 and H4 be-

M90403
0220C15
tween the bottom of the aftmost guide
shoe and the manoeuvring-side crosshead
guide. F3 F4
Measure the clearance M between the
bottom of the aftmost guide strip and the 16.
manoeuvring-side crosshead guide.

Fore
M90403
0220C16

K H2 H1

17.

Aft
M90403
0220C17

H4 H3 M

When referring to this page, please quote Procedure M90403 Edition 0220 Page 7 (8)
904-3.1 Reciprocating Parts
Checking MAN B&W

18. The guide strip clearance, calculated as

19.
J+C, K+C, L+D and M+D, is adjusted by
the insertion of shims so that it is symmet-
rical in relation to the clearance between
the piston skirt and the cylinder liner.

Parallelism between the guide strip and

guide is to be kept within a tolerance of 0.2
mm per 1000 mm.

19. It is recommended that the measured re-

sults are noted down so that possible later
Unit mm Cyl. 1 2 3 changes can be ascertained.
Piston/Liner PF
PA Compare the measured results with the val-
Framebox E1 ues stated on the data sheet.
E2
E3
E4
F1
F2
F3
F4
G1
G2
G3
G4
H1
H2
H3
H4
S
K
L
M
C
D
R1
Piston Rod
R2
ZF
Crankthrow
ZA
M90403
0220C19

Page 8 (8) When referring to this page, please quote Procedure M90403 Edition 0220
 Crankpin Bearing 104-4
Data

SAFETY PRECAUTIONS
Special Edition
S50ME-C
D10404
104-4 Data 0042 Crankpin Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D04-43 Crankpin bearing clearance, max. 0.6 mm

D04-44 Crankpin bearing clearance, min. 0.2 mm
D04-46 Crankpin bearing, upper shell 17 kg
D04-47 Crankpin bearing, lower shell 13 kg
D04-48 Crankpin bearing cap + shell + bearing studs 150 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400 -1650 bar

When referring to this page, please quote Data D10404 Edition 0S42 Page 1 (2)
MAN B&W Diesel A/S
104-4 Crankpin Bearing
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

P90451 47 Wire guide

P90451 59 Lifting attachment - connecting rod
P90451 96 Bracket for support, crosshead
P90451 106 Bracket for support, crosshead
P90461 Connecting Rod - Hydraulic Tools
P91356 Lifting Tools, Etc.
P91366 50 Feeler gauge
P91351 10 Hydraulic pump, pneumatically operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10404 Edition 0S42
MAN B&W Diesel A/S
 Crankpin Bearing 904-4.1
Checking
Crankpin Bearing
S46MC-C
0226
Checking
904-4.1

2.
The bottom clearance between the journal and
a new bearing shell is the result of a summation
of the production tolerances of the bearing as-
sembly components.

For the bottom clearance of a specific bearing,

see the measurement in the Adjustment Sheet
in Volume I, OPERATION.

1. Open the crankcase door at the relevant

cylinder.

2. Turn the crank concerned to BDC.

GW904-1.1 239 02
3. Measure the clearance in the crankpin
bearing by inserting a feeler gauge at the
bottom of the bearing shell in both sides.
See Data for bottom clearance.
3.
4. The difference between the actual clear-
ance measurement and the measurement
recorded in the Adjustment Sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.1 mm. If so, the
crankpin bearing must be disassembled for
inspection.
See Procedure 904-4.2.

5. The wear limit for the crankpin bearing

shells is based on an evaluation of the
bearing condition at the time of inspection.
GM904-6.1 69 03

D04-43
An average wear rate of 0.01 mm per
10,000 hours is regarded as normal. D04-44

6. For further external inspection of the crank-

pin bearing, see Chapter 708 ‘Bearings' in 5.
the instruction book, Volume I, OPERA-
TION.
GN904-4.1 219 05

When referring to this page, please quote Procedure M90404 Edition 0226 Page 1 (8)
0$1% :'LHVHO$6
904-4.2 Crankpin Bearing
Dismantling
Dismantling
904-4.2

2. 1. Turn the crank to BDC.

2. Suspend two tackles from the lifting brack-

ets, in the athwartship direction.

3. Turn the crank to TDC.

Mount eye bolts in each side of the crankpin

bearing cap and, using shackles and wire
ropes, hook on the tackles and haul tight.

Loosen the crankpin bearing stud nuts, us-

ing the hydraulic jacks.
GW904-2 226 02

For operation of the hydraulic jacks, see

Procedure 913-1.

Remove the hydraulic jacks and the nuts.

3.
4. Lower the bearing cap while seeing care-
fully that the studs do not damage the
crankpin journal.

Land the bearing cap on a couple of planks

placed in the oil pan.

Inspect the bearing shell.

D13-02
For evaluation of bearings, see Volume I,
Chapter 708.
GN904-4.2 203 03

4.

D04-48
GW904-4.2 226 04

Page 2 (8) When referring to this page, please quote Procedure M90404 Edition 0226
0$1% :'LHVHO$6
 Crankpin Bearing 904-4.2
Dismantling

5. If the bearing shell needs to be replaced, 5.

remove the whole bearing cap from the
crankcase.

Hook the tackle on to an eye bolt on one

side of the bearing cap.

Mount the wire guide in the top of the

crankcase door opening.

Using the tackle from the frame box inside D04-48

wall, together with a tackle suspended from
the platform bracket, lift the bearing cap out
of the crankcase.

6. Place the bearing cap on one side on a

couple of planks.

Inspect the bearing shell.

See Volume I, Chapter 708.
GW904-4.2 226 05

If necessary, dismount the bearing shell

lock screws and replace the bearing shell
by a new one.
6.
Note! D04-47
Normally bearing shells are replaced in
pairs.
GN904-4.2 203 06

If only one of the shells needs replace-

ment, MAN B&W Diesel should be con-
tacted for advice beforehand.

7. Turn to TDC. 7.
Mount the four supports for guide shoes on
the crosshead guides.

Carefully turn the crank down until the

guide shoes rest on the supports.

Adjust the support brackets to the guide

shoes so that the weight of the crosshead
is evenly distributed on the four supports.
HN904-4.2 217 07

When referring to this page, please quote Procedure M90404 Edition 0226 Page 3 (8)
0$1% :'LHVHO$6
904-4.2 Crankpin Bearing
Dismantling

8. 8. Mount a lifting attachment for securing the

connecting rod at the lower end, on one
side.

Hook on the tackle to a beam under the gal-

lery platform and haul tight.

9. Carefully turn the crankshaft downwards,

while ‘following’ with the tackle, making
sure that the upper part of the bearing
comes completely clear of the recess in the
crankshaft when the parts begin to ‘sepa-
rate’.
GW904-4.2 226 08

Continue turning the crankshaft until the

bearing surface can be freely inspected.

Inspect the bearing shell surface and the

9. crankpin journal.

10. If it is necessary to replace the bearing

shell, proceed as follows:

Turn the crankshaft to BDC.

Release the tackle so that the connecting

rod is hanging freely.
GW904-4.2 226 09

10.
GW904-4.2 226 10

Page 4 (8) When referring to this page, please quote Procedure M90404 Edition 0226
0$1% :'LHVHO$6
 Crankpin Bearing 904-4.2
Dismantling

11. Dismount the bearing shell lock screws and 11.

lift out the bearing shell.

D04-46

GN904-4.2 219 11

When referring to this page, please quote Procedure M90404 Edition 0226 Page 5 (8)
0$1% :'LHVHO$6
904-4.4 Crankpin Bearing
Mounting
Mounting
904-4.4

1. 1. Bearing shells of three mm undersize are

available as spares in case of journal recti-
fication. Please contact MAN B&W Diesel
for advice.

Coat the bearing shell surfaces and the

journal with clean oil.
HM904-6.0 61 16

The excess height X is to ensure the cor-

rect tightening-down of the bearing shell,
and must not be eliminated.
2.
2. Lift the upper bearing shell for the crankpin
concerned into the crankcase.

Carefully lift the bearing shell into position

in the connecting rod, and mount the lock
screws.

D04-46
GN904-4.4 219 02

Page 6 (8) When referring to this page, please quote Procedure M90404 Edition 0226
0$1% :'LHVHO$6
 Crankpin Bearing 904-4.4
Mounting

3. Hook the tackle on to a beam under the gal- 4.

lery platform and on to the lifting attach-
ment on the connecting rod, and haul tight.

Carefully turn the crankshaft upwards,

while following up with the tackle, making
sure that the upper part of the bearing en-
ters the recess in the crankshaft when the
parts turn together.

Remove the tackle and the lifting attach-

ment from the connecting rod.

4. Turn the crosshead to TDC.

Remove the guide shoe support brackets

from the crosshead guides.

GW904-4.4 226 04

5.
HN904-4.4 217 05

When referring to this page, please quote Procedure M90404 Edition 0226 Page 7 (8)
0$1% :'LHVHO$6
904-4.4 Crankpin Bearing
Mounting

6. 5. Suspend the tackles from the lifting brack-

ets in the top of the frame box.

Lift the bearing cap assembly into the

crankcase and land it on a couple of planks
placed in the oil pan.

6. Hook the tackles on to the wire ropes and

lift the bearing cap into position against the
connecting rod.

D04-48
Caution!

During mounting, take care that the studs

do not damage the crankpin journal, and
check that the guide pins mounted in the
bearing cap enter the holes in the con-
necting rod.

Mount the nuts and, by means of spacer

rings and hydraulic jacks, tighten the crank-
GW904-4.4 226 06

pin bearing cap. See Data.

For operation of hydraulic jacks, see Sec-

tion 913.

7. Remove the tackles from the top of the

frame box.

Check the bearing clearance.

See Procedure 904-4.1.
GW904-4.4 226 07

D13-01

Page 8 (8) When referring to this page, please quote Procedure M90404 Edition 0226
0$1% :'LHVHO$6
 Connecting Rod 104-5
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
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
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D04-48 Crankpin bearing cap + shell + bearing studs 160 kg

D04-50 Connecting rod, without bearing caps 950 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar

When referring to this page, please quote Data D10405 Edition 0066 Page 1 (2)
104-5 Connecting Rod
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

P90451 047 Wire guide

P90451 059 Lifting attachment - connecting rod
P90451 060 Lifting tools - crosshead
P90451 096 Bracket for support, crosshead
P90451 106 Bracket for support, crosshead

P90461 Connecting rod - hydraulic tools

P91351 010 Hydraulic pump, pneumatically operated

P91351 046 Hose with unions (1500 mm), complete
P91351 058 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete
P91351 117 5-way distributor block, complete

P91356 Lifting tools, etc.

P91366 058 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10405 Edition 0066
 Connecting Rod 904-5.2
MAN B&W Dismantling

1. Turn the crank to BDC.

1.
D13-02
Dismount the crosshead bearing stud nuts.
See Procedure 904-1.2.

2. Mount two shackles in the top of the

crankcase in the lifting brackets, in the
athwartship direction, and suspend two
tackles.

3. Turn the crank to TDC.

Dismount the crankpin bearing cap, and re-

move the bearing cap from the engine.

M90405-0241D01
See Procedure 904-4.2.

2.
M90405-0241D02

3.

D13-02

D04-48
M90405-0241D03

When referring to this page, please quote Procedure M90405 Edition 0241 Page 1 (7)
904-5.2 Connecting Rod
Dismantling MAN B&W

4. 4. Mount the four supports for guide shoes on

the crosshead guides.

Carefully turn the crank down towards the

camshaft side, until the guide shoes rest
on the supports.

Adjust the support brackets to the guide

shoes so that the weight of the crosshead
is evenly distributed on the four supports.

5. Mount the lifting attachments for securing

the connecting rod on the head of the con-
necting rod.
M90405-0241D04

Fasten tackles to lifting brackets A and B

on the frame box wall, and attach the tack-
le hooks to the mentioned lifting attach-
ments on the connecting rod head.
5.
Haul the tackles tight.
D04-50
Also mount a lifting attachment on the
A B lower end of the connecting rod, on the ex-
haust side.

C 6. Turn the crankthrow carefully towards BDC

while ‘following’ with the tackles, thus con-
tinuously supporting the connecting rod.

The crosshead now rests on the four sup-

ports.
M90405-0241D05

Turn the crankthrow to 90° before BDC.

6.

A B

C
M90405-0241D06

Page 2 (7) When referring to this page, please quote Procedure M90405 Edition 0241
 Connecting Rod 904-5.2
MAN B&W Dismantling

7. Shift tackle B from the lifting attachment

7.
on one side of the connecting rod to the
lifting attachment on the other side.
A B
Dismount the lifting attachment on the
camshaft side of the connecting rod.

Attach a tackle to lifting bracket A on the

frame box wall and connect the tackle C
hook to the lifting attachment on the lower
end of the connecting rod.

Mount the wire guide on the door frame.

M90405-0241D07
Turn the crankthrow towards TDC while
‘following’ with the tackles, thus continu-
ously supporting and guiding the connect-
ing rod towards the doorway.

8. Attach a tackle to the gallery-mounted lift- 8.

ing bracket E, and hook on to the lifting at-
tachment on the connecting rod.
A B E
Unhook tackle A from the lifting attachment
on the head of the connecting rod.

Turn the crank carefully upwards while ‘fol-

lowing’ with tackles A, B and E, guiding C
the head of the connecting rod out of the
doorway.

Shift the tackles from one lifting attach-

M90405-0241D08

ment to the other as necessary.

9. Mount a strap around the connecting rod

and suspend the connecting rod from the
engine room crane. Shift tackle B from the
lifting attachment on the head of the con- 9.
necting rod to the lifting attachment at the
bottom of the connecting rod.
A B E
Remove tackles A and E.

Continue turning upwards till about 30°

after TDC while ‘following’ with the tackles
and the engine room crane.
M90405-0241D09

When referring to this page, please quote Procedure M90405 Edition 0241 Page 3 (7)
904-5.2 Connecting Rod
Dismantling MAN B&W

10. Lift the connecting rod out of the engine,

10.
using the tackles and the engine room
crane.
A B E
Remove the tackles, and lift the connect-
ing rod away by means of the engine room
crane.
M90405-0241D10

Page 4 (7) When referring to this page, please quote Procedure M90405 Edition 0241
 Connecting Rod 904-5.4
MAN B&W Mounting

1. Equip the connecting rod with the same

2.
lifting attachments as mentioned under dis-
mantling.
A B E
Turn the crank to a position about 25° past
TDC on the camshaft side.
D04-50
Apply clean lubricating oil to the crankpin
bearing shell and journal.

2. Carefully lift the connecting rod into the

crankcase by alternate use of the engine
room crane and the tackles attached to lift-
ing brackets A and B.

M90405-0241M02
3. When the end of the connecting rod rests
on the crankpin journal, follow with tackle
A.

4. Turn the crankthrow towards BDC, past 3.

TDC, while ‘following’ with the tackles and
the engine room crane.
A B E
Attach tackle B to the upper end of the
connecting rod.

Attach a tackle to bracket E and the upper

end of the connecting rod.

Haul tight and remove the strap around the

connecting rod.
M90405-0241M03

4.

A B E
M90405-0241M04

When referring to this page, please quote Procedure M90405 Edition 0241 Page 5 (7)
904-5.4 Connecting Rod
Mounting MAN B&W

5. Turn the crankthrow to 90° before BDC.

5.
Shift tackle A from the lower end to the top
A B of the connecting rod.

Remove the tackle at E.

Shift tackle B from the lifting attachment

on one side to the other side of the con-
necting rod.
C

Remove the wire guide on the door frame.

M90405-0241M05

Remove the lifting attachment at the lower

end of the connecting rod.

6. Turn the crankthrow towards TDC while

‘following’ with the tackles.
6.
Caution!
Take care that the studs do not damage
the crosshead bearing shell.
A B

7. When the crank is in TDC, mount the

crankpin bearing cap.
See Procedure 904-4.4.
M90405-0241M06

7.

D13-01
M90405-0241M07

Page 6 (7) When referring to this page, please quote Procedure M90405 Edition 0241
 Connecting Rod 904-5.4
MAN B&W Mounting

8. Remove the four supports from the cross-

8.
head guides and the lifting attachments
from the connecting rod.

Turn the crosshead down far enough to fa-

cilitate the tightening of the nuts.

9. Tighten all four crosshead bearing cap nuts

simultaneously. See Data.

M90405-0241M08
9.
M90405-0241M09

D13-01

When referring to this page, please quote Procedure M90405 Edition 0241 Page 7 (7)
 Connecting Rod and Crosshead Panel Plate
P90451-0133
Connecting Rod and Crosshead Panel
0133
P90451

When referring to this page, please quote Plate P90451 Edition 0133 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod and Crosshead Panel
P90451-0133

Item Item
Item Description Item Description
No. No.

011 Panel for tools

023 Name plate
047 Wire guide
059 Lifting attachment
060 Lifting tool for crosshead
072 Chain for suspending of piston
084 Retaining tool for telescope pipe
096 Support crosshead
106 Support crosshead
118 Rubber cover for crosshead
120 Rubber cover w. hole for crosshead
214 Torque wrench offset tool
251 Alignment tool

Notes:

Page 2 (2) When referring to this page, please quote Plate P90451 Edition 0133
MAN B&W Diesel A/S
 Connecting Rod - Hydraulic Tools Plate
P90461-0069
Connecting Rod - Hydraulic Tools
0069
P90461

When referring to this page, please quote Plate P90461 Edition 0069 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod - Hydraulic Tools
P90461-0069

Item Item
Item Description Item Description
No. No.

028 Jack-hydraulic, complete

030 Support
053 Sealing ring with back-up ring
065 Sealing ring with back-up ring
089 Key, hexagon socket screw
090 Tommy bar
100 Stud setter
207 Hydraulic toolset, complete

Page 2 (2) When referring to this page, please quote Plate P90461 Edition 0069
MAN B&W Diesel A/S
 Connecting Rod - Tools Plate
P90462-0020
Connecting Rod - Tools
0020
P90462

When referring to this page, please quote Plate P90462 Edition 0020 Page 1 (2)
MAN B&W Diesel A/S
Plate Connecting Rod - Tools
P90462-0020

Item Item
Item Description Item Description
No. No.

011 Guide shoe extractor, complete

Page 2 (2) When referring to this page, please quote Plate P90462 Edition 0020
MAN B&W Diesel A/S
 Main Bearing 105-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0004
105-1 Main Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10501 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
105-1 Main Bearing
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10501 Edition 0004
MAN B&W Diesel A/S
 Main Bearing 905-1.1
Checking
Main Bearing
S50MC-C
0209
Checking
905-1.1

1.
General

The condition of the main bearings can be

checked by:

• Deflection readings

• Visual checking

• Edge checking and

• Measuring of top clearance.

HM905-2.0 46 01
Crankshaft deflection readings

Crankshaft deflection readings should be taken

while the ship is afloat (i.e. not while in dry
dock).
2.
As the alignment is influenced by the engine Positive (+)
temperature as well as the loading conditions,
deflection measurements should, for compari-
son purposes, always be made under nearly
the same temperature and load conditions.

1. Place a dial gauge axially in the crank throw

opposite the crankpin, as illustrated on the
sketch. The correct mounting position is
marked with punch marks on the crank Negative ( )
throw. See also Chapter 708 in Volume I.
KN905-1.1 208 02

2. “Closing” of the crank throw (compression

of the gauge) is regarded as negative (–)
and “opening” as positive (+).

3. Set the dial gauge to zero at the B1 side

near BDC. Whilst turning clockwise, take 3.
the readings when the throw passes the po-
sitions:

B1 (near bottom)
C (camshaft side)
T (top)
E (exhaust side)
B2 (near bottom)
1/2 (B2+B1) = B
XZ905-1.1 204 03

When referring to this page, please quote Procedure M90501 Edition S209 Page 1 (4)
0$1% :'LHVHO$6
905-1.1 Main Bearing
Checking

4. 4. When taking deflection readings for the

three aftmost cylinders, the turning gear
should, at each stoppage, be turned a little
backwards to ease off the tangential pres-
sure on the turning wheel teeth. Otherwise,
this pressure may falsify the readings.

For evaluation of the crankshaft deflection

readings, see Volume I, OPERATION,
Chapter 708.

If the crankshaft deflection (alignment indi-

cator) is approaching the tolerance limits
(see Vol. I, OPERATION), the two adjacent
main bearings must be checked for wear.
See next page for checking of main bear-
ing.

If the bearings are found to be in good

order, please contact MAN B&W Diesel or
the engine manufacturer for checking of the
bedplate alignment.
HM905-2.0 46 01

As reference, use the “after seatrial” deflec-

tion table.

5. The condition of the bearing can be checked as

follows:

5. Visually look for bearing metal fragments in

the oil pan, and check the filters for metal
fragments.

Such fragments can be from crosshead,

guide shoe or crankpin bearings. If frag-
ments are found, the damaged bearing can
be found by edge checking with a feeler.

General
KN905-1.1 208 05

Bearing damage usually propagates rather

quickly towards the edge of the bearing where,
eventually, it causes chips to be broken off,
which means that loose pieces of white metal
can fall down into the crankcase beneath the
bearing support.

Large, thick pieces will normally be found dur-

ing a crankcase inspection, and small, thin
pieces can enter the filter. A check of the bear-
ing edges together with inspection of the crank-
case and the filter normally provides a good
indication of the bearing condition.

Page 2 (4) When referring to this page, please quote Procedure M90501 Edition S209
0$1% :'LHVHO$6
 Main Bearing 905-1.1
Checking

Checking the bearing edges 6.

6. Bearing edges can be checked with a “feel-

er” that is able to follow the bearing edge
against the journal the whole way round on
each side. If white metal is missing at the
edge, the tip of the “feeler” will enter the
hole, thus locating the damage. In most
cases this hole can be seen by the naked
eye as a dark spot when using a strong
flashlight.

The No. 1 and the two aftmost main bear- Hole in

ings are more difficult to access on the the edge

KN905-1.1 208 06
whole circumference on each side, but it is
often possible to bend the “feeler” to suit
the situation and thus reach as far round as
possible.

Wire-feeler(made by crew) 7.
<1.2 mm
>0.7 mm
7. It is rather easy to make a feeler (see 1 7-10 mm
sketch). The “feeler” should be made from
a piece of steel wire (e.g. a welding rod)
approx. 0.6 - 1 m long depending on the
engine type, and 2 to 3 mm thick. Approx.
7 to 10 mm of the wire should be bent to an
angle of approx. 65° to form a “feeler tip”.
Grind the tip smooth to obtain the shape
and dimension shown on the sketch. Note 60-70
that the thickness of the white metal is ap-
prox. 1.5 mm, which is why the tip should 2-3 mm
be less than 1.2 mm thick, and bigger than
500-1000

the max. top clearance. At the other end of

the tip, a “handle” should be made by bend-
ing a hook or similar in the same direction
as the tip.
Wire feeler

Note!

The above dimensions of the “wire-

feeler” are guideline values and may
KN905-17.02

depend on the engine type as well as

individual, personal designs.

When referring to this page, please quote Procedure M90501 Edition S209 Page 3 (4)
0$1% :'LHVHO$6
905-1.1 Main Bearing
Checking

8. 8. Remove the lub. oil pipe from the main

bearing cap.

Calibrate the main bearing measuring tool:

See the wooden box for the measuring tool.

9. Insert the measuring tool and check the

clearance between the upper shell and the
journal.

Note!
BG905-3.1 71 01

The bearing clearances for a new bear-

ing stated in Data (see Data 105-2) are
for guidance purposes only.

9. 10. The difference between the actual clear-

ance measurement and the measurement
recorded in the adjustment sheet (or the
clearance noted for a new bearing installed
later) must not exceed 0.10 mm. If it does,
see Volume I, Operation, Chapter 708.

For evaluation of the bearing, see Volume

I, Operation, Chapter 708.

If the bearing needs to be diassembled for

inspection, see procedure 905-2.2.
BM905-2.1 239 03

10.
HN905-2.1 227 03

Page 4 (4) When referring to this page, please quote Procedure M90501 Edition S209
0$1% :'LHVHO$6
 Main Bearing 105-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0044
105-2 Main Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
2 x 600 kg
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
x2

Data
4 x 1,5 m
Ref. Description Value Unit 1x3m
Top clearance in main
bearing
Max. ..................................... 0.65 mm
Min. ...................................... 0.35 mm

D-1 Main bearing cap 290 kg

D-2 Main bearing shells [NJ

– upper 20 kg
– lower 20 kg

D-3 Hydraulic pressure

– dismantling 1500-1650 bar
– tightening 1500 bar

When referring to this page, please quote Data D10502 Edition 0044 Page 1 (2)
MAN B&W Diesel A/S
105-2 Main Bearing
Data

Plate
90551

1175465-2

Spare Parts

Plate – Item No. Description Qty

91210-xxxx 050 Screw 2

91210-xxxx 108 Main bearing, upper shell 1
91210-xxxx 121 Main bearing, lower shell 1

Page 2 (2) When referring to this page, please quote Data D10502 Edition 0044
MAN B&W Diesel A/S
 Main Bearing 905-2.2
Dismantling
Main Bearing
S50MC-C
0241
Dismantling
905-2.2

Positioning the crankshaft 1.

Aftmost main bearing (= Journal bearing)
1. Dismantling of main bearing.

The bearings are divided into two catego-

ries:

• The main bearings

• The aftmost main bearing

often referred to as “Journal bearing”
(See Procedure 905-4).

2. Before any dismantling, check and write

down the main bearing top clearances and
crankshaft deflection readings for the cylin-

KN905-2.2 238 01
der unit concerned.
Main bearings

3. Turn the crank throw to the position shown Thrust bearing

on the sketch and in such a way that the top
of the studs is flush with the crank throw. 2.

Note!

Be sure that the crosshead for the neigh-

bouring cylinder is in a higher position
than for the cylinder you are working on,
otherwise it will be impossible to lift the
cap.
KN905-2.2 238 02

3.
EXH-SIDE MAN-SIDE
KN905-2.2 238 03

When referring to this page, please quote Procedure M90502 Edition S241 Page 1 (13)
0$1% :'LHVHO$6
905-2.2 Main Bearing
Dismantling

4.
Oil pipes

4. Disconnect the lubricating oil pipe from the

main pipe.

Note!

On some engines, the oil pipes for the

Axial Vibration Damper (AVD) have to be
removed together with the oil pipe on
main bearing No. 1.
KN905-2.2 238 04

Note!

Some engines have temperature sensors

2. fitted to the main, crosshead, and crank-
pin bearings. These sensors must be
carefully handled to avoid damaging the
equipment.

5. Mount the extension studs, the spacers, the

hydraulic jacks and the nuts on the exten-
sion studs. Loosen the main bearing stud
nuts, using the hydraulic jacks.
For operation of the hydraulic jacks, see
Procedure 913-1.

6. Remove the hydraulic main bearing tools

from the engine.
GN905-2.2 204 02

Unscrew and remove the nuts from the

main bearing studs.

Remove the rectangular nut washers from

5. the bearing cap.
KN905-2.2 238 07

Page 2 (13) When referring to this page, please quote Procedure M90502 Edition S241
0$1% :'LHVHO$6
 Main Bearing 905-2.2
Dismantling

7. Mount the lifting tool on the main bearing 7.

cap.

Mount the pulley on the web-plate over the

main bearing, and mount the wire rope from
the lifting tool in the pulley.

Mount an eye bolt in one of the threaded

holes on the opposite web-plate.

8. Mount the wire guide as shown.

Move the lifting pipes below the platform

outside the relevant cylinder.

GN905-2.2 241 07
Mount tackles in the following positions:

A + B: Two 2-ton chain tackles, below the

platform.

C: One 1-ton chain tackle. 8.

D: One ½-ton chain tackle, in the eye bolt

on the opposite web-plate. A
B
9. Attach the wire rope from the lifting tool to C
tackle A.

Using tackle A, lift the main bearing cap

free of the studs. D
GN905-2.2 241 08

Note!

Owing to space requirements below the

9. P
web-plate, it might be necessary to dis-
mount the eye bolt from the lifting tool.
P
D

A
GN905-2.2 241 09

When referring to this page, please quote Procedure M90502 Edition S241 Page 3 (13)
0$1% :'LHVHO$6
905-2.2 Main Bearing
Dismantling

10.
10. Pull the bearing cap clear of the crosshead
guides by using chain tackle D.
D
11. Attach tackle C to the eye bolt in the centre
of the lifting tool.

Dismount the balancing handle from the lift-

A ing tool for main bearing cap.

Tighten tackle C, and release tackles A and

D.

When released, dismount tackle A from the

wire rope, and dismount the wire rope from
GN905-2.2 241 10

the pulley.

12. Lift out the bearing cap, using tackles B and

A.
11.

B A

D
GN905-2.2 241 11

12.

A
B
C

D
GN905-2.2 241 12

Page 4 (13) When referring to this page, please quote Procedure M90502 Edition S241
0$1% :'LHVHO$6
 Main Bearing 905-2.2
Dismantling

13.
13. Mount the lifting tool on the upper main
bearing shell, and lift out the shell by hand.

14. If the crankshaft is turned with the bearing

cap dismounted, use the two stops to pre-
vent the lower shell from being rolled out.

15. Place the crosspiece in the bedplate with

the ends resting on the cross girders, and
position the hydraulic jacks beneath the
crank webs as shown.

Tighten the screws against the crank webs

and compress the jacks.

Connect the hydraulic jacks to the high-

pressure pump, and raise the pressure until

EN905-2.2 206 08
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the two adjacent
bearings.

Note down the pressure for later reference.

14.
KN905-2.2 238 24

15.
KN905-2.2 238 27

When referring to this page, please quote Procedure M90502 Edition S241 Page 5 (13)
0$1% :'LHVHO$6
905-2.2 Main Bearing
Dismantling

16. 16. Check that there is min. 0.1 mm clearance

Min. 0,1 mm between journal and bearing shell, or be-
tween bearing shell and main bearing sup-
port, on both sides of the journal.

Note!

The feeler blade must be inserted mini-

mum 60 mm into the gap to pass the bore
relief in the bearing shell.
EXH CAM

If the clearance is less than 0.1 mm, move

KN905-2.2 238 28
Min. 60 mm

the crosspiece sideways until clearance is

obtained. Normally, adjustment needs to be
50-150 mm to the exhaust side (the side
where the clearance is missing).

17.
Note!

The lower shell must be lifted out to the

side with the most clearance, which is
normally the camshaft side.

17. If re-positioning of the crosspiece does not

ensure a vertical lift, place a 5-tonne jack
between the side wall and the crank throw,
to correct the journal position in this way.

If it is available, note down the pressure ap-

plied to the jack. This data is used to en-
KN905-2.2 238 25

sure that the crankshaft is in the same

position when the new bearing is installed.

Note!

It is recommended that the crankshaft lift-

ing tool is only removed if it is urgently
necessary and then only after the main
bearing shell has been reinstalled.

Page 6 (13) When referring to this page, please quote Procedure M90502 Edition S241
0$1% :'LHVHO$6
 Main Bearing 905-2.2
Dismantling

18. Dismount the locking screws. 18.

Place the dismantling tool on top of the low-

er bearing shell. Make sure that the flap on
the dismantling tool enters the oil groove in
the bearing shell.

19. Pull the lower shell around and up until it

lies over the main bearing journal. Never
use a tackle larger than 0.5 tonne.

Note!

While pulling out the shell, it is recom-

mended to hold a foot or hand on the
wire rope, to tighten it up and to observe
whether the shell is sticking.
KN905-2.2 238 26

19.
JM905-2.2 236 27

When referring to this page, please quote Procedure M90502 Edition S241 Page 7 (13)
0$1% :'LHVHO$6
905-2.2 Main Bearing
Dismantling

20. 20. Take the lower shell out of the engine in the
same way as the upper shell, i.e. using the
lifting tool.
EN905-2.2 206 08

Page 8 (13) When referring to this page, please quote Procedure M90502 Edition S241
0$1% :'LHVHO$6
 Main Bearing 905-2.3
Overhaul
Overhaul
905-2.3

1. Clean and inspect the bearing shells. It is 1 + 2.

recommended that the main bearing shells
be replaced in pairs.

If it is nevertheless desired to replace only

one shell, this requires a careful evaluation
of the condition of the shell that is to be re-
installed.
See Instruction book, Volume I,
Chapter 708.

For advice on replacing individual bearing

shells, it is recommended to contact MAN
B&W Diesel A/S or the engine builder.

2. Before remounting:

• Check the bearing support for damage

and burrs. If damage is found, contact KN905-2.2 238 25
MAN B&W Diesel for advice.

• Make sure that all parts are clean, use

non-fluffy cloth to clean between journal
and main bearing support.

• Lubricate the bearing journal, the main

bearing support and the back of the
shell, with main engine lubricating oil.

When referring to this page, please quote Procedure M90502 Edition S241 Page 9 (13)
0$1% :'LHVHO$6
905-2.4 Main Bearing
Mounting
Mounting
905-2.4

1. Mounting of bearing shells

1. Lubricate the journal and the bearing sup-

port with clean oil

Using the bearing shell lifting tool, lift the

lower bearing shell into the crankcase and
land it on the crankshaft journal.

2. Position the guide tool for the lower bearing

shell on the main bearing support. Remove
the lifting tool from the bearing shell.
GN905-2.4 241 01

Place the lower bearing shell on the journal

and push it down by hand.

To ensure that the shell is correctly mount-

ed, check that the distance from the main
2. bearing support to the shell is equal in both
sides.

3. Mount the locking screws in the bearing

support.

Lower the crankshaft and remove the hy-

draulic jacks and the crosspiece from below
the crankshaft.

Wipe the contact surfaces between the up-

per and the lower bearing shells clean with
a non-fluffy piece of cloth.
MC905-3.0 118 19

3.
XZS905-13 07

Page 10 (13) When referring to this page, please quote Procedure M90502 Edition S241
0$1% :'LHVHO$6
 Main Bearing 905-2.4
Mounting

4. Land the upper bearing shell on the main 4.

journal in the same way as the lower bear-
ing shell.

Make sure that none of the edges of the up-

per bearing shell are resting on the edge of
the bearing support.

If necessary, place the special tool between

the studs and press the shell into place.

Clean the contact surfaces between the

bearing support and the bearing cap. Make
sure that no oil is left on the contact surfac-

XZS905-13 09
es.

5. Mount the lifting tool on the bearing cap.

Using the tackles and pulleys, lift the cap 5.

into the crankcase in reverse order to dis-
mantling.
See Procedure 905-2.2, steps 12-9.

Note!

Be sure that the cap lands correctly and

that the spring pin in the assembly sur-
face enters the hole in the bearing cap.
KN905-2.4 238 09

When referring to this page, please quote Procedure M90502 Edition S241 Page 11 (13)
0$1% :'LHVHO$6
905-2.4 Main Bearing
Mounting

6. 6. Mount the rectangular nut washers and

screw the round nuts on to the main bearing
studs.

Using the hydraulic jacks, fully tighten the

nuts on both sides of the bearing cap.

For tightening pressure, see Data.

For operation of the hydraulic tools,

see Procedure 913-1.

7.









Note!

1
0

Before removing the hydraulic jacks,

7. check the top clearance between the
upper bearing shell and the journal.

8. Remove all tools from the engine.

Note!

Search the crankcase to ensure that

there are no tools, shackles or rags left
behind.
BM905-2.1 239 03

8.
KN905-2.4 238 14

Page 12 (13) When referring to this page, please quote Procedure M90502 Edition S241
0$1% :'LHVHO$6
 Main Bearing 905-2.4
Mounting

9. Mount the lubricating oil pipe on the main 9.

bearing cap.

KN905-2.4 238 15

When referring to this page, please quote Procedure M90502 Edition S241 Page 13 (13)
0$1% :'LHVHO$6
 Thrust Bearing 105-3
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
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
X Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D05-06 Thrust bearing segment 27 kg

D05-07 Segment stopper 25 kg
D05-09 Segment stopper, fore 25 kg
D05-10 Segment stopper, aft 18 kg
D05-32 Segment stopper stud, screwing in torque 450 Nm
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar

When referring to this page, please quote Data D10503 Edition 0077 Page 1 (2)
105-3 Thrust Bearing
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

P90551 100 Tool for turning out segments

P90662 Camshaft - Hydraulic Tools

P91351 010 Hydraulic pump, pneumatically operated

P91351 046 Hose with unions (1500 mm), complete
P91351 058 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete

P91356 Lifting Tools, Etc.

P91366 058 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10503 Edition 0077
 Thrust Bearing 905-3.1
Checking
Thrust Bearing
S50ME-C
0233
Checking
905-3.1

1.
The clearance in the thrust bearing was meas-
ured during testbed trials of the engine and not-
ed down in the ‘Adjustment Sheet' which is
inserted at the front of Volume I, OPERATION.

For a new engine the clearance is 0.5-1.0 mm,

and for an engine in service it must not exceed
2.0 mm.

In service it is only necessary to measure the

wear of the thrust bearing pads, and to inspect
for white metal below the thrust bearing.

GW905-3.1 233 01
1. To measure the wear in the thrust bearing,
it is necessary to dismount the foremost
segment stopper.
For dismantling the segment stopper, see
Procedure 905-3.2.
2.
A wear groove of 1 mm is positioned in the
uppermost thrust segment. (The segment
with thermometers).

2. To measure the wear, the thrust segment

has to be pressed against the thrust cam,
to eliminate any gap, i.e. by using a suitable
crowbar on the back of the segment.

If a feeler gauge of 0.1 mm is not able to

enter the groove (the wear is more than 0.9
mm), the thrust bearing must be over-
hauled.
GN905-3.1 224 02

3. Note down the wear for later reference.

3.
KN905-2.2 238 02

When referring to this page, please quote Procedure M90503 Edition 0233 Page 1 (5)
MAN B&W Diesel A/S
905-3.2 Thrust Bearing
Dismantling
Dismantling
905-3.2

1. 1. Remove the lub. oil pipe from the bearing,

the protective shield, and the lub. oil pipe
for the thrust segments.

2. Loosen and remove the nuts from the seg-

ment stoppers.
For operation of the hydraulic jacks, see
Procedure 913-1.

Use a stud setter to loosen the segment

stopper studs. Remove the segment stop-
per studs.
GW905-3.2 233 01

Mount an eye bolt in the segment stopper

and use a rope around the horizontal lub.
oil pipe to remove the segment stoppers.
Lift the stoppers out of the chain casing.

2. 3. Mount the tool for turning out the segments

on the edge on the thrust bearing cam.
D13-02
GW905-3.2 233 02

3.
GW905-3.2 233 03

Page 2 (5) When referring to this page, please quote Procedure M90503 Edition 0233
MAN B&W Diesel A/S
 Thrust Bearing 905-3.2
Dismantling

4. Turn up the segments, one at a time, by 4. D05-06

turning the engine, and remove the seg-
ment from the thrust bearing casing. In-
spect the segment and remount it before
turning up the next segment.
See Procedure 905-3.4.

Note!

Never remove more than one segment at

a time.

GW905-3.2 233 04

When referring to this page, please quote Procedure M90503 Edition 0233 Page 3 (5)
MAN B&W Diesel A/S
905-3.4 Thrust Bearing
Mounting
Mounting
905-3.4

1. 1. Suspend a tackle above the segments

which are to be mounted. Still, it is possible
to lift the segments by hand.
D05-06
Mount the tool for turning out segments on
the thrust bearing cam.

Land the segment on the journal and re-

move the eye bolt from the segment.

Carefully slide the segment on to the seg-

ment tool. Turn the engine to dismantle the
next segment.
See Procedure 905-3.2.

2. After the last segment has been mounted,

turn the segment tool up and dismount it.
GW905-3.4 233 01

2.
GW905-3.4 233 02

Page 4 (5) When referring to this page, please quote Procedure M90503 Edition 0233
MAN B&W Diesel A/S
 Thrust Bearing 905-3.4
Mounting

3. Mount the segment stopper. 3.

D05-07
Mount the segment stopper studs. D05-32
Mount the hydraulic jacks and tighten the
nuts on the stopper.

For operating hydraulic jacks,

see Procedure 913-1.

4. Mount the lub. oil pipe for the thrust seg-

ments and the lub. oil pipe on the bearing.
D13-01

GW905-3.4 233 03
GW905-3.4 233 04 4.

When referring to this page, please quote Procedure M90503 Edition 0233 Page 5 (5)
MAN B&W Diesel A/S
 Journal Bearing 105-4
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0003
105-4 Journal Bearing

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
x2
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors
2x3m

Data
Ref. Description Value Unit

D-1 Min. bearing clearance 0.35 mm

D-2 Max. bearing clearance 0.65 mm

D-3 Main bearing cap 290 kg

D-4 Upper bearing shell 20 kg

[NJ
D-5 Lower bearing shell 20 kg

D-6 Hydraulic pressure

– dismantling 1500-1650 bar

D-7 Hydraulic pressure

– tightening 1500 bar

When referring to this page, please quote Data D10504 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
105-4 Journal Bearing
Data

Plate
90551

1175465-2

Spare Parts

Plate – Item No. Description Qty

91210-xxx 108 Screw 2

91210-xxx 121 Main bearing 1

Page 2 (2) When referring to this page, please quote Data D10504 Edition 0003
MAN B&W Diesel A/S
 Journal Bearing 905-4.1
Checking
0212 Bearing
Journal S50MC-C
Checking
905-4.1

1. Aftmost main bearing (= Journal bearing)

1. Before any dismantling of the journal bear-
ing, check the clearances as described in
Procedure 905-1.1.

2. Write down the journal bearing clearances.

3. Also check the journal bearing by visually

searching the area underneath the bearing
support.

KN905-2.2 238 01
Main bearings

Thrust bearing

2.
KN905-2.2 238 02

3.
KN905-4.1 202 03

When referring to this page, please quote Procedure M90504 Edition S212 Page 1 (8)
MAN B&W Diesel A/S
905-4.2 Journal Bearing
Dismantling
Dismantling
905-4.2

2. 1. Dismount the screws for the end cover.

Mount a ½-ton tackle above the end cover.

Remove the end cover.

2. Disconnect the lubricating oil pipe from the

main pipe.

Remove the protective shield for the thrust

bearing.

Turn the crank throw for the aftmost cylin-

der to TDC.

3. Mount the extension studs, the spacers, the

GN905-2.2 204 13

hydraulic jacks and the nuts on the exten-

sion studs. Loosen the bearing stud nuts,
using the hydraulic jacks

For operation of the hydraulic tools, see

3.
Procedure 913-1.

4. Remove the hydraulic main bearing tools

from the engine

Unscrew and remove the nuts from the

bearing studs.
GN905-2.2 204 02

4.
KN905-2.2 238 07

Page 2 (8) When referring to this page, please quote Procedure M90504 Edition S212
MAN B&W Diesel A/S
 Journal Bearing 905-4.2
Dismantling

5. Remove the rectangular nut washers from 5.

the bearing cap.

Mount the lifting attachment at the journal

bearing cap, and lift the cap out of the en-
gine by using the ½-ton tackle above the
bearing.

6. Mount the lifting attachment on the upper

shell, and lift the shell out of the engine.

7. Place the crosspiece under the turning

wheel as shown. Mount a dial gauge to
measure the lift of the crankshaft.

GN905-2.2 224 16
Tighten the screw against the turning wheel
and compress the jacks.

Connect the hydraulic jacks to the high- 6.

pressure pump, and raise the pressure until
the crankshaft has been lifted 0.2-0.5 mm,
but max. the clearance in the adjacent
bearing.
GN905-2.2 224 17

7.
GN905-2.2 224 19

When referring to this page, please quote Procedure M90504 Edition S212 Page 3 (8)
MAN B&W Diesel A/S
905-4.2 Journal Bearing
Dismantling

8. 8. Dismount the locking screws.

Place the dismantling tool on top of the low-

er bearing shell. Make sure that the flap on
the dismantling tool enters the oil groove in
the bearing shell.

Pull the lower bearing shell round and up-

wards until it lies over the bearing journal.
Never use a tackle larger than 0.5 ton.

9. Take the lower shell out of the engine in the

same way as the upper shell, i.e. using the
lifting tool.
KN905-2.2 238 26

9.
GN905-2.2 224 17

Page 4 (8) When referring to this page, please quote Procedure M90504 Edition S212
MAN B&W Diesel A/S
 Journal Bearing 905-4.3
Overhaul
Overhaul
905-4.3

1. Clean and inspect the bearing shells. It is 1 + 2.

recommended that the main bearing shells
be replaced in pairs.

If it is nevertheless desired to replace only

one shell, this requires a careful evaluation
of the condition of the shell that is to be re-
installed.
See Instruction book, Volume I,
Chapter 708.

For advice on replacing individual bearing

shells, it is recommended to contact MAN
B&W Diesel A/S or the engine builder.

2. Before remounting:

• Check the bearing support for damage

and burrs. If damage is found, contact KN905-2.2 238 25

MAN B&W Diesel for advice.

• Make sure that all parts are clean, use

non-fluffy cloth to clean between journal
and bearing support.

• Lubricate the bearing journal, the bear-

ing support and the back of the shell,
with main engine lubricating oil.

When referring to this page, please quote Procedure M90504 Edition S212 Page 5 (8)
MAN B&W Diesel A/S
905-4.4 Journal Bearing
Mounting
Mounting
905-4.4

1. 1. Lubricate the journal, the lower bearing

shell and the bearing support with clean oil.

Using the bearing shell lifting tool, lift the

lower bearing shell into the crankcase and
land it on the crankshaft journal.

2. Position the guide tool for the lower bearing

shell on the bearing support. Remove the
lifting tool from the bearing shell.

Lubricate the journal, the lower bearing

shell and the bearing support with clean oil.
GN905-2.2 224 17

Place the lower bearing shell on the journal

and push it down by hand.

To ensure that the shell is correctly mount-

2. ed, check that the distance from the bear-
ing support to the shell is equal in both
sides.

3. Remove the guide tool when the lower

bearing shell has been mounted.

Mount the locking screws in the bearing

support.

Lower the crankshaft and remove the hy-

draulic jacks and the crosspiece from under
the crankshaft.
MC905-3.0 118 19

Wipe the contact surfaces between the up-

per and the lower bearing shells clean with
a non-fluffy piece of cloth.

3.
XZS905-13 07

Page 6 (8) When referring to this page, please quote Procedure M90504 Edition S212
MAN B&W Diesel A/S
 Journal Bearing 905-4.4
Mounting

4. Land the upper bearing shell on the main 4.

journal in the same way as the lower bear-
ing shell.

Make sure that none of the edges of the up-

per bearing shell are resting on the edge of
the bearing support.

If necessary, place the special tool between

the studs and press the shell into place.

Clean the contact surfaces between the

bearing support and the bearing cap. Make
sure that no oil is left on the contact surfac-

XZS905-13 09
es.

5. Mount the lifting tool on the bearing cap.

Using the lifting tool and the tackles, lift the
bearing cap into the crank casing in reverse 6.
order to dismantling.
See Procedure 905-4, step 5.

6.

Note!

Be sure that the cap lands correctly and

that the guide pin in the assembly sur-
face enters the hole in the bearing cap.

7. Mount the rectangular nut washers, the

KN905-2.4 238 09

nuts, the spacer rings, the hydraulic jacks,

and tighten the nuts. See Data.

For operation of the hydraulic tools,

see Procedure 913-1. 7.
MN913-1 208 11

When referring to this page, please quote Procedure M90504 Edition S212 Page 7 (8)
MAN B&W Diesel A/S
905-4.4 Journal Bearing
Mounting

8. 8.

Note!

Before removing the hydraulic jacks,

check the top clearance between the
upper bearing shell and the journal.

9. Remove all tools from the engine.

BM905-2.1 239 03

Note!

Search the crankcase to ensure that

there are no tools, shackles or rags left
9. behind.

10. Mount the lubricating oil pipe on the bear-

ing cap, and mount the end cover.
KN905-2.4 238 14

10.
KN905-2.4 238 15

Page 8 (8) When referring to this page, please quote Procedure M90504 Edition S212
MAN B&W Diesel A/S
 Axial Vibration Damper 105-5
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
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D05-18 Inner studs, screwing-in torque 150 Nm

D05-19 Nuts on inner studs, tightening torque 500 Nm
D05-22 Outer studs, screwing-in torque 450 Nm
D05-23 Horizontal screws, tightening torque 450 Nm
D05-24 Horizontal screws, tightening torque/angle 100/25 Nm/°
D05-25 Damper housing, upper part 275 kg
D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar

When referring to this page, please quote Data D10505 Edition 0063 Page 1 (2)
105-5 Axial Vibration Damper
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

P90662 Camshaft - Hydraulic Tools

P91351 010 Hydraulic pump, pneumatically operated

P91351 058 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete

P91356 Lifting Tools, Etc.

P91359 Torque Spanners

Page 2 (2) When referring to this page, please quote Data D10505 Edition 0063
 Axial Vibration Damper 905-5.1
MAN B&W Checking

For checking the effectiveness of the axial vi-

bration damper, it is necessary to measure the 1.
longitudinal movements of the fore end of the
crankshaft during running.

The measurement (or reading) should be taken

at the same r/min as during the sea trials.
(Preferably 90% and 100% of MCR.)

As different equipment may be mounted on the

specific engines, the checking procedure de-
scribes three systems:

A: Electronic, with Axial Vibration Monitor

B: Mechanical, (without angle encoder fore)

C: Mechanical, with angle encoder fore.

A: Electronic, with Axial Vibration Monitor

M90505-0235C01A

The probe is connected to a control unit which

displays peak-to-peak movements and sends
signals to the engine control system.

A proximeter probe is built onto the damper

housing. The probe can either be fitted on the
lower part of the damper housing or on the up-
per part of the damper housing.

1. In this case, the proximeter probe is built

onto the lower part of the damper housing.

Concerning overhaul and setting of the

electronic device, see makers instructions
and Volume I, Operation, Chapter 701.

The peak-to-peak values displayed in mm

are to be compared with the original val-
ues obtained during sea trial and the limits
given in Volume I, Operation, Chapter 701.

If the peak-to-peak value exceeds the Nor-

mal Service Value, it is necessary to over-
haul the axial vibration damper, see Proce-
dure 905-5.2.

When referring to this page, please quote Procedure M90505 Edition 0235 Page 1 (9)
905-5.1 Axial Vibration Damper
Checking MAN B&W

2. In this case, the proximeter probe is

2. mounted on the upper part of the damper
housing.

The overhaul and settings of the electrinic

device are the same as those mentioned
under point 1. Interpretation of peak-to-
peak displayed values is also the same as
mentioned under point 1.
M90505-0235C02A

Page 2 (9) When referring to this page, please quote Procedure M90505 Edition 0235
 Axial Vibration Damper 905-5.1
MAN B&W Checking

B: Mechanical (without angle encoder fore)

1.
1. Stop the engine.

Unscrew the two plugs from the cover at

the front of the engine.

2. Fit the shaft piece to the end of the crank-

shaft, using the handle.

After tightening the shaft, remove the han-

dle.

-ç#"
Screw the measuring arm into the small
threaded hole beside the centre hole, so
that the arm is perpendicular to the shaft
piece. Tighten the lock nut.

Attach a pencil to the arm.

2.
Note!
To obtain a correct measurement, the
tip of the pencil should protrude 10 mm
from the end of the arm.

3. Start the engine, and let the speed rise

to the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.)
-ç#"

When measuring, press the measuring arm

against the shaft piece with the one hand.
With the other hand, move a sheet/block of
paper, clipped on to a solid backing plate,
lightly downwards against the tip of the
pencil.
3.
To ensure a certain inertia, the backing
plate should have a mass of approx. 1-2
kg.

The axial movements (S2) recorded on the

paper must be measured with a slide cal-
liper as shown in the sketch.
PULL
M90505-0235C03C

When referring to this page, please quote Procedure M90505 Edition 0235 Page 3 (9)
905-5.1 Axial Vibration Damper
Checking MAN B&W

4. Before comparing the measured value (S2)

4. with the Normal Service Value (S1), stated
S1 in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.

For a standard measuring tool (L1 = 38 mm

and L2 = 200 mm), the ratio is 5.3. There-
L2 fore, S1 can be calculated as follows:
L1 S2
S2
S1 = ___
5.3

If a non-standard tool is used, S1 can be

M90505-0235C04B

calculated as follows:
L
S1 = S2 x __1
L2

If the peak-to-peak value exceeds the Nor-

mal Service Value, it is necessary to over-
haul the axial vibration damper, see Proce-
dure 905-5.2.

Page 4 (9) When referring to this page, please quote Procedure M90505 Edition 0235
 Axial Vibration Damper 905-5.1
MAN B&W Checking

C: Mechanical, with angle encoder fore

1.
For engines with angle encoder fore, a measur-
ing tool is available for mounting on the angle
encoder housing.

1. Stop the engine.

Dismantle the protection shield over the an-

gle encoder. (Not always on engine).

Dismantle the cover on the angle encoder

housing.

Apply some MolycoteTM on the fore side of

the shaft cam.

2. Fit the axial vibration measuring tool, using

the screws from the cover.

Attach a pencil to the arm.

-ç##

Note!
To obtain a correct measurement, the
tip of the pencil should protrude 10 mm
from the end of the arm.

2.
-ç##

When referring to this page, please quote Procedure M90505 Edition 0235 Page 5 (9)
905-5.1 Axial Vibration Damper
Checking MAN B&W

3. Start the engine, and let the speed rise

3. to the number of revolutions at which the
measurement is to be taken. (Preferably
90% and 100% of MCR.)

When measuring, pull the measuring arm

against the shaft cam with one hand. With
the other hand, move a sheet/block of
paper, clipped onto a solid backing plate,
PULL
lightly sidewards against the tip of the pen-
cil.

To ensure a certain inertia, the backing

M90505-0235C03C

plate should have a mass of approx. 1-2

kg.

The axial movements (S2) recorded on the

paper must be measured with a slide cal-
liper as shown in the sketch.
4.
4. Before comparing the measured value (S2)
with the Normal Service Value (S1), stated
in Volume I, Operation, Chapter 701, it is
necessary to compensate for the ratio in
the tool.

For a standard measuring tool (L1 = 35 mm

and L2 = 178 mm), the ratio is 5.1. There-
fore, S1 can be calculated as follows:
S1
S1 = ___
5.1

If a non-standard tool is used, S1 can be

calculated as follows:
L
S1 = S2 x __1
L2

If the peak-to-peak value exceeds the Nor-

mal Service Value, it is necessary to over-
haul the axial vibration damper, see Proce-
M90505-0235C04C

dure 905-5.2.

Page 6 (9) When referring to this page, please quote Procedure M90505 Edition 0235
 Axial Vibration Damper 905-5.2
MAN B&W Dismantling

Dismantling of the axial vibration damper is

1.
carried out from the crankcase of cyl. No. 1.

1. Turn the engine to 90º after TDC.

Disconnect the lubricating oil pipes for the

main bearing and axial vibration damper. D13-02
Loosen and remove the nuts from the inner
studs and the hydraulic nuts from the outer
studs. For operation of the hydraulic tools,
see Procedure 913-1.

Loosen and remove the horizontal screws.

M90505-0235D01
Only the upper part of the housing needs
to be removed, while the lower half remains
mounted on the bedplate.

2. Fit an eyebolt in the centre lifting hole on 2.

the upper part.

Engines with chain box fore:

Fit a tackle in the bracket above the axial
vibration damper inside the chain box.

Engines without chainbox fore:

Fit a tackle below the fore end platform,
and dismount the cover on the lifting hole
above the axial vibration damper.

3. By means of the tackle and wire rope, sep-

M90505-0235D02

arate and raise the upper part of the damp-

er housing to a position in which it is pos-
sible to change the oil seals and springs.

Note!
3.
Before starting the work under the sus-
pended upper part, secure the upper D05-25
part with, e.g. a wire rope or another
tackle.
M90505-0235D03

When referring to this page, please quote Procedure M90505 Edition 0235 Page 7 (9)
905-5.3 Axial Vibration Damper
Overhaul MAN B&W

1. Dismantle and remove the springs from the

1.
oil sealing rings.

Remove the oil sealing rings.

Note!
It is recommended to discard both the
springs and the oil sealing rings.

When installling the new oil sealing rings,

first insert the lower half of the rings in the
lower housing.
-ç/

Then press the tension springs into the

groove between the oil sealing ring half and
the housing.

2. 2. Install all the upper halves of the oil seal-

ing rings in such a way that the clearance
at both joints on each oil sealing ring is the
same.

Now hook the new tension springs into

place, ensuring that they are centralised in
the grooves of the oil sealing rings.

Note!
The lower half of the oil sealing rings will
protrude above the centreline.
-ç/

Page 8 (9) When referring to this page, please quote Procedure M90505 Edition 0235
 Axial Vibration Damper 905-5.4
MAN B&W Mounting

1. Release and carefully lower the upper part

1.
of the damper housing.

When reaching the oil sealing rings, take D05-25

care that the rings enter the sealing ring
grooves correctly.

Before landing the upper part on the lower

part, be sure that the guide pins have en-
tered the guide pin holes.

2. Install and tighten the vertical nuts. See

Data.

Install and tighten the hydraulic nuts. For

operation of the hydraulic tools, see Proce-
dure 913-1.

Fit and tighten the horizontal screws. See

Data.

Note!
M90505-0235M01

Search the crankcase to ensure that

there are no tools, shackles or rags left
behind.

Connect the lubricating oil pipes.

2.
D05-18
Engines without chainbox fore: D05-19
Fit the cover for the lifting hole above the
axial vibration damper. D05-22

Note! D13-01
After overhaul of the axial vibration
damper, it is recommended to check the
axial vibrations. See Procedure 905-3.1.
D05-23
D05-24
M90505-0235M02

When referring to this page, please quote Procedure M90505 Edition 0235 Page 9 (9)
 Tacho Pick-Ups 105-7
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0002
105-7 Tacho Pick-Ups

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Tacho pick-ups for governor

system(Gov. and BMS maker : Lyngso)
– check distance 5 ±1.0 mm

When referring to this page, please quote Data D10507 Edition 0S02 Page 1 (2)
MAN B&W Diesel A/S
105-7 Tacho Pick-Ups
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10507 Edition 0S02
MAN B&W Diesel A/S
 Tacho Pick-Ups 905-7.1
Checking
Tacho Pick-Ups
S46MC-C
0201
Checking
905-7.1


The engine is equipped with below pick-ups:

• Governor system pick-ups

Governor system pick-ups:

1. The tacho pick-ups are placed next to the

turning wheel.

2. Check the distance between the tacho pick-

ups and the turning wheel, see Data.

If necessary, adjust the distance.

If the tacho pick-ups are renewed, note

down the wiring to ensure the correct re-
mounting.

EN905-7.1 201 01



Turning wheel
EN905-7.1 201 02

When referring to this page, please quote Procedure M90507 Edition 0201 Page 1 (1)
0$1% :'LHVHO$6
 Crankshaft, Thrust Shaft,
Main Bearing, etc. - Panel Plate
MAN B&W P90551-0227

When referring to this page, please qoute Plate P90551 Edition 0227 Page 1 (2)
 Crankshaft, Thrust Shaft,
Plate Main Bearing, etc. - Panel
P90551-0227 MAN B&W
Item Item Description
No.
015 Panel for tools
027 Name plate
040 Wire pulley, main bearing
076 Lifting tool, main bearing cap
088 Dismantling tool, main bearing shell
090 Mounting tool, thin bearing shell
100 Tool, turning out segments
111 Lifting attachment
123 Retaining tool, main bearing shell
135 Lifting tool, relief valve
172 Mounting tool, thin bearing shell
184 Lifting tool, main bearing shell

Page 2 (2) When referring to this page, please qoute Plate P90551 Edition 0227
 Main Bearing - Hydraulic Tools Plate
P90561-0079
Main Bearing - Hydraulic Tools
0079
P90561

When referring to this page, please quote Plate P90561 Edition 0079 Page 1 (2)
MAN B&W Diesel A/S
Plate Main Bearing - Hydraulic Tools
P90561-0079

Item Item
Item Description Item Description
No. No.

010 Wooden box

021 Jack-hydraulic, complete
033 Jack-hydraulic, complete
045 Jack-hydraulic, support
057 Stud
069 Nut, hexagon
070 Sealing ring with back-up ring
082 Sealing ring with back-up ring
094 Sealing ring with back-up ring
130 Ball handle
141 Lifting tools
165 Stud setter

Page 2 (2) When referring to this page, please quote Plate P90561 Edition 0079
MAN B&W Diesel A/S
 Crankshaft - Tools Plate
P90562-0125
Crankshaft - Tools
0125
P90562

When referring to this page, please quote Plate P90562 Edition 0125 Page 1 (2)
MAN B&W Diesel A/S
Plate Crankshaft - Tools
P90562-0125

Item Item
Item Description Item Description
No. No.

015 Support
039 Screw with special head
052 Nut

Page 2 (2) When referring to this page, please quote Plate P90562 Edition 0125
MAN B&W Diesel A/S
 Thrust Shaft - Tools Plate
P90570-0004
Thrust Shaft - Tools
0004
P90570

When referring to this page, please quote Plate P90570 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
Plate Thrust Shaft - Tools
P90570-0004

Item Item
Item Description Item Description
No. No.

019 Lifting tool for thrust shaft

Page 2 (2) When referring to this page, please quote Plate P90570 Edition 0004
MAN B&W Diesel A/S
 Main Bearing - Measuring Tools Plate
P90572-0003
Main Bearing - Measuring Tools
0003
P90572

When referring to this page, please quote Plate P90572 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Main Bearing - Measuring Tools
P90572-0003

Item Item
Item Description Item Description
No. No.

010 Measuring tool main bearing

clearence
021 Calibration tool
045 Key, hexagon socket screws
057 Wooden box

Page 2 (2) When referring to this page, please quote Plate P90572 Edition 0003
MAN B&W Diesel A/S
 Tuning Wheel - Tools Plate
P90573-0001
Tuning Wheel - Tools
0001
P90573

When referring to this page, please quote Plate P90573 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Tuning Wheel - Tools
P90573-0001

Item Item
Item Description Item Description
No. No.

015 Wooden box

027 Support
039 Jack-hydraulic, complete
040 O-ring with back-up ring
052 O-ring with back-up ring
076 Key, hexagon socket screw
090 Tommy bar

Page 2 (2) When referring to this page, please quote Plate P90573 Edition 0001
MAN B&W Diesel A/S
 Chains 106-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0033
106-1 Chains

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D06-10
D-1 Max. wear of teeth
on chain wheel 3.0 mm

D06-11
D-2 Original length
(chain pitch x 10 links) 889.0 mm

D06-12
D-3 10 links measurements
+ 1% of a tensioned chain
= scrapping of chain 897.9 mm

When referring to this page, please quote Data D10601 Edition 0S33 Page 1 (2)
MAN B&W Diesel A/S
106-1 Chains
Data

Plate
90651
1175454-4.0

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10601 Edition 0S33
MAN B&W Diesel A/S
 Chains 906-1.1
Checking
Chains
S50MC-C
0236
Checking
906-1.1

4.
Carry out the inspection as follows:

1. Make a general inspection for loose bolts

and screws.

2. Inspect lube oil pipes for damage, and

check jet nozzles for possible stoppages or
deformations.

3. Examine the rubber track of the guideways

for cracks or other damage.

Replace the guideway if bits have started to

be “plucked out” of the rubber track.

4. Check the teeth of the chain wheels. If ab-

normal wear is found, take a measurement
(see Data).

Measurements are best taken by placing a

short straight-edge over points A and B and
then measuring the distance D06-10.
HN906-1.1 204 04

5. If abnormal wear is observed at the bottom D06-10

of the teeth, make a drawing in scale 1:1 of
the teeth and wear profile.

For assessing the measurement results, 5.

contact MAN B&W Diesel.

In most cases, scratches caused by the

side plates of the chain will be found on the
sides of the teeth. Such scratches can gen-
erally be considered normal.
HN906-1.1203 05

When referring to this page, please quote Procedure M90601 Edition 0236 Page 1 (4)
MAN B&W Diesel A/S
906-1.1 Chains
Checking

7. 6. The chains for the camshaft drive are

matched together to ensure an even load
distribution.

To keep such matching chains in their pairs,

the side plates of the outer link nearest to
the assembled link have been marked with
year, month, day and chain number.
D06-12
D06-11 Example:
Ma D06-

No. 1 order,
Dx0. D 12

840520 1A
6-016

840520 1B
1-58

(840520 1C, possible 3rd chain)

No. 2 order,
840520 2A
MN906-1.1 226 07

840520 2B
(840520 2C, possible 3rd chain)

On the same links there is an arrow (–>)

which indicates the mounting direction.

Check the chains for cracks on possibly de-

fective rollers and side plates.

Check that the chain rollers can run freely

and that the chain links can freely move on
the pin and bushing (that they are not
“seized” between the pin and the bushing).

It is normal, however, that the rollers get

light, circumferential scratches during the
running-in period. These fine scratches are
of no importance and need not be consid-
ered.

It is recommended that each single link is

checked.

7. Check chain wear by measuring the length

of 10 chain links. Use two master squares
and a steel measuring tape as shown on
the sketch. Compare the result with the val-
ues given in Data.

If necessary, adjust the chain tightener.

See Procedure 906-2.3.

Page 2 (4) When referring to this page, please quote Procedure M90601 Edition 0236
MAN B&W Diesel A/S
 Chains 906-1.2
Dismantling
Dismantling
906-1.2

It may become necessary to disassemble 1.

the chain if, for instance, cracked rollers or
seizures between pin and bushing have
been discovered during the inspection.
See Procedure 906-1.1.

Note!

Every time a chain link is disassembled,

a new link must always be fitted as the
link pin press-fit is destroyed when
breaking the chain.

GN906-1.2 203 01
When a new link is fitted in one chain, the
corresponding link in the other chain
must also be renewed.

1. Remove the tension on the chain by loos- 2.

ening the chain tightener.
(See Procedure 906-2.3).

Turn the engine until the slack part of the

chain, with the chain link that is to be dis-
assembled, is in a favourable position for
the work. If the engine is equipped with bal-
anceweights, continue the turning until the
balanceweights are hanging vertically
downwards, as shown in the sketch.

2. Mount a wire round the link rollers a short

distance from the disassembly point, and
GN906-1.2 203 02

tighten the wire lightly with a tackle.

Protect the link rollers over which the wire

is wrapped.
3.
Note!

If the chain is to be completely removed,

contact MAN B&W Diesel for further
information.

The riveting of the pins that are to be

pressed out is to be chiselled or ground
away.

3. Place the chain bursting tool over the outer

chain link, and dismantle the link by alter-
GN906-1.2 203 03

nately tightening the screws on the tool.

When referring to this page, please quote Procedure M90601 Edition 0236 Page 3 (4)
MAN B&W Diesel A/S
906-1.4 Chains
Mounting
Mounting
906-1.4

1. Before assembling the inner and outer

links, clean the pins and bushings.

1. Combine the inner chain link with the outer

chain link and mount the compression tool.

Force the loose side plate of the outer link

into place by alternately tightening the
screws on the compression tool.

2. When the link has been assembled, remove

the compression tool and lock the pin ends
by riveting.
GN906-1.4 203 01

Repeat this procedure until the chain has

been assembled.

Remove the tackle and wire and adjust the

chain tension.
(See Data and Procedure 906-2.3).

Page 4 (4) When referring to this page, please quote Procedure M90601 Edition 0236
MAN B&W Diesel A/S
 Chain Tightener 106-2
Data
SAFETY PRECAUTIONS

X Stopped engine
X Block the star ting mechanism
X Shut off star ting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D06-21 Tightening angle = xx hexagons 720/12 ° / hex

D06-23 Reduced tightening angle = xx hexagons 600/10 °
D06-25 Mechanical or blocked chain tightener, clearance 0.1 mm
D06-26 Max.distance 265 mm
D06-66 D max. 165 mm

When referring to this page, please quote Data D10602 Edition 0054 Page 1 (2)
MAN B&W Diesel A/S
106-2 Chain Tightener
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

P91366 50 Feeler gauge

Page 2 (2) When referring to this page, please quote Data D10602 Edition 0054
MAN B&W Diesel A/S
 Chain Tightener 906-2.3
Adjusting
Chain Tightener
S50MC-C
0239
Adjusting
906-2.3

1.
1. To retighten the chains, loosen nuts A, B,
C and D to free the chain tightener bolt.

2. Turn the engine so that the slack part of the

chains is on the same side as the tightener
wheel.

If balanceweights are mounted, continue

the turning until they are hanging vertically
downwards.

3. With the balanceweights in this position,

tighten nut B on the chain tightener bolt un-

M90602-0239O01
til there is a clearance between the shaft
and the nut as stated in D06-25.

Then tighten nut B as stated in D06-21 (see

Data).
M90602-0239O02 2.

3.
D06-21

D06-25
M90602-0239O03

When referring to this page, please quote Procedure M90602 Edition 0239 Page 1 (2)
MAN B&W Diesel A/S
906-2.3 Chain Tightener
Adjusting

4. 4. Tighten nut C hard against the contact face

of the shaft.

Tighten nut D.

Lock nuts C and D with the tab washer.

5. Tighten nut A.

Lock nuts A and B with the tab washer.

6. Measure distance X.
M90602-0239O04

7. If the chain is worn (X > D06-66 mm), re-

peat the procedure from step 1, but tighten
nut B only to the reduced tightening angle,
see Data D06-23.

5. If distance X exceeds the max. distance

A (see Data), find and eliminate the cause of
the abnormal chain elongation, e.g. a de-
fective chain, damaged chain wheels or
bearings, etc. Repeat the procedure from
step 1.
M90602-0239O05

6. X

B
M90602-0239O06

Page 2 (2) When referring to this page, please quote Procedure M90602 Edition 0239
MAN B&W Diesel A/S
 Camshaft 106-3
Data

SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10603
106-3 Data 0036 Camshaft

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D06-27 Max. permissible change in lead angle 2 °

D06-28 corresponding to 3.5 mm
D06-29 Pin gauge for top dead centre of crankthrow No.1, 697 mm
check measurement
D06-30 Pin gauge for camshaft, check measurement 340 mm

When referring to this page, please quote Data D10603 Edition 0036 Page 1 (2)
MAN B&W Diesel A/S
106-3 Camshaft
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

P90664 Crankshaft - Pin Gauge

P90668 Camshaft - Pin Gauge

Page 2 (2) When referring to this page, please quote Data D10603 Edition 0036
MAN B&W Diesel A/S
 Camshaft 906-3.1
Checking
Camshaft
S46MC-C
0214
Checking
906-3.1

1.
1. Turn the crankthrow for cylinder 1 to TDC.

Turn in the AHEAD direction to ensure that

the tension of the chain on the chain drive
is correct. If necessary, adjust the chain
tension.
See Procedure 906-2.3.

HM906-7.0 56 01
Check the TDC of cylinder 1 against the
mark on the turning wheel.

2. Check the TDC position with the pin gauge 2.

on the crankthrow.

GN906-3.1 203 02

D06-29

When referring to this page, please quote Procedure M90603 Edition 0214 Page 1 (3)
MAN B&W Diesel A/S
906-3.1 Camshaft
Checking

3. 3. Position the camshaft pin gauge in the cen-

tre punch mark, and measure the deviation,
if any, in lead angle.

For max. permissible change, see Data.

4. Check and, if necessary adjust the cylinder

lubricator. See Procedure 903-2.1.
D06-30
Check the setting of the starting air distrib-
utor. See Procedure 907-1.1.
D06-28
5. When checking the camshaft position, also
check the running surface of the cams.

D06-27 As the inspection must include the entire

GN906-3.1 203 03

surface of the cam, the cam should be

turned one complete revolution during the
inspection.

The running surface of the cam must be

5.
completely smooth and bright.

6. If light scratches are ascertained, remove

them by carefully polishing the cam in the
direction of rotation with a fine carborun-
dum stone. Such light scratches can appear
if the roller guide and the cam are not cor-
rectly aligned.
GN906-3.1 203 05

In the event of heavier scratches or direct

flaking of the material on the running path,
MAN B&W Diesel should be contacted for
further instructions.
6.
GN906-3.1 203 06

Page 2 (3) When referring to this page, please quote Procedure M90603 Edition 0214
MAN B&W Diesel A/S
 Camshaft 906-3.3
Adjustment
Adjustment
906-3.3

1. If the chains prove to be so heavily worn 1.

that the deviation between the measuring
points and the pin gauge has reached the
maximum value stated in Procedure 906-
3.1, MAN B&W Diesel should be contacted
for further instructions.

D06-28

D06-27

GN906-3.3 203 01

When referring to this page, please quote Procedure M90603 Edition 0214 Page 3 (3)
MAN B&W Diesel A/S
 Camshaft Bearings 106-4
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
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D06-31 Screws for bearing cap, tightening torque 125 Nm

D06-33 Clearance between cap/bearing housing 3 ± 0.3 mm
D06-34 Bearing shell, max. wear 0.1 mm
D06-37 Camshaft bearing cap 13 kg
D06-65 Bearing shell, minimum thickness 7.35 mm

When referring to this page, please quote Data D10604 Edition 0048 Page 1 (2)
106-4 Camshaft Bearings
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

P91351 022 Hydraulic pump, hand operated

P91351 058 Hose with unions (3000 mm), complete

P90651 152 Hydraulic jack for lift of camshaft

P91356 Lifting Tools, Etc.

P91359 Torque Spanners

P91366 061 Slide caliper

Page 2 (2) When referring to this page, please quote Data D10604 Edition 0048
 Camshaft Bearing 906-4.1
MAN B&W Diesel Checking

1. As the upper shell of the camshaft bear-

1.
ing assembly has been dispensed with on
this engine, it is no longer necessary to
measure the top clearance of the camshaft
bearing.

Dismount the inspection covers from the

front of the camshaft housing.

Check for wiped
out metal at the bearing

ends, and for fragments of metal in the
camshaft housing.

M90604
0225C01
In the event of any signs of anomalies, the
bearing shell must be dismantled for closer
investigation and, if necessary, the bearing
shell must be replaced.

If no anomalies are found during the visual

inspection, dismantling need not be carried
out.

When checking the camshaft bearings, it is

recommended also to check the condition
of the fuel and exhaust cams.
See Procedures 908
5 and 909
3.

When referring to this page, please quote Procedure M90604 Edition 0225 Page 1 (5)
906-4.2 Camshaft Bearing
Dismantling MAN B&W Diesel

1. Warning!
Before dismantling any camshaft bear-
ings, the main chain must be relieved of
tension by loosening the chain tightener
to avoid damaging engine parts.

See Procedure 906
2.3.

1. Remove the inspection covers on each side

of the bearing from the camshaft housing.

Dismount the lubricating oil connecting

M90604
0225D01

pipe and the plug screws from the base-

plate above the bearing in question.

Lift the roller guide of the exhaust valve ac-

tuator. See Procedure 908
7.
2.
2. Loosen the bearing cap screws through the
holes in the baseplate.

Remove the screws from the bearing cap.

Remove the bearing cap from the housing.

D06
37
M90604
0225D02

Page 2 (5) When referring to this page, please quote Procedure M90604 Edition 0225
 Camshaft Bearing 906-4.2
MAN B&W Diesel Dismantling

3. Place a hydraulic jack between two pieces

of wood in the camshaft housing under- 3. Max. 20/100 mm
neath the camshaft, close to the bearing.

Place a dial gauge on the camshaft, and lift

the camshaft 0.20 mm.

4. Press lightly on the upper edge of the shell

to turn the shell up over the camshaft.

Remove the shell from the camshaft hous-

ing.

M90604
0225D03
4.
M90604
0225D04

When referring to this page, please quote Procedure M90604 Edition 0225 Page 3 (5)
906-4.3 Camshaft Bearing
Overhaul MAN B&W Diesel

1. For assessment of the bearing condition,

1. see Volume I OPERATION, Chapter 708
‘Bearings’.

Inspect the entire surface of the bearing

journal for seizures.

If seizures are found on the bearing journal

surface (on account of bearing breakdown),
polish the surface with a fine carborundum
stone to re
establish a bright and smooth
D06
34 surface.
D06
65
By closely examining the sliding surface
M90604
0225O01

of the bearing shell visually, an impression

can be formed of whether the lubrication of
the bearing surface has been insufficient or
entirely missing. Normally, camshaft bear-
ing damage only occurs due to faulty lubri-
cation.

Measure the thickness of the bearing shell

with a micrometer to check the amount of
wear.

Page 4 (5) When referring to this page, please quote Procedure M90604 Edition 0225
 Camshaft Bearing 906-4.4
MAN B&W Diesel Mounting

1. Clean the bearing journal, the bearing sup-

port and the bearing shell. 1.

2. Coat the bearing journal and the bearing

shell with plenty of lubricating oil. Mount
the shell on the camshaft, and turn it into
place.

Relieve the hydraulic jack of pressure

to lower the camshaft. Remove the dial
gauge, the pieces of wood and the hydrau-
lic jack from the camshaft housing.

M90604
0225M01
3. Place the bearing cap on the camshaft and
mount the outermost bearing cap screw.

Note!
Be careful not to scratch the camshaft
surface. 2.

Tighten the outermost screw lightly by

hand until the clearance given in D06
33 D06
31
is reached. Then mount and tighten the in-
nermost screw with a torque spanner. See
Data D06
31. This procedure ensures that
the outermost screw will obtain the correct
torque.

Check the torque on the outermost screw D06
33

with a torque spanner.
M90604
0225M02

Check the clearance D06
33 on both sides

of the camshaft. Then mount the lubricating
oil pipe and the plug screws in the base-
plate.
3.
4. Lower the exhaust valve actuator roller
guide. See Procedure 908-7.

5. Clean the camshaft housing and mount the

inspection covers.
M90604
0225M03

When referring to this page, please quote Procedure M90604 Edition 0225 Page 5 (5)
 Moment Compensator 906-5.1
MAN B&W Checking

If dismantling has been necessary, the fly-

weights must be assembled in the correct 1.
&ORæçCYLINDERæENGINES
position in relation to the engine crankshaft. In- VIEWEDæFROMæ!&4
correctly mounted flyweights can cause (heavy)
vibrations of the engine.

Note!
The following applies to a clockwise-ro-
tating engine

Aftmost 2nd Order Moment Compensator 

ª

Turn the crankthrow of cylinder No. 1 in the

-ç#
ahead direction to the position shown in the
figures for 4, 5, 6-cylinder engines, respec-
tively.

Check that the flyweights point vertically down- #YLINDERæ.O

wards (max. deviation one-half chainwheel
tooth pitch). 2.
&ORæçCYLINDERæENGINES
VIEWEDæFROMæ!&4
Tighten the chain in accordance with the in-
struction.
See Procedure 906-2.3.

Note!
For an anticlockwise-rotating engine,
the degrees mentioned in the respective
figures must be before tdc, not after 
ª
tdc.
-ç#

#YLINDERæ.O

3.
&ORæçCYLINDERæENGINES
VIEWEDæFROMæ!&4


ª
-ç#

#YLINDERæ.O

When referring to this page, please quote Procedure M90605 Edition 0226 Page 1 (1)
 Replacement of Cams on Camshaft 106-6
Data

SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10606
106-6 Data 0007 Replacement of Cams on Camshaft

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D06-47 Exhaust cam screws, tightening torque 560 Nm

D06-48 Indicator cam screws, tightening torque 50 Nm
D06-49 Fuel cam screws, tightening torque 880 Nm
D06-50 Fuel cam, marking scratch 65 mm
D06-51 Fuel cam, axial movement 145 mm
D06-52 Exhaust cam, marking scratch 55 mm
D06-53 Exhaust cam, axial movement 220 mm

When referring to this page, please quote Data D10606 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
106-6 Replacement of Cams on Camshaft
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

P91351 22 Hydraulic pump, hand operated

P91351 58 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete
P91359 Torque spanners

Page 2 (2) When referring to this page, please quote Data D10606 Edition 0007
MAN B&W Diesel A/S
 Replacement of Cams on Camshaft 906-6.2
Dismantling
Replacement of Cams on Camshaft
S42MC
0203
Dismantling
906-6.2

1.
Fuel Cam

1. Remove the front cover of the camshaft

housing.

2. Lift the roller guide from the cam in ques-

tion. See Procedures 908-5 or 909-5.

3. Turn the camshaft so that the marking

scratch can be seen.

4. Extend the marking scratch on the shaft by

D06-50. See Data.

XZ906-6.2 201 01
XZ906-6.2 201 02 2.

4.
XZ906-6.2 201 04

D06-50

When referring to this page, please quote Procedure M90606 Edition 0203 Page 1 (7)
0$1% :'LHVHO$6
906-6.2 Replacement of Cams on Camshaft
Dismantling

5. 5. Remove the plug from the cam and mount

gaskets and snap-on connectors instead.

6. Connect the snap-on connectors to the hy-

draulic high-pressure pump.

Apply oil pressure to the cam, using the

high-pressure pump.

When oil seeps out along the cam, press

the cam sideways, in the direction towards
the forward end of the engine.

7. The cam should be moved as stated in

XZ906-6.2 201 05

D06-51 to be sure that it gets free of the lin-

er for the roller guide.

8. In case the cam cannot be moved as de-

6. scribed in item 6, MAN B&W should be con-
tacted for further instructions.
XZ906-6.2 201 06

7.

D06-51
XZ906-6.2 201 07

D06-51

Page 2 (7) When referring to this page, please quote Procedure M90606 Edition 0203
0$1% :'LHVHO$6
 Replacement of Cams on Camshaft 906-6.2
Dismantling

Exhaust Cam 9.

9. Remove the front cover of the camshaft

housing.

10. Lift the roller guide from the cam in ques-

tion. See Procedure 908-5.

11. Extend the marking scratch on the indicator

drive cam onto the camshaft.

Extend the marking scratch on the exhaust

cam onto the camshaft by D06-52. See Da-
ta.

XZ906-6.2 201 01
XZ906-6.2 201 10 10.

11.
XZ906-6.2 201 11

D06-52

When referring to this page, please quote Procedure M90606 Edition 0203 Page 3 (7)
0$1% :'LHVHO$6
906-6.2 Replacement of Cams on Camshaft
Dismantling

12. 12. Dismantle and remove the indicator drive

cam from the camshaft when fitted.

13. Remove the plug from the cam and mount

gaskets and snap-on connectors instead.

14. Connect the snap-on connectors to the hy-

draulic high-pressure pump.

Apply oil pressure to the cam, using the

high-pressure pump.

When oil seeps out along the cam, press

the cam sideways, in the direction towards
XZ906-6.2 201 12

the aft end of the engine.

13.
XZ906-6.2 201 13

14.
XZ906-6.2 201 14

Page 4 (7) When referring to this page, please quote Procedure M90606 Edition 0203
0$1% :'LHVHO$6
 Replacement of Cams on Camshaft 906-6.2
Dismantling

15. The cam should be moved as stated in 15.

D06-53 to be sure that it gets free of the lin-
er for the roller guide.

16. In the event that the cam cannot be moved

as described in item 14, MAN B&W should
be contacted for further instructions.

D06-53

D06-53
XZ906-6.2 201 15

When referring to this page, please quote Procedure M90606 Edition 0203 Page 5 (7)
0$1% :'LHVHO$6
906-6.4 Replacement of Cams on Camshaft
Mounting
Mounting
906-6.4

1. Fuel Cam

1. Before mounting the two-part spare cam,

the bore and the area on the shaft must be
degreased.

Place the two-part spare cam on the shaft,

mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.

2. Make sure that the marking scratches on

the cam and the camshaft coincide, and
that the running surface of the cam is op-
posite the roller.

Tighten the screws just hard enough to

avoid that the cam slips when the roller
guide is lowered onto the cam.

Measure the fuel cam lead (see Procedures

909-1 and 909-2) and adjust if necessary.
XZ906-6.4 201 01

Tighten the screws to D06-49 and check

that the gap is still equal at both sides.

Lock the screws with Loctite, type 242

2. (EN243S).

3. Mount the cover on the front of the cam-

shaft housing.

D06-49
XZ906-6.4 201 02

Page 6 (7) When referring to this page, please quote Procedure M90606 Edition 0203
0$1% :'LHVHO$6
 Replacement of Cams on Camshaft 906-6.4
Mounting

Exhaust Cam 4.

4. Mount the indicator drive cam and adjust

according to Chapter 706 in the Operation
manual when fitted.

Tighten the self-locking nuts as stated in

D06-48.

5. Before mounting the two-part spare cam,

the bore and the area on the shaft must be
degreased.

Place the two-part spare cam on the shaft,

XZ906-6.4 201 04
mount the four screws, and tighten slightly,
so that the gap between the two parts is
equal at both sides.

6. Make sure that the marking scratches on 5.

the cam and the camshaft coincide, and
that the running surface of the cam is op-
posite the roller.

Tighten the screws just hard enough to

avoid that the cam slips when the roller
guide is lowered onto the cam.

Measure the fuel cam lead (see Procedure

908-7) and adjust if necessary.

Tighten the screws to D06-47 and check

that the gap is still equal at both sides.
XZ906-6.4 201 05

Lock the screws with Loctite, type 242

(EN243S).

7. Mount the cover on the front of the cam- 6.

shaft housing.
XZ906-6.4 201 06

D06-47
D06-49

When referring to this page, please quote Procedure M90606 Edition 0203 Page 7 (7)
0$1% :'LHVHO$6
 Chain Drive and Camshaft Panel Plate
P90651-0173

When referring to this page, please quote Plate P90651 Edition 0173 Page 1 (2)
MAN B&W Diesel A/S
Plate Chain Drive and Camshaft Panel
P90651-0173

Item Item Description Item Item Description

No. No.

019 Panel for tools

020 Name plate
044 Impact spanner, fuel cam
056 Assembling tool, chain
068 Disassembling tool, chain
152 Hydraulic jack, lift of camshaft

Page 2 (2) When referring to this page, please quote Plate P90651 Edition 0173
MAN B&W Diesel A/S
 Camshaft - Hydraulic Tools Plate
P90662-0046

When referring to this page, please quote Plate P90662 Edition 0046 Page 1 (2)
MAN B&W Diesel A/S
Plate Camshaft - Hydraulic Tools
P90662-0046

Item Item Description Item Item Description

No. No.

020 Jack - hydraulic, complete

032 Support
044 Tommy bar
056 Sealing ring with back-up ring
068 Sealing ring with back-up ring
093 Spanner
103 Stud setter
211 Hydraulic tool set, complete

Page 2 (2) When referring to this page, please quote Plate P90662 Edition 0046
MAN B&W Diesel A/S
 Crankshaft - Pin Gauge Plate
P90664-0005
Crankshaft - Pin Gauge
0005
P90664

When referring to this page, please quote Plate P90664 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
Plate Crankshaft - Pin Gauge
P90664-0005

Item Item
Item Description Item Description
No. No.

021 Pin gauge for crankshaft

Page 2 (2) When referring to this page, please quote Plate P90664 Edition 0005
MAN B&W Diesel A/S
 Camshaft - Pin Gauge Plate
P90668-0003
Camshaft - Pin Gauge
0003
P90668

When referring to this page, please quote Plate P90668 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Camshaft - Pin Gauge
P90668-0003

Item Item
Item Description Item Description
No. No.

011 Pin gauge for camshaft

Page 2 (2) When referring to this page, please quote Plate P90668 Edition 0003
MAN B&W Diesel A/S
 Starting Air Distributor 107-1
Data

SAFETY PRECAUTIONS
Special Edition
S46MC-C
D10701
107-1 Data 0017 Starting Air Distributor

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D07-01 Gear wheel on camshaft, tightening torque 90 Nm

D07-03 Clearance between gear wheel and bushing: 0.9 - 1.6 mm
D07-04 Clearance with roller in outermost position: 1.0 - 3.0 mm
D07-05 Clearance with roller in innermost position: 1.0 - 2.0 mm

When referring to this page, please quote Data D10701 Edition 0017 Page 1 (2)
MAN B&W Diesel A/S
107-1 Starting Air Distributor
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 D10701 Edition 0017
MAN B&W Diesel A/S
 Starting Air Distributor 907-1.1
Checking
Starting Air Distributor
S46MCC
0216
Checking
907-1.1

1.
1. Turn the engine in AHEAD direction to bring
the piston of cylinder No. 1 to TDC.

Check with the pin gauge.

2. Remove the plug screw and gasket from the

side of the distributor housing, and insert
check pin K in slot S.

GN906-3.1 203 02
If pin K is not available, use the cylindrical
end of a drill of a suitable size.

3. If the check pin cannot enter the slot, i.e. if

the slot is not aligned with the hole in the
2.
distributor housing, the air distributor must
be adjusted.
See Procedure 907-1.3.
S

K S
EN907-1.3 204 02

When referring to this page, please quote Procedure M90701 Edition 0216 Page 1 (3)
0$1% :'LHVHO$6
907-1.3 Starting Air Distributor
Adjustment
Adjustment
907-1.3

1. 1. Turn the engine in AHEAD direction to bring

the piston of cylinder 1 to TDC.

Check with the pin gauge.

2. Dismount the end cover of the camshaft

housing, along with the starting air distrib-
utor, from the engine.
GN906-3.1 203 02

Remove the plug screw and gasket from the

side of the distributor housing, and insert
check pin K in slot S.

Turn the shaft together with the distributor

2. disc until check pin K enters slot S in the
disc and keep it there.

S 3. Check and, if necessary, adjust clearance

D07-03 between the gear wheel and the
bushing.

K S
EN907-1.3 204 02

3.
GN907-1.3 203 03

D07-03

Page 2 (3) When referring to this page, please quote Procedure M90701 Edition 0216
0$1% :'LHVHO$6
 Starting Air Distributor 907-1.3
Adjustment

4. Remove the lower half of the gearwheel 4.

drive cover. Mount the upper half of the
gearwheel drive cover with the complete
starting air distributor after loosening the
gear wheel on the camshaft, and then en-
gage the two gear wheels by turning the
wheel on the camshaft.

Tighten and lock the gear wheel screws on

the camshaft, see Data, D07-01.

Mount the lower half of the gearwheel drive

cover.

5. Remove check pin K from the distributor

housing and mount the gasket and plug
screw. D07-01
6. Check the clearance between the roller and GN907-1.3 203 02

the two interlocking valves with the roller in

its innermost and outermost positions, re-
spectively ( ASTERN and AHEAD).
5.
K
S
GN907-1.3 203 02

6.

D07-01
EN907-1.3 204 06

D07-04

When referring to this page, please quote Procedure M90701 Edition 0216 Page 3 (3)
0$1% :'LHVHO$6
 Starting Air Valve 107-2
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
Shut off cooling water
Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D07-09 Piston tightening torque 180 Nm

D07-10 Valve tightening torque 175±20 Nm
D07-11 Valve tightening angle 50/30 °
D07-12 Starting air valve 24 kg

When referring to this page, please quote Data D10702 Edition 0042 Page 1 (2)
MAN B&W Diesel A/S
107-2 Starting Air 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 095 Grinding ring for starting valve

P90151 105 Grinding handle for starting valve
P91359 Torque Spanners

Page 2 (2) When referring to this page, please quote Data D10702 Edition 0042
MAN B&W Diesel A/S
 Starting Air Valve 907-2.2
MAN B&W Diesel Dismantling

1. Shut off the starting air and control air in-

let. 1.

Dismount the control air pipes.

Unscrew the fixing nuts of the starting

valve flange.

2. Pull the starting air valve out of the cylinder

cover and remove it from the engine.

M90702-0219D01
2.

D07-12
M90702-0219D02

When referring to this page, please quote Procedure M90702 Edition 0219 Page 1 (5)
907-2.3 Starting Air Valve
Overhaul MAN B&W Diesel

1. Remove the top cover fixing screws and re-

1. move the cover.

Remove and discard the gasket.

2. Screw off the valve spindle nut and remove

the valve spindle from the valve housing.

Take out the piston, distance pipe, valve

spring, and the liner.

Remove and discard the O-ring.

M90702-0219O01

2.
M90702-0219O02

Page 2 (5) When referring to this page, please quote Procedure M90702 Edition 0219
 Starting Air Valve 907-2.3
MAN B&W Diesel Overhaul

3. Grind the valve housing seating with the

grinding ring after applying grinding paste. 3.
Carborundum No. 200.

Grind the seatings of the spindle and hous-

ing to match, using the face wrench to ro-
tate the valve spindle.
Carborundum No. 500.

4. Thoroughly clean all parts before reassem-

bling the valve.
CARBORUNDUM
No. 200
Lubricate all internal parts (sliding surfaces)
with, for instance, Molybdenum Disulphide,
MoS2.

5. First mount the liner in the valve housing,

then the valve spindle, the distance pipe,
the spring and the piston. M90702-0219O03

CARBORUNDUM
No. 500

5.
M90702-0219O05

When referring to this page, please quote Procedure M90702 Edition 0219 Page 3 (5)
907-2.3 Starting Air Valve
Overhaul MAN B&W Diesel

6. Mount the nut on the valve spindle and

6. tighten the nut, see D07-09.
D07-09
7. Place a new gasket on the valve housing.

Mount and tighten the top cover.

Replace the O-ring on the valve housing.

8. If the starting air valve is not to be mount-

ed in the engine immediately after the
overhaul, all openings of the valve should
be covered with plastic to prevent dirt from
entering the valve during storage.
M90702-0219O06

7.
M90702-0219O07

Page 4 (5) When referring to this page, please quote Procedure M90702 Edition 0219
 Starting Air Valve 907-2.4
MAN B&W Diesel Mounting

1. Carefully clean the starting valve bore in

the cylinder cover and, if necessary, recon- 1.
dition the seat for the starting valve in the
bore.
See Procedure 901-1.3.

If not already done, replace the O-ring on

the overhauled valve and lubricate with
Neverseize or Molybdenum Disulphide,
MoS2.
For overhaul, see Procedure 907-2.3.

2. Mount the valve in the cylinder cover.

M90702-0219M01
3. Mount the nuts and tighten-up either to
specified torque or to specified torque and
angle, not both.
See Data D07-10 or D07-11.

Mount the control air pipes and turn on 2.

starting air and control air.

D07-12
M90702-0219M02

3.
D07-10
or
D07-11
M90702-0219M03

When referring to this page, please quote Procedure M90702 Edition 0219 Page 5 (5)
 High-Pressure Pipe 108-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0017
108-1 High-Pressure Pipe

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
10-120 Nm
Shut off cooling water
Shut off fuel oil
X Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Weight of high-pressure pipe 34 kg

D-2 Tightening torque –

High-pressure pipe 36 Nm

When referring to this page, please quote Data D10801 Edition 0017 Page 1 (2)
MAN B&W Diesel A/S
108-1 High-Pressure Pipe
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D10801 Edition 0017
MAN B&W Diesel A/S
 High-Pressure Pipe 908-1.2
Dismantling
High-Pressure Pipe
S50MC-C
0212
Dismantling
908-1.2

1.
1. When replacing the hydraulic high-pressure
pipe, exhaust valve or hydraulic actuator,
check the high-pressure pipe sealing sur-
faces.

2. Before dismounting the high-pressure pipe,

stop the camshaft oil pump.

Loosen the screws for the high-pressure

pipe and lift the pipe slightly away from the
actuator to let the oil in the pipe drain
through the drain holes in the actuator. D-1
3. Remove the screws in both ends of the
high-pressure pipe. Lift the high-pressure
pipe away from the engine.

GN908-1.2 203 01

2.
GN908-1.2 203 02

When referring to this page, please quote Procedure M90801 Edition 0212 Page 1 (3)
0$1% :'LHVHO$6
908-1.3 High-Pressure Pipe
Overhaul
Overhaul
908-1.3

1. The two ends of the pipe are identical and

should both be overhauled as follows:

1. Remove the thrust piece from the actuator/

exhaust valve.

Remove and discard the O-rings from the

thrust piece and the thrust flange.

Clean and inspect the conical seats of the

high-pressure pipe and the thrust piece.

Note!
GN908-1.3 203 01

The seats cannot be reconditioned.

If a seat is damaged, the thrust piece/
high-pressure pipe must be replaced.
2.
2. To change the internal O-ring, proceed as
follows:

Lift the thrust flange upwards.

Remove the spring ring from the two-part

sleeve.

3. Remove the thrust flange from the pipe

end.

Remove and discard the internal O-rings.

DM908-1.1 61 02

Mount new internal O-rings lubricated with

a little camshaft lubricating oil.

4. Assemble the high-pressure pipe in the re-

3. verse order to disassembling.
DM908-1.1 61 03

Page 2 (3) When referring to this page, please quote Procedure M90801 Edition 0212
0$1% :'LHVHO$6
 High-Pressure Pipe 908-1.4
Mounting
Mounting
908-1.4

1. Mount new O-rings, lubricated with a little 1.

camshaft lubricating oil, on the thrust piec-
es and thrust flanges.

Mount the thrust pieces on the actuator/ex-

haust valve.

Mount the high-pressure pipe on the en-

gine.

Note!

When mounting the high-pressure pipe,

take care not to damage the conical
seats of the pipe/thrust pieces.

2. After fitting the pipe to the exhaust valve

and actuator, tighten up the screws of the
pressure flanges diagonally, see Data.

3. Check the system for tightness.

GN908-1.2 203 01

2.

D-2
GN908-1.4 203 02

When referring to this page, please quote Procedure M90801 Edition 0212 Page 3 (3)
0$1% :'LHVHO$6
 Exhaust Valve 108-2
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
X Engage turning gear
X Shut off cooling water
Shut off fuel oil
X Stop lubricating oil supply
X Lock the turbocharger rotors

Data

Ref. Description Value Unit

D08-04 Safety valve, opening pressure 23 bar

D08-05 Screws for lifting eye bolt, tightening torque 50 Nm
D08-06 Oil cylinder, tightening torque 70 Nm
D08-07 Safety valve, tightening torque 50 - 80 Nm
D08-09 Bottom piece seat, grinding angle 29.9 - 30.0 °
D08-10 Valve spindle seat, grinding angle 30.5 - 30.6 °
D08-11 Bottom piece seat, max. grinding 2.3 mm
D08-12 Gap of bottom piece seat 1.0 mm
D08-13 Spindle, max. burn-off 8.0 mm
D08-14 Spindle, max. grinding 2.0 mm
D08-15 Spindle stem, measuring area, min. 235 mm
D08-16 Spindle stem, measuring area, max. 345 mm
D08-17 Spindle stem, min. diameter 59.8 mm
D08-18 Bushing max. diameter, top 60.6 mm
D08-19 Bushing max. diameter, bottom 62.0 mm
D08-20 Oil cylinder max. inside diameter 71.2 mm
D08-21 Piston rings, min. thickness 2.6 mm
D08-24 Exhaust valve, complete 460 kg
D08-25 Exhaust valve housing 260 kg
D08-26 Oil cylinder 65 kg
D08-27 Air cylinder 20 kg
D08-28 Spindle 45 kg
D08-29 Bottom piece 55 kg
D08-30 Air piston 6 kg

D13-01 Hydraulic pressure, mounting 1500 bar

D13-02 Hydraulic pressure, dismantling 1400-1650 bar

When referring to this page, please quote Data D10802 Edition 0095 Page 1 (2)
108-2 Exhaust 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

P90851 065 Lifting tool for exhaust valve

P90851 077 Cone ring for pneumatic piston
P90851 089 Pressure tester for safety valve
P90851 090 Gauge for exhaust valve spindle
P90851 150 Gauge for exhaust valve bottom piece
P90851 161 Lifting tool for exhaust valve spindle
P90851 185 Grinding ring for exhaust valve bottom piece

P90862 Exhaust Valve - Hydraulic Tools

P91351 010 Hydraulic pump, pneumatically operated

P91351 034 Hose with unions (1000 mm), complete
P91351 058 Hose with unions (3000 mm), complete
P91351 117 5-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D10802 Edition 0095
 Exhaust Valve 908-2.1
MAN B&W Checking

Checks during running:

1.
1. Check of valve spindle rotation

The engine must run when the valve func-

tion and spindle rotation are checked. Lift
the valve spindle rotation indicator, turn it
90° and let it rest on the air piston.

The indicator will now follow the move-

ments of the valve spindle and the air pis-
ton. During rotation of the valve spindle,
the top position of the indicator will change
about 6 mm, because of the groove in the

M90802
0252C01
piston.

During engine operation, the spindle must

On Surface InGroove
rotate. The rotation can vary with unit and
engine load. In the event of no rotation, at-
tention should be paid to avoid seat prob- 2.
lems. When check of the valve rotation is
finished, lift the rotation indicator and lock
it in the top position.

The indicator must not be in constant op-

eration.

Exhaust valve performance condition

See volume I chapter 706 Performance
Evaluation

2. Check of bottom piece sealings

M90802
0254C03

With the exhaust valve mounted in the cyl-

inder cover, check the cooling water inlet
and outlet to the cylinder cover and ex-
haust valve is open.

Check the tightness of the sealing rings

between the bottom piece and the exhaust
valve housing. IF water flows from the small
bore on the manoeuvring side of the ex-
haust valve, the lowermost sealing ring is
leaking.

If water flows from the any of the rings, the

exhaust valve must be dismounted and the
sealing rings replaced.

When referring to this page, please quote Procedure M90802 Edition 0273 Page 1 (23)
908-2.1 Exhaust Valve
Checking MAN B&W

Check with stopped engine:

3.
In connection with port stays, at an interval
of e.g. one month, an easy check of all ex-
haust valves is recommended.

3. Check of spindle drop
down time:

Engage all rotation indicators on the ex-

haust valves.

Shut off and release the spring air on the

valve, next to the engine
side manoeuvring

stand.

Check the drop down time for all spindles:

• Spindles dropping down within 30 min-

utes: Check and overhaul, See next step
“Check of Air Spring tightness”.

• Spindles dropping down between 30

M90802
0273C03

minutes and 1 hour: Keep under obser-

vation.

• Spindles dropping down after 1 hour:

OK.

When check of drop down time is finished,

lift the rotation indicators and lock them in
the top position.

Page 2 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.1
MAN B&W Checking

4. Check of Air spring tightness

4.
Connect compressed air to the non return
(A) valve on the air cylinder.

Disconnect and remove the drain oil pipe

from the oil cylinder (C).

Check if air is coming out from:

B A
• The bore (B): Leakage from spindle
stem sealing , change and overhaul.

• Hole for drain oil (C): If yes, the leakage

comes from the safety valve or the air
piston. Check the safety valve (D). If air
still is coming out, the leakage comes
from the air piston: change and over-
haul.

• Remove the air supply to the non
return

valve on the air cylinder and check the
non
return valve for tightness.
D A
The checks is for guidance only, minor
leaks is difficult to detect.

D
C

C
M90802
0273C04

When referring to this page, please quote Procedure M90802 Edition 0273 Page 3 (23)
908-2.2 Exhaust Valve
Dismantling MAN B&W

1. Close off cooling water

1.
Close the cooling water inlet and outlet
connections, and drain the exhaust valve.

Close the air supply to the exhaust valve.

2. Dismount the oil pipe connections

Dismount the high
pressure pipe for the hy-

draulic valve actuation.
See Procedure 908
1.2

Dismount the return oil pipe from the ex-

haust valve.
M90802
0273D01

2.
M90802
0273D02

Page 4 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.2
MAN B&W Dismantling

3. Disconnect pipe connections

3.
Disconnect the cooling water connections
from the exhaust valve and the air pipe for
the air spring.

Remove the plate jacket and insulation

from the intermediate pipe.

Loosen the screws which attach the inter-

mediate pipe to the exhaust valve housing.

Support the intermediate pipe by e.g. a

chain block and remove the screws.

M90802
0273D03
4. Dismantling of hydraulic nuts.

Remove the protective caps from the ex-

haust valve studs.
4.
Loosen and remove the hydraulic nuts, see
Data. See Procedure 913
1.
D13
02
M90802
0273D04

When referring to this page, please quote Procedure M90802 Edition 0273 Page 5 (23)
908-2.2 Exhaust Valve
Dismantling MAN B&W

5. Lift of exhaust valve

5.
Check all connections to the valve are re-
D08
24 moved.

Attach the crane to the eye bolt fitted on

top of the valve and start lifting the exhaust
valve. During the lift
check the valve goes
clear of all other engine components.

Land the exhaust valve on a wooden plate

on the platform.

Carefully clean the exhaust valve bore in

the cylinder cover and recondition the seat-
ing and sealing surfaces of the bore, if re-
quired.

See Procedure 901
1.3.

For overhaul of the exhaust valve, see Pro-

cedure 908
2.3
M90802
0273D05

Page 6 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.3
MAN B&W Overhaul

1. Oil cylinder
1.
Place the exhaust valve on a wooden sup-
port on the platform.

Remove the nuts and the safety strap from

the oil cylinder.
D08
26
Lift away and place the oil cylinder on a
wooden support.

2. Conical locking ring

Relieve the air pressure through the

non
return valve from below the piston. Use
a small screwdriver to press the ball into
the non
return valve. Cover the non
return
valve with a rag to catch the oil drops.

Unscrew the non-return valve from the air

cylinder.
M90802
0273O01

Remove the four screws from the flange

on top of the air piston and dismount the
flange.

Loosen the air piston from the conical lock-

ing ring by means of a tin hammer, and re-
move the conical locking ring. 2.
M90802
0273O02

When referring to this page, please quote Procedure M90802 Edition 0273 Page 7 (23)
908-2.3 Exhaust Valve
Overhaul MAN B&W

3. Spindle
3.
Use the oil cylinder as a lifting tool for the
exhaust valve housing. Lift the oil cylinder
with the crane, and guide it down over the
studs for the oil cylinder. Mount four nuts
D08
24 so that the load from the valve housing is
evenly distributed.

Lift the valve housing clear of the valve

spindle. Take care – when the internal
O
ring in the air piston and the internal
rings for the sealing arrangement at the
bottom of the air cylinder pass the groove
for the conical ring at the top of the spin-
dle.

4. Bottom piece

Unscrew and remove the lock screws

which retain the bottom piece. Lift the
valve housing approx. 10 mm.
M90802
0273O03

If the bottom piece has become stuck, use

a tin hammer to release it.

Lift the valve housing away and land it on a

couple of wooden planks.
4.
Remove the oil cylinder.

D08
29
M90802
0273O04

Page 8 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.3
MAN B&W Overhaul

5. Air piston and cylinder

5.
Dismount the air piston from the air cylin- D08-30
der.

Mount two eye bolts in the air cylinder and

dismount the air cylinder.
D08-27
Remove and discard the O
ring on the air
cylinder.

6. Guide bushing

Clean the exhaust valve housing.

M90802
0273O05
Inspect the bushing in the spindle guide for
wear and measure the top and bottom di-
ameters. See Data.

6.

D08
18
M90802
0255O10

D08
19

When referring to this page, please quote Procedure M90802 Edition 0273 Page 9 (23)
908-2.3 Exhaust Valve
Overhaul MAN B&W

7. Bushing renewal
7.
If it proves necessary to replace the bush-
ing, remove the screws and knock out the
bushing with a hammer and a suitable
mandrel.

Alternatively, if the extractor tool is avail-

able, mount the extractor tool and pull up
the bushing.

The extractor tool is optional, and can be

ordered as spare part.

When a new bushing is mounted, mount

a new O
ring for sealing between bush-
ing and exhaust valve housing. Mount and
tighten the screws for the bushing.

8. Bottom piece inspection

Before cleaning the bottom piece, See Vol-

M90802
0256O08

ume I, supplement 707
03

Inspect and evaluate the seating according

to Volume I.

8.
M90802
0256O09

Page 10 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.3
MAN B&W Overhaul

9. Bottom piece Measuring

9.
In connection with evaluation of the bottom
piece according to Volume I, wear or the
total amount the seat has been ground, is
measured as described below.
G3
Use the bottom piece template and a feeler D08
12
gauge, take measurements G2 and G3. All
measurements should be taken at four dia-
metrically opposite points on the circumfer-
ence of the bottom piece seating.

For maximum wear or grinding, see Data

D08
11 and D08
12.
D08
09
If the seat or the recess G3 is ground, see
Data D08 – 09 for correct grinding angle.

IF the template rests on the lower surface

in the groove, i.e. G2 = 0, THEN Further
grinding or reconditioning is not recom- G2
mended.
M90802
0255O14

D08
11
10. Bottom piece sealing face

If necessary grind the outside seating.

Use carborundum 200 and the special 10.

grinding tool. Turn the special grinding tool
by hand, turning alternately clockwise and
anticlockwise. Grind until a smooth surface
is achieved.

Clean the bottom piece.

M90802
0255O15

When referring to this page, please quote Procedure M90802 Edition 0273 Page 11 (23)
908-2.3 Exhaust Valve
Overhaul MAN B&W

11. Bottom piece sealing rings

11.
Mount new sealing rings on the bottom
piece.

Mount one O
ring in the upper groove.

Make sure that the groove for the U
seal is

clean.

Heat the U
seal in 100°C hot water for min-

imum five minutes and then mount it in the
groove immediately.
M90802
0256O12

12. Bottom piece mounting

Use the oil cylinder as a lifting tool for the

exhaust valve housing.

12. Check the face on the valve housing is

clean.

If fitted, check that the guide pin in the

bottom piece enters the hole in the bottom
of the exhaust valve housing.

Land the exhaust valve housing on the bot-

tom piece. Mount and tighten the retaining
screws for the bottom piece.
M90802
0273O12

Page 12 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.3
MAN B&W Overhaul

13. Spindle inspection

13.
Before cleaning the spindle, See Volume I,
supplement 707
03

Inspect and evaluate the spindle according

to Volume I.

14. Spindle burn
off and grinding check

In connection with evaluation of the spindle

according to Volume I, burn
off and wear or
the total amount the seat has been ground,
are measured as described below.

M90802
0256O14
The burn
off F1 of the valve spindle is
checked by measuring along the spindle
template from point A to point D and in
point E.
14.
For the maximum allowable burn
off, see G1
Data D08
13.

The maximum seat grinding, gap G1 is

measured between the spindle template,
and the seating of the spindle with a feeler
gauge. D08
14

For maximum seat grinding, see data D08

– 14. F
1
If necessary to grind the seat, see Data D08
10
M90802
0256O15

D08
10 for correct grinding angle.

A
D08
13 D E

When referring to this page, please quote Procedure M90802 Edition 0273 Page 13 (23)
908-2.3 Exhaust Valve
Overhaul MAN B&W

15. Spindle stem check

15.
In connection with evaluation of the spindle
according to Volume I, the spindle stem
wear is measured as described below.
D08
16 D08
15
Check the spindle stem for wear in the
area D08
15 to D08
16 measured from the
top of the spindle.
D08
17
For minimum stem diameter, see data D08

17.

If the exhaust valve spindle needs recondi-

tioning, contact MAN Diesel for advice.

16. Spindle transport

When lifting or transporting the exhaust

valve spindle, use the special valve spindle
lifting tool.
M90802
0252O19

16.

D08
28
M90802
0255O16

Page 14 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.3
MAN B&W Overhaul

17. Spindle bushing sealing
rings

17.
Check the top of the spindle bushing and
the face on the housing is clean.

Fit new o
rings on the spindle bushing as

shown in the sketch.

18. Spindle mounting

Lubricate the inside of the bushing in the

spindle guide with plenty of lubricating oil.

Use the oil cylinder as a lifting tool for the

M90802
0256O18
exhaust valve housing.

Carefully land the exhaust valve housing

with the bottom piece on the exhaust valve
spindle.
18.
Remove the oil cylinder.
M90802
0273O18

When referring to this page, please quote Procedure M90802 Edition 0273 Page 15 (23)
908-2.3 Exhaust Valve
Overhaul MAN B&W

19. Air cylinder

19.
Clean the air cylinder.

Dismount the safety valve from the air cyl-

inder, use the machined faces to unscrew
the valve.

Unscrew the plug for the bore to the spin-

dle stem bushing. Blow through all bores
in the air cylinder. Clean the bottom of the
air cylinder for possible coke deposits. Re-
mount the plug. Mount a new O
ring in the
Compressed Air groove on the outside of the air cylinder.

20. Safety valve

Place the safety valve in the pressure test-

ing device. Connect the testing device with
the high pressure pump by means of a
hose.
M90802
0256O20

Check the opening pressure, see Data.

If the opening pressure is not correct, loos-

en the lock nut and, using a screwdriver,
adjust the safety valve until the correct
pressure is indicated. Tighten the lock nut
20. and test the opening pressure once more.

Mount a new gasket and a new O
ring on

the safety valve. Mount the safety valve in
the bore near the bottom of the air cylinder.
When mounting the safety valve in the air
D08-04 cylinder, use only the machined faces on
the valve housing and tighten, see Data.

Finally, mount the protective cap.

M90802
0256O21

D08-07

Page 16 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.3
MAN B&W Overhaul

21. Air cylinder mounting

21.
Lubricate the O
rings on the spindle bush-
ing.

Carefully land the air cylinder on the ex-

haust valve housing and check correct en-
gaging with the locating pin. Some engines
are not equipped with the locating pin.

Note!
Take care not to damage the O
rings on
the outside of the spindle bushing.

M90802
0256O22
22. Air piston seals

Check the teflon guide ring and teflon seal-

ing ring for wear, if it is necessary to re- 22.
place the sealing rings on the air piston, cut
them and remove them.

Be careful not to damage the edges of the

ring grooves in the piston.

Note!
Before mounting, heat the new teflon
rings in 100°C hot water for at least five
minutes. When mounting the teflon rings,
M90802
0252O32

be careful not to damage the running

surfaces.

After mounting, compress the teflon rings

by means of the conical ring from tool
panel 908. This is done by pressing the air
piston through the conical ring.

Mount new O
rings in the inside grooves of

the air piston.

When referring to this page, please quote Procedure M90802 Edition 0273 Page 17 (23)
908-2.3 Exhaust Valve
Overhaul MAN B&W

23. Air piston mounting

23.
IMPORTANT!
Fill the bottom of the air cylinder up to
the drain hole with clean lubricating oil.
Clean oil
Fit the conical guide ring for the air piston
Oil level on the air cylinder. Lubricate the guide ring
and the running surface of the air cylinder.
Lower the air piston over the valve spindle
down into the air cylinder.

Use a nylon block and a hammer to press

the air piston down in the cylinder

Remove the conical guide ring from the air

cylinder.

Mount the non return valve for spring air

24. Locking ring

M90802
0273O23

Mount the two part conical locking ring and

apply compressed air below the air piston
to lift the piston.

Mount the flange on top of the air piston

24. and, by means of the four screws, tighten
the air piston and the flange together.

On valve models where the bolts are de-

signed for securing, secure the bolts. See
Procedure 913
7.

Compressed Air
M90802
0273O24

Page 18 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.3
MAN B&W Overhaul

25. Oil cylinder

25.
Loosen the screws and remove the lifting
bracket from the oil cylinder to gain access
to the orifice plug.

Remove and discard the gasket. Unscrew

and clean the orifice plug. Remove and dis-
card the sealing disc. Check and clean the
bore for the orifice plug in the top of the oil
cylinder.

Place the oil cylinder in a horizontal posi-

tion. Remove the flange and take out the
piston. Inspect the inside of the liner in the
oil cylinder for scoring. Measure the cylin-
der diameter. If the diameter of the oil cylin-
der exceeds Data D08
20, either renew the D08-20
liner or send the complete oil cylinder to an
authorised MAN Diesel workshop for over-
haul, depending on the valve model.
M90802
0273O25

26. Oil piston

Remove the piston rings from the oil pis-

ton and check them for wear. If the thick-
ness of the rings has worn down to the
minimum, see Data, discard the rings and
mount new ones. Check that the TOP mark 26.
on the piston rings faces upwards, when Top
mounting

Check the mesh once more.

D08
21
M90802
0253O42

When referring to this page, please quote Procedure M90802 Edition 0273 Page 19 (23)
908-2.3 Exhaust Valve
Overhaul MAN B&W

27. Oil cylinder assembly

27.
Mount the piston and the flange in the oil
cylinder. Tighten and lock the screws.

Return the oil cylinder to an upright posi-

tion. Mount a new sealing disc in the bore
for the orifice plug. Screw the orifice plug
into the bore. Place a new gasket on top
of the oil cylinder. Mount the lifting bracket
on the oil cylinder. Mount the screws and
tighten to the torque stated in Data.

28. Oil cylinder mounting

D08-05 Mount the overhauled oil cylinder on top of
the air cylinder. Mount the safety strap and
tighten the nuts. See Data.
M90802
0273O27

28.

D08
06
M90802
0273O29

Page 20 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.4
MAN B&W Mounting

1. Checks before mounting

1.
Before mounting an overhauled exhaust
valve in the engine, it is recommended that
the valve is checked and prepared as fol-
lows:

Check the oil level in the bottom of the air

cylinder. Unscrew and remove the non-re-
turn valve and the safety valve.

Fill oil into the non-return valve hole until oil

flows out from the safety valve hole.
Refit the two valves again.

Connect compressed air to the air cylinder D08
24

to close the valve.
Lift up the valve with the engine room
crane.
G3
Check that a 1.0 mm feeler gauge can be
inserted about 15 mm into gap G3, to en-
M90802
0273M01

sure that there is a clearance between the

outer parts of the seating faces of valve
housing and spindle.

The valve must be able to stay closed for a

minimum of 15 minutes or according to the
dropdown test in Procedure 908-2.1. 2.

Note!
If the air cylinder is fitted with new seal-
ing rings, the time the valve is closed
may be considerably shorter than 15
minutes. The dropdown test should not
be carried out until after a »running-in« Compressed Air
period of 500 hours on valves with new
sealing rings.

Check the valve is fitted with new sealing

rings in the grooves on the bottom piece.

2. Exhaust valve landing

Close the valve with compressed air. Copper Grease

Vaseline
Lubricate the sealing rings with vase-
line and the threads of the studs with
anti
seizure paste.
M90802
0273M02

Position the valve in the cylinder cover

bore, guiding it in accordance with the ex-
haust flanges and the guide pin on the ex-
haust side of the exhaust valve.

When referring to this page, please quote Procedure M90802 Edition 0273 Page 21 (23)
908-2.4 Exhaust Valve
Mounting MAN B&W

3. Mounting of hydraulic nuts.

3.
Mount and tighten the hydraulic nuts, see
Data.
D13
01 See Procedure 913
1.

Mount the protective caps on the exhaust

valve studs.

4. Mount the pipe connections

Connect the intermediate pipe to the ex-

haust valve.
M90802
0273M03

Mount and tighten the screws to the ex-

haust valve housing.

Mount the insulation and plate jacket

4. for the intermediate pipe.

Mount the cooling water connections for

the exhaust valve and the air pipe for the
air spring.

5. Mount the oil pipe connections

Mount the high
pressure pipe for the hy-

draulic valve actuation.
See Procedure 908
1.2

Mount the return oil pipe to the exhaust-

M90802
0273M04

valve.

Check that all pipe connections are prop-

erly tightened.

5.
M90802
0273M05

Page 22 (23) When referring to this page, please quote Procedure M90802 Edition 0273
 Exhaust Valve 908-2.4
MAN B&W Mounting

6. Open cooling water supply

6.
Check that all water connections are
mounted and tightened.

Open the cooling water inlet supply, and

vent the exhaust valve, open the cooling
water outlet valve

Open the air supply to the exhaust valve.

Check the tightness of the sealing ring be-

tween the bottom piece and the exhaust
valve housing. See Procedure 908
2.1.

7. Air spring check

The air supply to the exhaust valve must al-

ways be connected and pressurized before
turning on the oil supply to the exhaust
valve actuator.
M90802
0273M06

If the lubricating oil pumps have been

started before the exhaust valve pneumatic
springs are pressurize:

Engage the indicators on top of the ex-

haust valves and wait until the exhaust
valves are closed. 7.

Closing of the exhaust valves are eased

if the lubrication oil pumps are stopped
and the actuators are drained at the drain
screws.
M90802
0256M07

Closed Valve Open Valve

When referring to this page, please quote Procedure M90802 Edition 0273 Page 23 (23)
 Exhaust Valve Actuator 108-3
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
X 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
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D08-20 Oil cylinder max. inside diameter 71.2 mm

D08-21 Piston rings, min. thickness 2.6 mm
D08-32 Hydraulic actuator, tightening torque 300 Nm
D08-33 Locking plate, tightening torque 10 Nm
D08-34 Hydraulic actuator, tightening angle 25 °
D08-35 Hydraulic actuator 75 kg

When referring to this page, please quote Data D10803 Edition 0058 Page 1 (2)
108-3 Exhaust Valve Actuator
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

Page 2 (2) When referring to this page, please quote Data D10803 Edition 0058
 Exhaust Valve Actuator 908-3.1
Checking
0226
Exhaust Valve Actuator S42MC-C
Checking
908-3.1

1.
1. The non-return valve A is built into the oil
inlet pipe to the actuator.

To check the valve, dismantle and clean it

and connect a supply of working air (7 bar)
to the outlet side of the valve (the side fac-
ing the actuator). If the air flow can be felt
at the inlet side of the valve, the valve must
be overhauled.

DM908-3.1 226 01

When referring to this page, please quote Procedure M90803 Edition 0226 Page 1 (4)
MAN B&W Diesel A/S
908-3.2 Exhaust Valve Actuator
Dismantling
Dismantling
908-3.2

1. 1. Stop the engine and shut off the oil supply.

Turn the camshaft so that the roller rests on

the circular part of the cam.

Remove the inspection cover of the roller

guide housing to check the position of the
exhaust cam.

Dismount the inlet pipe and the drain pipe

from the exhaust valve.

Dismount the high-pressure pipe.

See Procedure 908-1.2.
DM908-3.0 92 02

2. Fit eye screws in the lifting holes of the ac-

tuator housing and hook on a tackle.

2. Unscrew the nuts on the two short studs,

then loosen the nuts on the long studs suc-
D08-35 cessively until the roller guide spring is re-
lieved.

Dismount the nuts and lift the housing care-

fully, leaving the piston on top of the roller
guide.

Remove the spring.

3. Remove the locking plate for the piston.

Turn the piston 90° to release it from the
bayonet joint.
DM908-3.0 92 03

Remove the piston from the roller guide.

4. Overhaul the actuator housing and the pis-

3. ton as required.
See Procedure 908-3.3 .
HM908-3.0 70 03

Page 2 (4) When referring to this page, please quote Procedure M90803 Edition 0226
MAN B&W Diesel A/S
 Exhaust Valve Actuator 908-3.3
Overhaul
Overhaul
908-3.3

1. Clean the piston in kerosene and wipe dry 1.

with a clean piece of cloth.
D08-21

Take off the piston rings and check them for

wear. If the ring thickness has worn down
to the minimum (see Data) , discard the
rings and mount new ones.

Check that the TOP mark on the piston

rings faces upwards when mounting.

2. Inspect the sliding surfaces of the piston to

ensure that there are no scratch marks or
seizure marks.

3. Clean the oil cylinder and inspect the bores

for deposits.

Check the bore of the oil cylinder for possi-

ble scores and measure it for wear.
HM908-3.0 69 04

If the bore is seized or worn down to the

measurement stated in Data, send the oil
cylinder to an MAN B&W authorised work-
shop for reconditioning.
3.

D08-20
DM908-3.0 92 06

When referring to this page, please quote Procedure M90803 Edition 0226 Page 3 (4)
MAN B&W Diesel A/S
908-3.4 Exhaust Valve Actuator
Mounting
Mounting
908-3.4

1. 1. Mount the actuator piston in the roller guide

and turn 90° to lock it in the bayonet joint.

Mount the locking plate and tighten as stat-

ed in Data. Lubricate the piston with plenty
of camshaft lubricating oil.

2. Mount the spring on the roller guide. Care-

fully lower the actuator housing on to the
piston, taking care not to damage the piston
rings.

Mount the washers and nuts on the two

long studs and tighten alternately until the
KC908-3.0 76 05

actuator housing rests firmly against the

roller guide housing.

Mount the washers and nuts on the two

2. short studs. Tighten all four nuts as stated
in Data.
D08-35
Note!

Use only the tightening angle OR the

D08-32 tightening torque, NOT both.

D08-34
3. Mount the oil inlet pipe and the drain pipe
from the exhaust valve.

Mount the hydraulic high pressure pipe.

See Procedure 908-1.4.
DM908-3.0 92 08

3.
DM908-3.0 92 09

Page 4 (4) When referring to this page, please quote Procedure M90803 Edition 0226
MAN B&W Diesel A/S
 Exhaust Valve Roller Guide 108-4
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
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D08-36 Bushing/shaft pin, max. clearance 0.5 mm

D08-38 Roller guide complete 38 kg

When referring to this page, please quote Data D10804 Edition 0042 Page 1 (2)
108-4 Exhaust Valve Roller Guide
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

P90851 053 Lifting tool for roller guide

P90851 173 Lifting tool for exhaust valve roller guide

P91366 073 Dial gauge and stand tool

Page 2 (2) When referring to this page, please quote Data D10804 Edition 0042
 Exhaust Valve Roller Guide 908-4.1
Checking
Exhaust Valve Roller Guide
S42MC
0216
Checking
908-4.1

2.
1. The exhaust valve roller guide can be par-
tially checked while mounted on the engine,
using the following procedure:

Lift the roller guide.

See Procedure 908-4.2.

2. Remove the camshaft inspection cover.

Turn the engine to provide the maximum

space between the roller guide and the cam
disc.

GN908-4.1 203 01
Check the movability of the roller by turning
this by hand to ascertain if the roller moves
freely and without unnecessary resistance
or “hard” points.

Also inspect the surface of the roller for 5.

possible damage marks, seizures or
scratches. Make sure that no traces of '
bearing metal exist in the roller guide hous-
ing.

Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.

3. A more suitable and reliable method is to

check the roller guide and the bearing
clearance when the roller guide is dis-
mounted.
For dismantling of the roller guide see Pro-
cedure 908-4.2.

4. Inspect the surfaces of the roller guide and

the roller for damage marks, seizures or
scratches.
GN908-4.3 203 02

5. To measure the clearance in the roller

guide slide bearing, place the roller guide
vertically upside down on a couple of
planks with the roller hanging freely.

6. Place a dial gauge against the roller. Then

lift the roller as much as the clearance per-
mits, which makes it possible to read the
clearance D-2 directly on the dial.

When referring to this page, please quote Procedure M90804 Edition 0216 Page 1 (4)
0$1% :'LHVHO$6
908-4.1 Exhaust Valve Roller Guide
Checking

7. It is recommended that the roller guide

shold ONLY be dismantled if:

• irregularities when turning the roller,

• damage to the roller,

• larger clearance than stated on the Data

sheet,

• seizure marks on the slide surfaces,

have been observed during the checking of

the roller guide.

Note!

For disassembling of the roller guide,

contact an MAN B&W authorized repair
shop.

Page 2 (4) When referring to this page, please quote Procedure M90804 Edition 0216
0$1% :'LHVHO$6
 Exhaust Valve Roller Guide 908-4.2
Dismantling
Dismantling
908-4.2

1. Dismantle the hydraulic actuator above the 1.

exhaust valve roller guide.
See Procedure 908-3.2.

2. Mount the roller guide lifting tool as follows:

• Lift the lock ring of the tool up on the

shaft of the tool.

• Place the tool in such a manner that its

foot rests on the thrust piece in the bayo-
net joint of the roller guide.

• Turn the tool 90° so as to allow the foot to

engage properly in the bayonet joint.

• Lower the lock ring, thereby securing the

foot in the locked position.

Lift the roller guide out of the roller guide

housing, using the crane. Take care not to
damage the sliding surfaces of the roller
guide when lifting.
GN908-4.2 203 01

2.

'
GN908-4.2 203 02

When referring to this page, please quote Procedure M90804 Edition 0216 Page 3 (4)
0$1% :'LHVHO$6
908-4.4 Exhaust Valve Roller Guide
Mounting
Mounting
908-4.4

1. 1. Mount the lifting tool for the roller guide as

follows:

• Lift the lock ring of the tool up on the

shaft of the tool.
'
• Place the tool in such a manner that its
foot rests on the thrust piece in the bayo-
net joint of the roller guide.

• Turn the tool 90° so as to allow the foot to

engage properly in the bayonet joint.

• Lower the lock ring, thereby securing the

foot in the locked position.

Clean and lubricate the sliding surfaces of

the roller and the roller guide and lower it
carefully into the roller guide bushing.

Remove the lifting tool.

2. Mount the actuator.

GN908-4.2 203 02

See Procedure 908-3.4.

Page 4 (4) When referring to this page, please quote Procedure M90804 Edition 0216
0$1% :'LHVHO$6
 Exhaust Valve Cam 108-5
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
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D08-39 Check lifting height 10 mm

When referring to this page, please quote Data D10805 Edition 0016 Page 1 (2)
MAN B&W Diesel A/S
108-5 Exhaust Valve Cam
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

P90851 173 Lifting tool for exhaust valve roller guide

P91351 010 Hydraulic pump, pneumatically operated
P91351 058 Hose with unions (3000 mm), complete
P91351 166 Angle union
P91351 225 Disc, round-plain, Cu ø11x3 mm
P91366 073 Dial gauge and stand tool

Page 2 (2) When referring to this page, please quote Data D10805 Edition 0016
MAN B&W Diesel A/S
 Exhaust Valve Cam 908-5.1
Checking

1. Turn the crank throw of the cylinder con- 1.

cerned in AHEAD direction until TDC.
Check and write down the angle indicated
on the turning wheel.

2. Remove the high pressure pipe, see proce-

dure 908-1.2

Mount and tighten the lifting tool for the

exhaust valve roller guide to the actuator
piston (remove the screws for tightening to
the actuator housing and do not lift the
roller guide).

Mount a dial gauge (measuring range 0.00

- 20.00 mm) on the lifting tool for the ex-
haust valve roller guide.
Reset the scale and the pointer.
2.
Press the dial gauge against the face of the
actuator housing until the reading D08-39 +
1.00 mm is obtained.

3. Turn the roller guide in AHEAD direction

until lifted to D08-39, and the dial gauge
gives the reading 1.00 mm and calculate
the angle A, which is the number of de-
grees the crank throw has turned from TDC
position to the present position.

Continue turning AHEAD until the roller

M90805
0217C02

guide again is lifted to D08-39, and the dial

gauge gives the reading 1.00 mm.

Calculate the angle B, which is the number

of degrees the crank throw has turned from
TDC position to the present position.

Note!
When calculating the angles A and B, re-
member to take into account that the
scale on the turning wheel shifts from
360 to 0 (zero) degrees.

When referring to this page, please quote Procedure M90805 Edition 0217 Page 1 (4)
MAN B&W Diesel A/S
908-5.1 Exhaust Valve Cam
Checking

4. Calculate the lead angle as:

4. 180° – (A° + B°)/2

The lead angle is normally a negative fig-

ure.
The illustration shows the position of the
exhaust cam when the piston of the rel-
evant cylinder is in TDC.

The position of the cam must be correct

within a tolerance of +/-0.5°.

See the Adjustment Sheet in Volume I, OP-

ERATION, Chapter 701, for the “lead angle”
of the plant in question.

5. The cam lead angle can be checked visu-

ally by reading directly the scale position of
the exhaust cam over the marking scratch
5. on the camshaft and comparing this angle
with the angle stated in the Adjustment
Sheet.

At the same time, it is recommended to

check the position of the camshaft with the
pin gauge. See Procedure 906-3.1

Page 2 (4) When referring to this page, please quote Procedure M90805 Edition 0217
MAN B&W Diesel A/S
 Exhaust Valve Cam 908-5.3
Adjustment

Normally, adjustment of the exhaust cams

should not be necessary. Before adjust- 1.
ment of any cams, see Volume I, Chapter
706.

1. Remove the inspection cover from the

camshaft housing.

2. Dismount the exhaust valve high-pressure

pipe, see procedure 908-1.2.

3. Turn the camshaft until there is access to

the oil duct in the exhaust cam through the

M90805
0217O01
inspection hole.

If fitted, remove the plug from the oil duct

(using, for instance, a screwdriver).

Insert three copper gaskets in the oil duct.

3.
Mount one snap-on couplings in the oil
duct, but do not tighten it.

Fit a hose between the snap-on coupling

and the hydraulic high pressure pump.

4. Mount the special spanner on the exhaust

cam disc, ensuring that the two pins enter
the holes in the cam.

Apply a light pressure to the hydraulic sys-

tem and, after venting the system, tighten
M90805
0217O03

the snap-on couplings.

Raise the hydraulic pressure until oil seeps

out along the camshaft under the cam disc.

Keep the cam pressurised for at least two 4.

to five minutes before turning the cam.
Oil must sweep out with the pump running
during the operation.

Keep the cam pressurised during turning.

M90805
0217O04

When referring to this page, please quote Procedure M90805 Edition 0217 Page 3 (4)
MAN B&W Diesel A/S
908-5.3 Exhaust Valve Cam
Adjustment

5. Turn the cam disc, using the fitted spanner,

5. until the desired change of lead is ob-
tained. Check the change on the cam scale

To increase the lead angle and reduce the

compression pressure:
– turn the cam disc ASTERN.

To reduce lead angle and increase the

compression pressure:
– turn the cam disc AHEAD.

6. After completing the desired turning of the

cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.

Wait at least 15 minutes – the cam must be

allowed time to “settle” – before mounting
the plug again in the oil duct of the cam
disc.

After carrying out adjustment, measure the

exhaust cam lead again. See procedure
908-5.1.

Write down and file the new results for the

purpose of comparing with future measure-
ments and adjustment.

7. Mount the inspection cover on the cam-

shaft housing.

8. Mount the high pressure pipe for the ex-

haust valve. See procedure 908-1.4

9. After any adjustment of the cam position,

pcomp must be recorded and compared with
pcomp at a known engine reference load.

Page 4 (4) When referring to this page, please quote Procedure M90805 Edition 0217
MAN B&W Diesel A/S
 Exhaust Valve Special Running 108-7
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 lubriating oil pumps
X Engage turning gear
Shut off cooling water
Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

When referring to this page, please quote Data D10807 Edition 0034 Page 1 (2)
MAN B&W Diesel A/S
108-7 Exhaust Valve Special Running
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

P90851 124 Tool for emergency open exhaust valve

P90851 173 Lifting tool for exhaust valve roller guide

Page 2 (2) When referring to this page, please quote Data D10807 Edition 0034
MAN B&W Diesel A/S
 Exhaust Valve 908-7
Special Running
Exhaust Valve
S46MC-C
0225
Special Running
908-7

3.
Engine trouble might require that a cylinder be
taken out of action. The engine can continue
operation with the fuel and exhaust systems of
a single cylinder disconnected. See Volume I,
Section 704.

This can take place with the exhaust valve

locked in either the open or the closed position.
Either way, carry out the following procedure:

1. Lift the relevant fuel pump roller guide.

See Procedure 909-16.

DM908-7.0 224 03
2. Dismantle the hydraulic high-pressure
pipe.See Procedure 908-1.3.

3. Dismantle the non-return valve on the oil in-

let pipe. Loosen the union nut in the ex-
haust side of the oil pipe and turn the pipe 4.
to one side. Mount the non-return valve on
the oil pipe and blank off the non-return
valve with the plug from tool panel 908.

4. Remove the inspection cover of the cam-

shaft housing. Turn the engine until the ex-
haust roller guide is at TDC.

5. Position the lifting tool on the actuator and

GN908-4.1 203 01

screw the spindle into the top of the actua-

tor piston.

Tighten the lowermost nut on the tool to pull

up the roller guide as far as possible. 5.
Tighten the upper nut of the tool against the
lower nut to secure the roller guide in this
position.

6. If the cylinder is to operate with the exhaust

valve closed, the air supply must remain
connected to the air cylinder of the exhaust
valve. No further action is required.
GN908-7 203 05

When referring to this page, please quote Procedure M90807 Edition 0225 Page 1 (3)
MAN B&W Diesel A/S
908-7 Exhaust Valve
Special Running

7. If the cylinder is to operate with the exhaust

valve open, continue the procedure as follows:

7. Turn off the air to the exhaust valve.

Remove the venting plug screw, fitted just

above the ball cock on the air cylinder, to let
the air inside the air cylinder escape.

8. Dismantle the rotation indicator on the oil

cylinder and mount the tool for opening of
the exhaust valve.

The tool will keep the piston of the air cyl-

inder in the bottom position and thus keep
the exhaust valve open.
EN908-7.0 204 07

8.
EN908-7.0 204 08

Page 2 (3) When referring to this page, please quote Procedure M90807 Edition 0225
MAN B&W Diesel A/S
 Exhaust Valve 908-7
Special Running

After overhaul of the cylinder unit, re-engage 9.

the exhaust valve gear as follows:

9. Loosen the nuts of the lifting tool to lower

the roller guide on to the exhaust cam. Re-
move the tool.

10. If the engine has been running with the ex-

haust valve open, remove the tool mounted
in the oil cylinder and mount the rotation in-
dicator.

Note!

The rotation indicator should only be left

in the engaged position for short periods
of time during operation of the engine.

Leaving the rotation indicator in the

engaged position continuously might
damage the exhaust valve due to the for-
mation of a wear groove in the air piston
GN908-7 203 05

of the exhaust valve.

Re-connect the air supply to the air cylin-

der.
11.
11. Remove the plug from the non-return valve
and re-connect the oil inlet pipe on the ac-
tuator housing.

12. Mount the hydraulic high-pressure pipe.

See Procedure 908-1.2.

13. Engage the fuel pump roller guide.

See Procedure 909-16.
DM908-7.0 224 11

When referring to this page, please quote Procedure M90807 Edition 0225 Page 3 (3)
MAN B&W Diesel A/S
 Exhaust Valve - Panel Plate
MAN B&W P90851-0200

When referring to this page, please qoute Plate P90851 Edition 0200 Page 1 (2)
Plate Exhaust Valve - Panel
P90851-0200 MAN B&W

Item Item Description

No.
016 Panel for tools
028 Name plate
041 Tightening template, actuator
053 Lifting tool , roller guide
065 Lifting tool, exhaust valve
077 Conical ring, pneumatic piston
089 Pressure tester, safety valve
090 Gauge, exhaust valve spindle
124 Tool, emergency opening of exhaust
valve
150 Gauge, exhaust valve bottom piece
161 Lifting tool, exhaust valve spindle
173 Lifting tool, exhaust valve roller guide
185 Grinding ring, exhaust valve bottom
piece

Page 2 (2) When referring to this page, please qoute Plate P90851 Edition 0200
 Exhaust Valve - Hydraulic Tools Plate
P90862-0043

When referring to this page, please quote Plate P90862 Edition 0043 Page 1 (2)
MAN B&W Diesel A/S
Plate Exhaust Valve - Hydraulic Tools
P90862-0043

Item Item Description Item Item Description

No. No.

028 Jack-hydraulic, complete

030 Support
053 O-ring with back-up ring
065 O-ring with back-up ring
077 Tommy bar
090 Spanner
100 Stud setter
207 Hydraulic toolset, complete

Page 2 (2) When referring to this page, please quote Plate P90862 Edition 0043
MAN B&W Diesel A/S
 Fuel Pump Settings 109-1
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
X Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D09-02 Change of one index mark, corresponds to p-max being altered approx. 3-4 bar

When referring to this page, please quote Data D10901 Edition 0063 Page 1 (2)
MAN B&W Diesel A/S
109-1 Fuel Pump Settings
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 D10901 Edition 0063
MAN B&W Diesel A/S
 Fuel Pump Settings 909-1.3
Adjustment
Fuel Pump Settings
K98MC-C
0241
Adjustment
909-1.3

1.
Before adjustment of the fuel pump is carried
out, see Volume I, Chapter 706, also the fuel
cam lead should be checked, see Procedure
909-3.1.

pmax adjustment:

1. The Maximum Combustion Pressure (pmax)

is adjusted for the individual units at the fuel
pump VIT index arm. For collective adjust-
ments of pmax on all units, see Procedure
909-2.

HN909-1.3 240 01
2. Loosen lock nut B and then turn adjusting
screw H. The link can be adjusted by ap-
prox. 3 index marks.

3. To increase p max, adjust to higher VIT index 2.

(advance injection).

To decrease p max, adjust to lower VIT index

(delay injection).

One index mark will alter pmax approximate-

ly as given in Data D09-02.

Note!

The individual p max value must not devi-

ate more than 3 bar from the average
value for all cylinders.

4. If the required p max adjustment cannot be

HN909-1.3 240 02

attained by adjustment on the VIT index

arm, it is possible to carry out the adjust-
ment on the fuel cam disc. Contact MAN
B&W Diesel for advice.

When referring to this page, please quote Procedure M90901 Edition 0241 Page 1 (2)
MAN B&W Diesel A/S
909-1.3 Fuel Pump Settings
Adjustment

5. MIP adjustment:

5. The Mean Indicated Pressure (pi) for a cer-

tain cylinder is adjusted on the fuel pump
index arm.

Increase index for higher p i.

Decrease index for lower p i.

Note!
HN909-1.3 240 05

The mean indicated pressure is one of

the most important parameters in obtain-
ing good engine performance.
The mean indicated pressure should not
deviate more than 0.5 bar from the aver-
6. age value for all cylinders. See Volume I,
Chapter 706.

6. After adjustment of the fuel pumps a set of

observations must be taken, to evaluate the
adjustments see Volume I.
M90901-0242O06

Page 2 (2) When referring to this page, please quote Procedure M90901 Edition 0241
MAN B&W Diesel A/S
 VIT System 109-2
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 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 D10902 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
109-2 VIT System
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 D10902 Edition 0005
MAN B&W Diesel A/S
 VIT System 909-2.3
Adjustment
VIT System
K98MC-C
0206
Adjustment
909-2.3

1.
Before adjustment of any part of the VIT sys-
tem, see Volume I, Chapter 706. All adjust-
ments should be based on a set of
observations including a set of indicator dia-
grams taken when the engine is running just
above the breakpoint (90% MCR).

The engine may be equipped with either a me-

chanical or an electronic VIT (Variable Injection
Timing) system.

If the fuel quality has changed or if the fuel

M90902-0206O01
pumps are worn, the pmax will change, this
change can be corrected by adjusting the pmax
of all the cylinders with the VIT system, see
“Fine adjustment”.

Normally the VIT system is adjusted to start at

2.
40% engine load and to have break point at
90% of MCR engine output. Look in the test
sheet for actual start- and break point.

Mechanical VIT system

Basic adjustment:

When the basic adjustment is carried out the

engine must be stopped, normally only fine ad-
justment is necessary.

1. Engage the manual engine control, and ad-

just the regulating shaft to a fuel pump in-
dex corresponding to 90% engine load.
(The fuel index must correspond to 90%
load taken by measurement or from the test
bed sheet).

2. Check that the VIT lever is resting on both

rollers (break point for all cylinders).
M90902-0206O02

When referring to this page, please quote Procedure M90902 Edition 0206 Page 1 (5)
MAN B&W Diesel A/S
909-2.3 VIT System
Adjustment

3. 3. If necessary, adjust the lever by loosening

the nut A and turn the clamping arm B, until
lever contact with both rollers and tighten
nut A.

Adjust the VIT air pressure to 3.0 bar, by

axial displacement of the bracket with the
pilot valve and read the pressure on the
C pressure gauge C. See figure 2.

4. Spare pilot valves should be pre-adjusted

B to 0.5-5.0 bar control air pressure, corre-
sponding to 0.5-8.0 mm pressing-in of pin
M90602-0238O03

C.
A
To check a pilot valve already mounted on
the engine, remove the inlet and outlet pipe
connections at A and P, and connect a
4. Pbar pressure gauge at A and a pipe with work-
5 ing air (pressure 7 bar) at P on the pilot
4 valve.
3 Check that the pressure on the pressure
2 gauge and the pressing-in of pin C is in ac-
1.5 Pressing cordance with the curve.
0.5 1 in mm
0.1 Any necessary adjustment is done by turn-
0 1 2 3 4 5 6 7 8 ing adjusting screw B.
0.5

A
C
B
M90902-0206O04

Page 2 (5) When referring to this page, please quote Procedure M90902 Edition 0206
MAN B&W Diesel A/S
 VIT System 909-2.3
Adjustment

Fine adjustment: 5.

5. When the fine adjustment is carried out, the

engine must run at 90% load or just above.

Take a new set of indicator diagrams and

calculate the engine load.

Adjust the VIT air pressure to obtain cylin-

der p max of 140 bar. The VIT air pressure
must be maximum 5.0 bar.

Increase the pmax pressure by moving the

pilot valve toward the lever.

Decrease the p max pressure by moving the

pilot valve away from the lever.

For adjustment of pmax on a single cylinder,

see procedure 909-1.
M90902-0206O05

6. Run the engine at maximum load and check

that p max is 140 bar.

If the maximum combustion pressure devi-

ates more than 3.0 bar from 140 bar, adjust
the pressure by replacement of the lower- 6.
most roller.
M90902-0206O06

When referring to this page, please quote Procedure M90902 Edition 0206 Page 3 (5)
MAN B&W Diesel A/S
909-2.3 VIT System
Adjustment

7. Pmax
7. The uppermost roller is used to adjust the
adjusted on
Pbar VIT start point (40% engine load).
lowermost roller

Electronic VIT system

Break point
Pmax
8. The adjustment should be based on a set
adjusted on
uppermost roller of indicator diagrams taken when the en-
gine is running just above the breakpoint.

9. On the panel in the engine room control

Pcomp
room, change the p offset value in accord-
ance with the required increase or de-
M90902-0206O07

crease in the p max pressure. One

graduation mark on the p offset scale corre-
%Load
40 90 100 sponds to a change in p max of 1 bar.

10. Check the adjustment by taking a new set

8. of indicator diagrams while the engine is
running just above the breakpoint.
M90902-0206O08

Page 4 (5) When referring to this page, please quote Procedure M90902 Edition 0206
MAN B&W Diesel A/S
 VIT System 909-2.3
Adjustment

11. The I/P converter mounted on the engine 11.

receives a 4-20 mA signal I from the elec-
tronic governor system and converts this
into a 0.5-5.0 bar control air pressure
pcontrol .

12. To check the adjustment of the I/P convert-

er, operate the panel in the engine control
room to supply various signals I to the I/P
converter. P control

For operation of the panel, see the panel

manufacturer’s instructions.
P supply

On the pressure gauge mounted on the

control air line after the I/P converter check P control
that the control air pressures from the I/P
converter are in accordance with the curve. 5

4
13. If the control air pressure is not in accord-
ance with the curve, the I/P converter must 3

be adjusted. Remove the hood of the I/P 2

M90902-0206O11

1.5
converter and adjust the I/P converter ac- 1
0.5
cording to the manufacturer’s instructions. 0.1
0 I, mA
0 4 8 12 16 20

When referring to this page, please quote Procedure M90902 Edition 0206 Page 5 (5)
MAN B&W Diesel A/S
 Fuel Pump Cam 109-3
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 lubriating oil pumps
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

When referring to this page, please quote Data D10903 Edition 0050 Page 1 (2)
MAN B&W Diesel A/S
109-3 Fuel Pump Cam
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

P90651 44 Impact spanner for turning cam

P90951 45 Measuring tool for fuel pump
P91351 10 Hydraulic pump, pneumatically operated
P91351 46 Hose with unions (1500 mm), complete
P91351 58 Hose with unions (3000 mm), complete
P91351 154 Conical valve, 0 - 15
P91351 201 Quick coupling, male
P91351 225 Disc, round-plain, Cu ø11x3 mm

Page 2 (2) When referring to this page, please quote Data D10903 Edition 0050
MAN B&W Diesel A/S
 Fuel Pump Cam 909-3.1
Checking

Fuel cam lead:

1.
C
The lead C of the fuel cam is defined as the
number of mm the plunger is lifted from its X2 X1 Roller guide
bottom position when the main piston is in
TDC.

1. To measure the fuel cam lead (top lift):

Dismantle the puncture valve. Fuel cam

See Procedure 909-8.2.

Make sure that the reversing mechanism is

in AHEAD direction.

M90903
0233C01
Ahead

2. Push down the measuring pin through the

top cover, until it rests against the pump Lowest position
plunger. of pump plunger Main piston in TDC

Turn the engine until the lowest point of the 2.

cam is found, use a calliper to find the X
point.

3. Measure the distance x from the top of the

measuring pin to the transverse piece.

Note down the result as x2.

4. Turn ahead until the main piston of the cyl-

inder concerned is in TDC.

Again measure the distance x from the top

M90903
0233C03

of the measuring tool to the transverse

piece. Note down the result as x1.

Calculate the fuel cam lead C (top lift) as:

C = x1 – x2 (mm) 3.

5. Note down the result for comparison with

the testbed results and for future reference.
For adjustment of the fuel cam lead, see
Procedure 909-3.3.

Remount the puncture valve.

M90903
0233C04

When referring to this page, please quote Procedure M90903 Edition 0233 Page 1 (4)
MAN B&W Diesel A/S
909-3.2 Fuel Pump Cam
Adjustment

Normally, adjustment of the fuel cam should

1. not be necessary. Before adjustment of fuel
equipment, see Volume I, Chapter 706.

1. Remove the inspection cover from the

camshaft housing.

Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
M90903
0233O01

2. Dismount the puncture valve from the fuel

pump top cover, and mount the measuring
tool to check the cam adjustment.

2. 3. Turn the camshaft until there is access to

X the oil ducts in the fuel cam through the in-
spection hole.

If fitted, remove the plugs from the oil

ducts (using, for instance, a screwdriver).

Insert three copper gaskets in each oil

duct.

Mount snap-on couplings in the oil ducts,

but do not tighten them.
M90903
0233C03

Fit hoses between the snap-on couplings

and the distributor block and between the
distributor block and the hydraulic high-
pressure pump.

3.
M90903
0233O03

Page 2 (4) When referring to this page, please quote Procedure M90903 Edition 0233
MAN B&W Diesel A/S
 Fuel Pump Cam 909-3.2
Adjustment

4. Mount the special spanner on the fuel cam

disc, ensuring that the two pins enter the 4.
holes in the cam.

For better access to the cam, remove the

oil tray and carry out the adjustment from
the bottom of the cam shaft housing.
See Procedure 906-4.2

Apply a light pressure to the hydraulic sys-

tem and, after venting the system, tighten
the snap-on couplings.

Raise the hydraulic pressure until oil seeps

M90903
0233O04
out along the camshaft under the cam disc.

Keep the cam pressurised for at least two

to five minutes before turning the cam.

Oil must seep out with the pump running

during the operation to keep the cam
pressurised during turning.

Turn the cam disc, using the fitted spanner,

until the desired change of lead is ob-
tained.

To increase lead and pmax:

– turn the cam disc AHEAD.

To reduce lead and pmax:

– turn the cam disc ASTERN.

See Procedure 909-1.

5. After completing the desired turning of the

cam disc, relieve the hydraulic system of
pressure and dismount the spanner and the
hydraulic equipment.

Wait at least 15 minutes – the cam must be

allowed time to “settle” – before mounting
the plugs again in the oil ducts of the cam
disc.

After carrying out adjustment, measure the

fuel cam lead again.

Note down and file the new results for pur-

poses of comparison with future measure-
ments and adjustment.

When referring to this page, please quote Procedure M90903 Edition 0233 Page 3 (4)
MAN B&W Diesel A/S
909-3.2 Fuel Pump Cam
Adjustment

6. Mount the inspection cover on the cam-

shaft housing.

7. Mount the puncture valve.

See Procedure 909-8.4.

8. After any adjustment of the cam position,

pmax must be recorded and compared with
pmax at a known engine reference load.

Page 4 (4) When referring to this page, please quote Procedure M90903 Edition 0233
MAN B&W Diesel A/S
 Fuel Pump 109-4
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
X Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D09-18 Pump housing nuts, tightening torque 450 Nm

D09-19 Pump housing nuts, tightening angle 150/60 Nm/°
D09-20 Pump housing 100 kg
D09-21 Bottom plate 5 kg
D09-68 Fuel pump complete 210 kg
D09-39 Shock absorber 20 kg

When referring to this page, please quote Data D10904 Edition 0058 Page 1 (2)
MAN B&W Diesel A/S
109-4 Fuel Pump
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

P90951 070 Lifting tool for fuel pump housing

Page 2 (2) When referring to this page, please quote Data D10904 Edition 0058
MAN B&W Diesel A/S
 Fuel Pump 909-4.2
Dismantling
Fuel Pump
K90MC-C
0224
Dismantling
909-4.2

1.
1. Close the fuel oil inlet valve.

Open the drain cock, enabling the oil to es-

cape.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

2. Dismantle the fuel pump top cover and con-

MA909-1.1 223 03
nected pipes.
See Procedure 909-5.2.

3. Dismantle the barrel/plunger assembly.

See Procedure 909-6.2.
4.
4. Remove the screws holding the fuel oil inlet
pipe between the fuel pump and the fuel in-
D09-39
let valve.

Remove the fuel oil inlet pipe.

Remove the shock absorber.

Remove the fuel oil outlet pipe.

Discard the gaskets.

5. Remove the drain pipes from the fuel pump

housing.
MA909-4.2 214 04

Remove the control air pipes from the actu-

ator for the VIT index arm.

When referring to this page, please quote Procedure M90904 Edition 0224 Page 1 (9)
MAN B&W Diesel A/S
909-4.2 Fuel Pump
Dismantling

6. 6. Loosen the four nuts by means of a slug-

ging spanner. Remove the nuts.

7. Fit the lifting tool using the top cover studs/

nuts, and lift the pump housing away.

Take care not to damage the threads of the

studs.

Land the fuel pump on wooden planks.

MA909-4.2 214 06

7.

D09-20
MA909-4.2 214 07

Page 2 (9) When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
 Fuel Pump 909-4.3
Overhaul
Overhaul
909-4.3

1. If the fuel index arm or the VIT index arm 3.

of the fuel pump is moving too tightly, the
regulating and timing systems of the fuel
pump must be overhauled.

2. In order to carry out this overhaul, the top

cover and plunger/barrel assembly of the
fuel pump must have been removed, and
the fuel pump must have been dismantled
from the pump base and landed on wooden
planks.
See Procedure 909-4.2.
See Procedure 909-5.2.

MA909-4.3 214 03
See Procedure 909-6.2.

3. Dismantle the actuator and actuator brack-

et.

4. Tilt the fuel pump housing into a horizontal 4.

position on the wooden planks. D09-20
5. Dismantle the screws and the bottom plate
from the fuel pump housing.

If the bottom plate is stuck, loosen it by

screwing two M10x80 mm screws into the
holes of the bottom plate.
MA909-4.3 214 04

5.

D09-21
MA909-4.3 214 05

When referring to this page, please quote Procedure M90904 Edition 0224 Page 3 (9)
MAN B&W Diesel A/S
909-4.3 Fuel Pump
Overhaul

6. 6. Dismantle the:

• Fuel index arm

• Regulating guide

• Sleeve

7. Dismantle the:

• Guide screw

• VIT index arm

MA909-4.3 214 06

• Timing guide

8. Remove the caps from the back of the fuel

pump housing.
7.
Remove the orifice plug from the front side
of the fuel pump housing.

Discard all sealing rings and gaskets.

MA909-4.3 214 07

8.
MA909-4.3 214 08

Page 4 (9) When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
 Fuel Pump 909-4.3
Overhaul

9. Dismantle and inspect the plug screws in 9.

both sides of the fuel pump housing.

If eroded, replace the plug screws.

10. Clean all the dismantled parts of the fuel

pump thoroughly in diesel oil or kerosene.
Dry all parts carefully.

Clean all inside surfaces of the fuel pump

housing.

Check that all the bores of the fuel pump

housing are clean.

11. Mount new sealing rings and gaskets.

MA909-4.3 214 09
Mount the caps and the orifice plug.

Mount new sealing rings on the plug screws

and mount the plug screws.
11.
Note!

Lubricate the threads of all the parts with

Molybdenum Disulphide (MoS 2) before
mounting.

12. Mount new sealing rings in the sleeves that

are provided with a pointer scratch.
MA909-4.3 214 11

Note!

Soak the sealing rings in lubricating oil

before mounting.
12.
HC909-3.4 121 11

When referring to this page, please quote Procedure M90904 Edition 0224 Page 5 (9)
MAN B&W Diesel A/S
909-4.3 Fuel Pump
Overhaul

14. Mounting

13. Lubricate the following with molybdenum di-

sulphide (MoS 2):

• all internal surfaces of the fuel pump

housing

• the sliding surfaces of all parts of the

regulating and timing systems.

• the teeth of the:

regulating guide
MA909-4.3 214 14

timing guide
VIT index arm

15. fuel index arm.

14. Mount the VIT index arm and the guide

screw.

Adjust the position of the VIT index arm so

that the scratch mark is aligned with the
centre of the fuel pump housing.

15. Mount the timing guide in the fuel pump

housing.

The timing guide must be mounted in such

a way that the scratch marks on the timing
MA909-4.3 214 15

guide, on the VIT index arm and on the fuel

pump housing are aligned.

16. Mount the sleeve in the fuel pump housing,

ensuring that the notch in the side of the
16.
sleeve is aligned with the pin hole in the
fuel pump housing.
MA909-4.3 214 16

Page 6 (9) When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
 Fuel Pump 909-4.3
Overhaul

17. Mount the fuel index arm. 17.

Adjust the position of the fuel index arm so

that the scratch mark on the fuel index arm
is aligned with the centre of the fuel pump
housing.

18. Mount the regulating guide in the fuel pump

housing.

The regulating guide must be mounted so

that the scratch mark on the regulating
guide is aligned with the scratch mark on
the fuel index arm.

19. Mount the bottom plate on the fuel pump

housing.

20. Return the fuel pump to a vertical position. MA909-4.3 214 17

Mount the actuator and actuator bracket on

the side of the fuel pump.

18.
MA909-4.3 214 18

19.
MA909-4.3 214 05

When referring to this page, please quote Procedure M90904 Edition 0224 Page 7 (9)
MAN B&W Diesel A/S
909-4.4 Fuel Pump
Mounting
Mounting
909-4.4

2. 1. Before mounting the fuel pump housing,

make sure that all sliding faces and threads
D09-20 are cleaned and lubricated with MOLYKOTE
antifriction spray D321R or molybdenum di-
sulphide (MoS 2).
See Procedure 913-11.

2. Mount the lifting tool on the fuel pump top

cover studs. Lift the fuel pump housing on
to the pump base, taking care not to dam-
age the threads of the studs.

Remove the lifting tool.

3. Mount the nuts on the studs and tighten to

the specified torque or angle, see Data.

Note!

Use either the tightening torque or the

tightening angle.
MA909.4.2 214 07

3.

D09-18
or
D09-19
MA909-4.2 214 06

Page 8 (9) When referring to this page, please quote Procedure M90904 Edition 0224
MAN B&W Diesel A/S
 Fuel Pump 909-4.4
Mounting

4. Mount the drain oil pipes on the fuel pump 5.

housing.

Connect the control air pipes to the actuator

for the VIT index arm. D09-39

5. Fit new gaskets on the fuel pump inlet pipe.

Mount the pipe between the fuel pump
housing and the fuel oil inlet and outlet
valve.

Mount the shock absorber.

6. Mount the barrel assembly in the fuel pump

housing. See Procedure 909-6.4.

MA909-4.2 214 04
7. Mount the top cover on the fuel pump hous-
ing. See Procedure 909-5.4.

Mount the air pipe for the puncture valve.

8. Close the drain cock and open the fuel oil 8.

inlet valve.
MA909-1.1 223 09

When referring to this page, please quote Procedure M90904 Edition 0224 Page 9 (9)
MAN B&W Diesel A/S
 Fuel Pump Top Cover 109-5
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
X Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D09-23 Top cover studs, screwing-in torque 130 Nm

D09-24 Top cover nuts, tightening torque 210 Nm
D09-26 Outlet seat, max.grinding diameter 18 mm
D09-27 Top cover 35 kg

When referring to this page, please quote Data D10905 Edition 0063 Page 1 (2)
MAN B&W Diesel A/S
109-5 Fuel Pump Top Cover
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

P90951 069 Lifting tool for fuel pump

P90951 094 Milling tool for fuel oil pipe seats

Page 2 (2) When referring to this page, please quote Data D10905 Edition 0063
MAN B&W Diesel A/S
 Fuel Pump Top Cover 909-5.1
Checking

1. Shut off the fuel oil inlet.

1.
Open the drain cock (at the bottom of the
pump housing), and drain off any oil left in
the high-pressure pipe and the fuel pump.

Note!
Before dismantling any part of the fuel
pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

M90905
0234D01
Dismount all drain pipes and the pipe con-
nections to the puncture valve.

Dismount the high-pressure pipes between

the top cover and the fuel valves.
See Procedure 909-14.2. 2.

Note!
If the puncture valve is to be overhauled,
remove the puncture valve from the top
cover at this stage.
See Procedure 909-8.2.

2. Remove the top cover fixing nuts and

mount the dismantling screws for top cover
in the two threaded holes.
M90905
0234D02

Pull the top cover with suction valve and

puncture valve (if still mounted) free by
tightening the dismantling screws.

When the top cover is loose, remove the 3.

dismantling screws and mount the lifting
tool in the threaded holes instead.

3. Lift the top cover carefully off.

D09
27
For overhaul of top cover, puncture valve
and suction valve, see Procedures 909-5.3,
909-7.3, 909-8.3.

Discard the gasket.

M90905
0234D03

When referring to this page, please quote Procedure M90905 Edition 0234 Page 1 (3)
MAN B&W Diesel A/S
909-5.2 Fuel Pump Top Cover
Dismantling

1. If not already done, dismount the protective

1. cap and the puncture valve from the top
cover.
See Procedure 909-8.2.

2. Mount the top cover in special bracket and

dismantle the suction valve and the lock
washer from the top cover.
See Procedure 909-7.2.

3. Fill the oil ducts of the top cover with

vaseline or heavy grease.

Screw the guide, with the miller, into the

M90905
0234O02

high-pressure pipe thread.

Mill the seat until a smooth surface is

achieved. For maximum seat diameter see
Data.
2.
After completing the milling, use com-
pressed air to blow the vaseline/ grease
out from the oil ducts.

D09
26 Clean the top cover with diesel oil/gas oil,

and blow dry with compressed air.

Note!
Make sure that all bores and threads in-
side the top cover are absolutely clean.
M909905
0234O03

If necessary, recondition the seats of the

fuel oil high-pressure pipes.
See Procedure 909-14.3.

3. 4. Mount a new lock washer and a new or

overhauled suction valve in the top cover.
See Procedure 909-7.4.
M909905
0234O04

Page 2 (3) When referring to this page, please quote Procedure M90905 Edition 0234
MAN B&W Diesel A/S
 Fuel Pump Top Cover 909-5.2
Dismantling

1. Make sure that the inside of the fuel pump

housing and the top of the fuel pump bar- 1.
rel is completely clean.

2. Mount a new gasket on top of the pump D09
27

housing.

Lubricate all sliding faces, studs and seal-

ing rings with molybdenum disulphide
(MoS2). See Procedure 913-11.

Mount the overhauled top cover (with over-

hauled suction valve and reconditioned

M90905
0234M01
seatings for the high-pressure pipes) on the
pump housing.

Check that the guide pin in the top cover

enters the hole in the pump housing.

Warning! 3.
D09
24
As a safety precaution, and before
mounting the top cover nuts, turn the
engine one revolution.

When doing this, the top cover must not

move upwards!

3. Mount the top cover fixing nuts, and

tighten them diagonally to the torque indi-
cated in Data.
M90905
0234M03

For adjustment of the fuel pump, see Pro-

cedure 909-1.1.

4. Finally, mount a new or overhauled punc-

ture valve on the top cover. See Procedure 4.
909-8.4.

Mount the protective cap over the puncture

valve and the two screws in the top cover.
Mount the high-pressure pipes and the
drain screw in the pump housing.

Mount the drain pipes on the top cover

and the connecting pipe to the puncture
valve. Open the fuel oil inlet.
M90905
0234M04

When referring to this page, please quote Procedure M90905 Edition 0234 Page 3 (3)
MAN B&W Diesel A/S
 Fuel Pump Barrel Assembly 109-6
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
X Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D09-29 Barrel assembly 28 kg

D09-30 Plunger 7 kg

When referring to this page, please quote Data D10906 Edition 0050 Page 1 (2)
MAN B&W Diesel A/S
109-6 Fuel Pump Barrel Assembly
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

P90951 057 Lifting tool for barrel and plunger

P90951 224 Tool for P. max rack
P90977 Mounting Tools - Pump Barrel Seals

Page 2 (2) When referring to this page, please quote Data D10906 Edition 0050
MAN B&W Diesel A/S
 Fuel Pump Barrel Assembly 909-6.2
Dismantling
Fuel Pump Barrel Assembly
S60MC-C
0219
Dismantling
909-6.2

1.
1. Shut off the fuel oil inlet.

Open the drain cock (at the bottom of the

pump housing), enabling the oil which is left
in the high-pressure pipe and the fuel pump
to escape.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

GN909-5.2 204 01
Dismount the pipe connections to the punc-
ture valve.

Dismount the fuel oil high-pressure pipes. 2.

See Procedure 909-14-2.

2. If the top cover is to be overhauled, dis-

mount the puncture valve.
See Procedure 909-8.2.

3. Dismount the fuel pump top cover.

See Procedure 909-5.2.
HN909-8.2 207 03

3.
GN909-5.2 204 03

When referring to this page, please quote Procedure M90906 Edition 0219 Page 1 (9)
0$1% :'LHVHO$6
909-6.2 Fuel Pump Barrel Assembly
Dismantling

4. 4. Position the lifting tool for the barrel/plunger

assembly (without measuring pin) in such a
manner that the two distance tubes of the
tool rest on the pump barrel.

Make sure that the two guide pins in the

bottom of the lifting tool enter the holes in
the top of the plunger.

Secure the lifting tool by screwing the two

screws into the pump barrel.

Loosen the stop ring on the spindle of the

GN909-6.2 204 01

tool and press the spindle down against the

pump plunger.

Turn the spindle in this position until the two

guide pins engage with the two holes in the
5. plunger top.

Tighten the centre screw of the spindle

against the plunger.

5. Remove the pump barrel guide screw from

the pump housing.
MB909-3.1 95 05

6. Disconnect the links for the timing drive and

the regulating drive. Dismount the union
and pointer for the timing drive and the reg-
ulating drive.
6.
Note the position of the scratch mark on the
lever arm.

Remove the locking plate and the lever

arm.

Mount the extractor tool and connect the

timing toothed rack to the pulling rod by
means of the pin.
GN909-6.2 204 03

Page 2 (9) When referring to this page, please quote Procedure M90906 Edition 0219
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 909-6.2
Dismantling

7. Turn the nut at the end of the pulling rod, 7.

whereby the timing rack will move out-
wards.

Continue turning the nut until the pin reach-

es the outer position of the slot in the tool,
whereby the thread of the fuel pump barrel

GN909-6.2 204 04
goes clear of the timing guide.

Keep the toothed rack in this position during

the overhaul or replacement of the pump
barrel.
8.
There is now a distance between the lifting
tool and the pump housing.

8. Pull the regulating toothed rack outwards

until the plunger foot has been turned clear
of the bayonet joint in the roller guide.

This can be ascertained by watching the

handles on the spindle of the lifting tool.
These will be parallel with the fore-and-aft
direction of the engine when the plunger
has been turned into position.

Remove the cover of the pump base to

make sure that the plunger is able to go
GN909-6.2 204 05

clear of the bayonet joint.

Lift the spindle so that the plunger foot goes

clear of the bayonet joint.

Move the stop ring of the spindle into con- 9.

tact with the upper flange of the tool, and
lock the stop ring in this position by means
of the stop screw.

9. Carefully lift the barrel/plunger assembly D09-29

out of the pump housing.

Dismount the tool.

Press the plunger upwards to the bottom of

the barrel.

Send the barrel/plunger assembly to an

MAN B&W authorized workshop for repair,
or overhaul it on board as described in Pro-
cedure 909-6.3.
GN909-6.2 204 06

When referring to this page, please quote Procedure M90906 Edition 0219 Page 3 (9)
0$1% :'LHVHO$6
909-6.3 Fuel Pump Barrel Assembly
Overhaul
Overhaul
909-6.3

1. 1. Clean the outside of the barrel.

Set up the pump barrel/plunger in a bench

vice provided with “soft” jaws.
D09-29
Remove and discard the sealing rings from
the barrel.

2. Pull the plunger carefully out of the barrel.

Carefully clean the plunger (for example in

clean kerosene) and wipe dry with a clean
piece of cloth. Also clean the bores in the
top of the plunger.
MB909-3.2 95 01

Clean the barrel and wipe dry with a clean

piece of cloth.

2. For evaluation of pump barrel/plunger, see

Volume I, OPERATION, Chapter 706.

3. Before mounting new sealing rings on the

barrel, heat them in 100°C hot water for at
least five minutes.

4. When mounting the new sealing rings on

the lower end of the pump barrel, the inner
sealing ring must be mounted first.

Mount the guide stick in the barrel and po-

D09-30 sition the big cone on the barrel.
MB909-3.2 95 02

Place the spring-loaded sealing ring on the

cone with the spring facing upwards, see
the sketch.

4. Use the pusher tool to push the sealing ring

into the groove.
MB909-3.2 95 04

Page 4 (9) When referring to this page, please quote Procedure M90906 Edition 0219
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 909-6.3
Overhaul

5. When mounting the sealing ring in the outer 5.

groove, place the spacer tool inside the
cone to obtain the correct distance to the
groove, and repeat the above procedure.

After mounting the sealing rings, compress

them by pressing the “sizer” tool over the
sealing rings.

6. Mount the guide stick and cone on the top

end of the barrel and mount the uppermost
sealing ring in the same way as above.

Make sure that the spring faces down-

MB909-3.2 95 05
wards, see the sketch.

7. Lubricate the plunger with molybdenum di-

sulphide (MoS 2).
6.
Carefully slide the plunger into the barrel
and press it to the bottom.

Note!

Do not use force as this will damage the

sliding surfaces of the plunger or barrel

If the barrel assembly is not to be mounted

immediately, all openings must be covered
with plastic to prevent dirt from entering the
barrel assembly during storage.
MB909-3.2 95 06

7.
MB909-3.2 95 07

When referring to this page, please quote Procedure M90906 Edition 0219 Page 5 (9)
0$1% :'LHVHO$6
909-6.4 Fuel Pump Barrel Assembly
Mounting
Mounting
909-6.4

1. 1. Place the supplied measuring pin – which

is of the same length as the plunger – on
the spindle of the lifting tool, and fasten it
by tightening the centre screw of the spin-
dle. Loosen the stop ring on the spindle.

Place the tool on the pump housing, and

press the spindle down until the pointed
end of the measuring pin is in contact with
the thrust piece of the roller guide.

Then press the stop ring down until it

reaches the flange of the tool and lock it
there by tightening the screw of the stop
ring against the spindle.

The stop ring is to remain tightened in this

position until the plunger has been correctly
mounted.

The engine must not be turned until the

mounting of the barrel/plunger assembly
HN909-6.4 207 01

has been completed.

2. Dismount the tool from the pump housing

and remove the measuring pin from the
spindle. Then mount the tool on the barrel/
2. plunger assembly which is ready for mount-
ing.

Secure the tool to the barrel by tightening

the two screws, and attach the plunger to
the spindle of the tool by tightening the cen-
tre screw of the spindle. The tool is thus
fixed on the barrel in such a way that its cor-
rect positioning is ensured during mount-
ing.

Before mounting the barrel/plunger in the

pump housing, lubricate the thread for the
timing guide and all sealing rings with mo-
lybdenum disulphide.

Using the spindle of the tool, pull the plung-

er as high up in the barrel as possible, at
the same time turning the spindle so as to
position the plunger foot correctly in relation
to the cutout of the regulating guide.
HN909-6.4 207 02

Page 6 (9) When referring to this page, please quote Procedure M90906 Edition 0219
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 909-6.4
Mounting

3. Pull the regulating toothed rack as far out 3.

as possible and check that the extractor
tool is mounted correctly on the timing
toothed rack when this is in its outer posi-
tion.

4. Check that the slot in the barrel coincides

with the hole for the guide screw.

Lower the barrel assembly carefully into the

GN909-6.4 204 03
pump housing.

If necessary, turn the regulating guide a lit-

tle (using the toothed rack) to make the foot
and the regulating block of the plunger fit
properly in the cutout of the regulating 4.
guide.

Lowering the barrel assembly so far down

into the pump housing that the sealing rings D09-29
of the barrel are about to enter the bore in
the pump housing.

Then continue pressing down the barrel/

plunger assembly until the barrel assembly
rests on top of the timing guide. There will
be a gap between the tool and the pump
housing.
GN909-6.4 204 04

When referring to this page, please quote Procedure M90906 Edition 0219 Page 7 (9)
0$1% :'LHVHO$6
909-6.4 Fuel Pump Barrel Assembly
Mounting

5. 5. Loosen the nut on the extractor, disconnect

the pulling rod from the timing toothed rack,
and remove the extractor.

Engaging the thread of the fuel pump barrel

with the timing guide is accomplished by
pressing-in the toothed rack. (A pressure of
about 30 kg may be required).

Check that the toothed rack is correctly en-

gaged by pressing-in the rack. When doing
this, the pump barrel shall move down-
wards.

The top flange of the tool is now resting on

the top of the pump housing.

6. After ‘landing’ the barrel assembly, press

the plunger down into contact with the
GN909-6.4 204 05

thrust piece of the roller guide.

Check that the stop disc of the spindle is in

full contact with the flange of the tool, as
when measuring.
6.
If necessary, turn the regulating guide a lit-
tle (using the toothed rack) to make the
plunger foot fit properly in the cutout of the
roller guide. Inspect the position of the
plunger foot through the inspection hole.

When the plunger is in place, press the reg-

ulating rod in, thereby turning the plunger
by means of the regulating guide and caus-
ing the plunger foot to “interlock” with the
bayonet joint of the roller guide.

Check that the plunger is correctly engaged

by pulling at the spindle of the lifting tool.
When doing this, it must not be possible to
lift the spindle.

Mount the inspection hole cover.

GN909-6.4 204 06

Page 8 (9) When referring to this page, please quote Procedure M90906 Edition 0219
0$1% :'LHVHO$6
 Fuel Pump Barrel Assembly 909-6.4
Mounting

7. Mount the pointer and union for the timing 7.

rack.

Mount the links for the timing drive and the

regulating drive in place in accordance with
the marks.

8. Mount the guide screw for the pump barrel

in the pump housing.

GN909-6.4 204 07
Remove the centre screw from the plunger,
and remove the tool.

9. Mount the top cover without mounting the 8.

nuts. Turn the engine one revolution, and
check that the top cover does not move up-
wards. If the top cover does move upwards,
the barrel/plunger assembly has to be re-
moved and re-inserted.

10. Mount the fuel pump top cover, including

the nuts. See Procedure 909-5.4.
GN909-6.4 204 08

When referring to this page, please quote Procedure M90906 Edition 0219 Page 9 (9)
0$1% :'LHVHO$6
 Fuel Pump Suction Valve 109-7
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
Shut off cooling water
X Shut off fuel oil
X Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D09-33 Suction valve, tightening torque 900 Nm

D09-34 Suction valve 2.5 kg

When referring to this page, please quote Data D10907 Edition 0039 Page 1 (2)
MAN B&W Diesel A/S
109-7 Fuel Pump Suction 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

P90951 128 Crowfoot spanner

P90979 Mounting Tools - Suction Valve Seals

Page 2 (2) When referring to this page, please quote Data D10907 Edition 0039
MAN B&W Diesel A/S
 Fuel Pump Suction Valve 909-7.1
Checking
Fuel Pump Suction Valve
S60MC-C
0214
Checking
909-7.1

1.
1. Using a brass mandrel, check that the valve
slide can slide freely up and down inside
the suction valve.

2. Check the seats for tightness by filling the

inlet hole with diesel oil or gas oil, and wait
five minutes. No oil may seep through the
seats of the slide/housing.

3. If the suction valve is not to be mounted on

the engine immediately after the checking,
cover all openings of the valve with plastic
to prevent dirt from entering the valve dur-
ing storage.

HN909-7.1 207 01

2.
KB909-3.3 105 08

When referring to this page, please quote Procedure M90907 Edition 0214 Page 1 (4)
0$1% :'LHVHO$6
909-7.2 Fuel Pump Suction Valve
Dismantling
Dismantling
909-7.2

1. 1.
Note!

Before dismantling the top cover, it is

recommended to dismantle the fuel pump
puncture valve, see Procedure 909-8.2.

Dismantle the fuel pump top cover and suc-

tion valve assembly from the fuel pump
housing. See Procedure 909-5.2.

2. Mount two eye bolts in the bottom of the top

cover and turn it upside down.

3. Mount the top cover in an upside down po-

GN909-5.2 204 03

sition in the top cover bracket mounted on

the bulkhead inside the engine room. Tight-
en the nuts of the bracket to fix the top cov-
er.
2.
Release the suction valve lock washer.

Dismount the suction valve from the top

cover.

Remove and discard the lock washer.

GN909-5.3 204 02

3.
KN909-7.2 213 03

Page 2 (4) When referring to this page, please quote Procedure M90907 Edition 0214
0$1% :'LHVHO$6
 Fuel Pump Suction Valve 909-7.3
Overhaul
Overhaul
909-7.3

1. Set up the suction valve in a bench vice 1.

with “soft” jaws and, using a brass mandrel
and a hammer, release the spring guide
from the valve thrust piece.

Disassemble the other parts of the suction

valve and clean the parts thoroughly in
clean diesel oil.

Remove and discard the sealing ring from

the valve thrust piece.

2. Inspect the seat of the valve slide and the

seat in the thrust piece for damage. If the
seats are damaged, both the suction valve
and the valve slide must be discarded.

KB909-3.3 105 05
Lapping of the seats must not be attempt-
ed.

3. Mount the O-ring in the groove of the seal- 2.

ing ring and position the cone on the thrust
piece.

Place the sealing ring on the cone and, us-

ing the pusher tool, push the sealing ring on
to the groove.

Note!
KB909-3.3 105 06

Make sure that the sealing ring is

mounted correctly. See the sketch.

After mounting the sealing ring, compress it 3.

by pressing the “sizer” tool over the sealing
ring.

4. Clean and overhaul all internal parts, and

lubricate them with molybdenum disulphide
(MoS 2).

5. Re-assemble the suction valve.

6. Check the suction valve after the overhaul.

See Procedure 909-7.1.
XZ909-7.3 204 03

When referring to this page, please quote Procedure M90907 Edition 0214 Page 3 (4)
0$1% :'LHVHO$6
909-7.4 Fuel Pump Suction Valve
Mounting
Mounting
909-7.4

1. 1. Mount the top cover in an upside down po-

sition in the top cover bracket mounted on
the bulkhead inside the engine room. Tight-
en the nuts of the bracket to fix the top cov-
D09-33 er.

Lubricate the thread of the suction valve

with copper grease.

Make sure that the bore for the suction

valve in the top cover is absolutely clean.

Fit a new lock washer and mount a new or

overhauled suction valve in the top cover.

Fit the two screws which secure the lock

washer.

Tighten the suction valve with a torque

spanner. See Data.

Lock the suction valve in position by bend-

ing up an edge of the lock washer over one
KN909-7.4 213 01

of the flats of the valve.

2. Remove the top cover from the bracket and

mount the top cover in the fuel pump hous-
2. ing. See Procedure 909-5.4.
GN909-5.2 204 03

Page 4 (4) When referring to this page, please quote Procedure M90907 Edition 0214
0$1% :'LHVHO$6
 Fuel Pump Puncture Valve 109-8
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
Shut off cooling water
X Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D09-35 Puncture valve, tightening torque 890 Nm

When referring to this page, please quote Data D10908 Edition 0050 Page 1 (2)
MAN B&W Diesel A/S
109-8 Fuel Pump Puncture 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

P90951 Crowfoot spanner

P90980 Mounting Tools - Air Piston Seals

Page 2 (2) When referring to this page, please quote Data D10908 Edition 0050
MAN B&W Diesel A/S
 Fuel Pump Puncture Valve 909-8.2
Dismantling
Fuel Pump Puncture Valve
S60MC-C
0217
Dismantling
909-8.2

2.
1. Shut off the fuel oil inlet.

Open the drain cock at the bottom of the

pump housing and drain off any oil left in
the fuel oil high-pressure pipe and fuel
pump.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

2. Dismantle the control air pipe and the pro-

tective cap above the puncture valve.

3. Unscrew and remove the puncture valve

from the fuel pump top cover.

4. After dismantling it is recommended always

HN909-8.2 207 02

to overhaul the puncture valve.

If the overhaul cannot take place immedi-

ately after the dismantling, it is recommend-
ed to place the puncture valve immersed in
diesel oil until the overhaul. 3.
HN909-8.2 207 03

When referring to this page, please quote Procedure M90908 Edition 0217 Page 1 (4)
0$1% :'LHVHO$6
909-8.3 Fuel Pump Puncture Valve
Overhaul
Overhaul
909-8.3

1. 1. Remove and discard the O-rings from the

puncture valve.

Set up the puncture valve in a bench vice

with “soft” jaws.

Loosen and remove the four screws and

dismount the plug. Use a screw to remove
the air piston from the housing.

Remove and discard the sealing rings from

the air piston.

Disassemble the other parts of the punc-

ture valve, using a brass mandrel and a
hammer. Take care not to damage the valve
seat.

Thoroughly clean all the parts in clean die-

sel oil.

2. Inspect the conical seats of the valve hous-

ing and the valve slide for wear marks or
scratches.

If the seats are damaged, the valve housing

and the valve slide must be discarded.

Lapping of the valve seats must not be at-

HN909-8.3 207 01

tempted.

2.
HG909-8.2 201 02

Page 2 (4) When referring to this page, please quote Procedure M90908 Edition 0217
0$1% :'LHVHO$6
 Fuel Pump Puncture Valve 909-8.3
Overhaul

3. When mounting the new sealing rings on 3.

the spindle of the air piston, the inner seal-
ing ring must be mounted first.

Mount the O-ring in the ring groove and po-

sition the large cone on the spindle.

Place the sealing ring on the cone and, us-

ing the pusher tool, push the sealing ring on
to the O-ring in the groove.

After mounting the sealing ring, compress it

by pressing the ‘sizer' tool, over the sealing
ring.

Mount the outer sealing ring in the groove

using the short cone, and repeating the
above procedure.

4. The new sealing ring is mounted on the

head of the air piston in accordance with
the same procedure as above.
GM909-3.3 89 10

Before assembling the puncture valve, lu-

bricate all parts with “MOLYKOTE anti-fric-
tion SPRAY D321R” or molybdenum
disulphide (MoS 2).
4.
Mount new O-rings on the housing.

5. If the puncture valve is not to be mounted

on the engine immediately after the over-
haul, cover all openings of the valve with
plastic to prevent dirt from entering the
valve during storage.
GM909-3.3 89 12

When referring to this page, please quote Procedure M90908 Edition 0217 Page 3 (4)
0$1% :'LHVHO$6
909-8.4 Fuel Pump Puncture Valve
Mounting
Mounting
909-8.4

2. 1. Make sure that the bore for the puncture

valve in the fuel pump top cover is absolute-
ly clean.

If this has not already been done, mount

new O-rings on the puncture valve.

Lubricate the thread of the puncture valve

with copper grease.

D09-35 2. Screw the puncture valve into the bore in

the top cover.

Using a crowfoot wrench and a torque

spanner, tighten the puncture valve to the
torque stated in Data.

3. Mount the protective cap and the control air

pipe on top of the puncture valve.

4. If open, close the drain cock on the fuel

pump and open the fuel oil inlet valve.
HN909-8.4 207 02

3.
HN909-8.4 207 03

Page 4 (4) When referring to this page, please quote Procedure M90908 Edition 0217
0$1% :'LHVHO$6
 Fuel Pump Shock Absorber 109-9
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
X Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D09-39 Shock absorber 20 kg

When referring to this page, please quote Data D10909 Edition 0032 Page 1 (2)
MAN B&W Diesel A/S
109-9 Fuel Pump Shock Absorber
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 D10909 Edition 0032
MAN B&W Diesel A/S
 Fuel Pump Shock Absorber 909-9.1
Checking
Fuel Pump Shock Absorber
S60MC-C
0214
Checking
909-9.1

To ensure satisfactory operation, the function-

ing of the fuel pump shock absorber should be
checked at regular intervals. Normally, inspec-
tion is necessary only at the intervals stated in
the maintenance programme. The checks
should be carried out while the engine is oper-
ating.

1. Remove the plug from the end cover of the

shock absorber. Check that air is ‘pulsating’
through the threaded hole.

Short bursts of air should be felt against the

HM909-4.0 09 01
hand, corresponding to the strokes of the
fuel pump.

The air pulses occur when the shock ab-

sorber piston is working and the air below
the piston is being compressed and forced
out through the threaded hole.

2. To check the ‘tightness’ of the piston, meas-

ure the amount of leakage oil flowing from
the drain pipe of the shock absorber hous-
ing. Note down the amounts measured and
compare with earlier measurements.

Increasing amounts indicate a deteriorating

piston sealing. Excessive amounts indicate
that the shock absorber requires overhaul-
ing.
See Procedure 909-9.3.

When referring to this page, please quote Procedure M90909 Edition 0214 Page 1 (3)
0$1% :'LHVHO$6
909-9.3 Fuel Pump Shock Absorber
Overhaul
Overhaul
909-9.3

1.

Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
D09-39 has been drained off.

1. Remove the shock absorber drain pipe.

Place a wire strap around the shock ab-
sorber and hook on the engine room crane.
Loosen the screws holding the shock ab-
GN909-9.3 204 01

sorber and remove it from the fuel pump

housing.

2. Remove the plug from the end cover of the

shock absorber. Fit a threaded rod between
2. the piston and the end cover to counteract
the force of the springs. Loosen the screws
of the end cover and remove the end cover
and piston. Discard the gasket.

3. Loosen the nut on the threaded rod to re-

lieve the springs and remove the threaded
rod. Remove and discard the sealing ring in
the shock absorber housing and the wear
ring on the piston.

4. Clean all parts and polish the sliding sur-

faces of the piston and the shock absorber
housing. Mount a new sealing ring in the
HG909-9.2 201 02

shock absorber housing and a new wear

ring on the piston.

5. Mount the springs and the spring guide be-

tween the end cover and the piston, using
4. the threaded rod.

Lubricate all sliding surfaces and assemble

the shock absorber. Take care not to dam-
age the sealing ring or wear ring when
mounting the piston. Check that the piston
slides easily in the shock absorber housing.

6. Mount the end cover. For tightening the

nuts, see Data. Lock with the locking de-
vice. Remove the threaded rod and insert
the plug.
HG909-9.2 201 04

Page 2 (3) When referring to this page, please quote Procedure M90909 Edition 0214
0$1% :'LHVHO$6
 Fuel Pump Shock Absorber 909-9.3
Overhaul

7. Fit a new gasket on the fuel pump housing

and mount the shock absorber. Mount the
shock absorber drain pipe.

If an excessive amount of drain oil is still

observed after the overhaul, the shock ab-
sorber must be replaced and the damaged
one sent to an authorized MAN B&W repair
shop for reconditioning.

When referring to this page, please quote Procedure M90909 Edition 0214 Page 3 (3)
0$1% :'LHVHO$6
 Fuel Valve 109-11
Data

SAFETY PRECAUTIONS
Special Edition
S50MC-C
D10911
109-11 Data 0061 Fuel Valve

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
X Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D09-40 Fuel valve opening pressure 350 - 380 bar

D09-41 Fuel valve tightening torque 25 Nm
D09-42 Inlet seat, max. diameter 18 mm
D09-43 Fuel valve 8 kg

When referring to this page, please quote Data D10911 Edition 0 S61 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 177 Grinding mandrel for thrust spindel
P90951 189 Grinding mandrel for holder - outside
P90951 190 Grinding mandrel for holder - inside
P90951 248 Hook wrench
P90951 297 Assembling tool for fuel valve
P90961 Fuel Valve tester, complete

Page 2 (2) When referring to this page, please quote Data D10911 Edition 0 S61
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking
Fuel Valve
S50MEC
0235
Checking
909-11.1

1.
The fuel valves must be given the utmost atten-
tion and care, as the greater part of irregulari-
ties 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 Schedules. 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 disassem-
bled, cleaned, inspected and re-assembled
befire testing. See Procedures 909-11.3 and
909-12.3.
GN909-11.1 204 01
Note!

In the event that the slide-type fuel valve

is pressure tested without being cleaned
between the fuel nozzle and the cut-off 2.
slide, the opening pressure value measu-
ered might be considerably lower than D09-41
specified.

All fuel valves must be function-tested before

being mounted in the cylinder cover.

1. Pressure testing pump

If an air supply of 10 bar is not available,

working air of 7 bar can be used. Regarding
the operation of the pressure testing pump,
see the supplier’s instructions.

Note!

The high-pressure pump should be peri-

odically checked in accordance with the
supplier’s instructions.

Prescribed oil: Hydraulic oil (rust-prevent-

ing) with a viscosity of between 7 and 10
cSt at 50°C.
Note: use clean oil only.
GN909-11.1 204 02

2. Setting-up the fuel valve

Place the fuel valve in the test rig and se-

cure it with the tubular spacers and nuts.

When referring to this page, please quote Procedure M90911 Edition 0235 Page 1 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

3. Tighten the nuts to the torque stated in Da-

ta. Mount the oil pipe between the pressure
testing pump and the fuel valve.

3. Pressure testing procedure

The subsequent items must be followed in
the sequence stated. Items 4, 6, 7 and 8
are each divided into the following four sub-
items:
A. Objective
B. Procedure
C. Acceptance criteria
D. Cause of fault.

Note!

If working air of 10 bar is not available,

pressures down to 7 bar are acceptable
for all the tests.
GN909-11.1 204 03

4. Flushing and jet control

A. Objective:
To remove air in the system and check the
fuel jet.
4.
B. Procedure:
The control handle must be in the OPEN
position. Slowly increase the working pres-
sure until straight jets of oil are ejected from
the nozzle holes (no atomization).

C. Acceptance criteria:
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 the height to
which the spindle is lifted during pressure
testing 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.

D. Cause of fault:
If the above point C is not fulfilled, the
cause may be:
GW909-11.1 235 04

• Dirt in the nozzle holes.

• The nozzle is not mounted correctly.

Page 2 (14) When referring to this page, please quote Procedure M90911 Edition 0235
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking

5. Atomization test 5.

Note!

Do NOT attempt to carry out an atomiza-

tion test on slide type fuel valves, as this
may damage the cut-off slide and nozzle.

The reason is that the atomization test may

damage the valve because it makes the
needle oscillate, with a small lift at a very
high frequency. The high pressure drop

GW909-11.1 235 05
across the cut-off edge and the high con-
tact pressure between slide and fuel noz-
zle, in combination with the poor lubricity of
the test oil, increase the risk of seizures be-
tween cut-off slide and nozzle.
6.
All of these conditions involve the risk of
seizure between the cut-off slide and the D09-40
nozzle.

6. Opening pressure

A. Objective:
To check the opening pressure.

B. Procedure:
The control handle is to be in the OPEN po-
sition.

Increase the oil pressure until oil is admit-

ted through the nozzle holes.

C. Acceptance criteria:
Check the opening pressure on the pres-
sure gauge.
GN909-11.1 204 06

When referring to this page, please quote Procedure M90911 Edition 0235 Page 3 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

7. D. Cause of fault:
If the opening pressure is higher than spec-
ified in D09-40, the cause may be that a
wrong type of spring is used – replace the
spring on the thrust spindle, if necessary,
replace the complete thrust spindle.

If the opening pressure is lower than spec-

ified in D09-40, the cause may be that the
spring has sagged – replace the spring, or
add a special 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 from step 4.

7. Sealing test and sliding function

A. Objective:
To check the needle valve seat for tightness
and the slide for correct closing.

B. Procedure:
The control handle must be in the OPEN po-
sition.

Slowly increase the oil pressure to about 50

bar below the opening pressure. Maintain
the built-up pressure by moving the control
handle into the CLOSED position. Repeat the
procedure two or three times.
GN909-11.1 204 07

C. Acceptance criteria:
Oil must not flow from the nozzle holes.

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.

Page 4 (14) When referring to this page, please quote Procedure M90911 Edition 0235
MAN B&W Diesel A/S
 Fuel Valve 909-11.1
Checking

D. Cause of fault:

D.1 Sealing test

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 re-
place 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.
See Procedure 909-13.3.

D.2 Sliding function

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!

There will always be an oil flow from the

GN909-11.1 204 07

leak oil outlet when the fuel valve is full of

oil.

If a quick pressure drop from 15 to 0 bar

cannot 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.

When referring to this page, please quote Procedure M90911 Edition 0235 Page 5 (14)
MAN B&W Diesel A/S
909-11.1 Fuel Valve
Checking

8. 8. Pressure test, O-ring sealings

A. Objective:
To ensure that the leak oil (circulation oil)
remains in the closed system.

B. Procedure:
The control handle is to be in the OPEN po-
sition.

Build up a working pressure of about max.

10 bar until oil flows out of the leak oil out-
let.

C. Acceptance criteria:
Close the leak oil outlet with a gasket and
plug screw.

Increase the working pressure to about 100

bar.

Move the control handle to the CLOSED po-

sition.

The built-up pressure of about 100 bar

should be maintained.

D. Cause of fault:
If oil leaks out at the union nut, the O-ring
inside the fuel valve head is defective, and
must be replaced.
GN909-11.1 204 08

Page 6 (14) When referring to this page, please quote Procedure M90911 Edition 0235
MAN B&W Diesel A/S
 Fuel Valve 909-11.2
Dismantling
Dismantling
909-11.2

1. Close the fuel oil inlet and outlet valves. 1.

Dismantle the high-pressure pipe. See Pro-

cedure 909-14.2.

Disconnect the return oil pipe from the fuel

valve.

2. Remove the nuts and the tubular spacers.

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

use the fuel valve dismantling tool to pull
the valve clear of the top cover.

GW909-11.2 235 01
If the valve is not to be overhauled immedi-
ately, the valve should be immersed in die-
sel oil until overhauling.

GN909-11.2 204 02 2.

3.

D09-43
MN909-11.2 206 03

When referring to this page, please quote Procedure M90911 Edition 0235 Page 7 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul
Overhaul
909-11.3

1. When fuel valves are overhauled, all parts

should be handled carefully and be kept clean.

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-
A fore reassembly.
GW909-11.3 235 01

1. Measure the length A of the protruding part

of the nozzle, and write down the result for
correct re-assembling of the valve.

2. 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-

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

Remove the valve from the valve holder.

GW909-11.3 235 02

3.
MN909-11.3 222 03

Page 8 (14) When referring to this page, please quote Procedure M90911 Edition 0235
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

4. Pull the valve head clear of the valve hous- 4.

ing.

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.

GW909-11.3 235 04

When referring to this page, please quote Procedure M90911 Edition 0235 Page 9 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul

5. 5. Carefully clean and examine all surfaces of

the:

• Fuel valve housing

D09-42 • 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 Carbo-
rundum No. 500).

This grinding must only be carried out man-

ually.

After the grinding, wash the parts in gas oil

and blow clean by means of compressed air
to remove any remains of the grinding com-
pound.

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 exceeding approx. 100 r/min). An am-
ple supply of cutting emulsion must be
used.

Note!

Take care not to exceed the maximum

diameter of the seat, see Data.
GN909-11.3 204 02

Page 10 (14) When referring to this page, please quote Procedure M90911 Edition 0235
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

6. The complete spindle guide, including the 6.

fuel nozzle, should be sent to an authorised
MAN B&W repair shop for overhaul. If this
is not possible, the spindle guide may be
overhauled on board.
See Procedure 909-12.3.

Note!

Do not attempt to remove the fuel nozzle

GW909-11.3 235 06
from the spindle guide unless the spindle
guide has been dismantled. Otherwise
the cut-off slide on the spindle may be
damaged.
7.
7. 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
valve may be overhauled on board.
See Procedure 909-13.3.

8. Mount the complete spindle guide, includ-

ing the fuel nozzle, in the fuel valve hous-
ing.

Carefully slide the spindle guide down into

GN909-11.3 204 04

the valve holder, and turn the nozzle until it

engages correctly with the guide pin. Check
that distance A corresponds to the meas-
urement taken before the valve was disas-
sembled.
8.

Note!

Make sure that the fuel nozzle engages

correctly with the guide pin in the fuel
valve housing. This can be ascertained
by attempting to turn the nozzle by hand
after mounting. It must not be possible to
turn the nozzle.
GW909-11.3 235 08

When referring to this page, please quote Procedure M90911 Edition 0235 Page 11 (14)
MAN B&W Diesel A/S
909-11.3 Fuel Valve
Overhaul

9. 9. Mount:

• 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

molybdenum disulphide (MoS 2).
For the correct use of this lubricant, see
Procedure 913-11.

Fit the valve head with new O-rings.

10. Make sure that the guide pin between valve

housing and valve head is intact. Press the
valve head down into the valve housing and
check that the guide pin engages correctly
so as to prevent relative turning of the
GW909-11.3 235 09

parts.

10.
GN909-11.3 204 07

Page 12 (14) When referring to this page, please quote Procedure M90911 Edition 0235
MAN B&W Diesel A/S
 Fuel Valve 909-11.3
Overhaul

11. Assemble the valve by means of the union 11.

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 tight-
en the union nut with a hook spanner.

After overhaul, the fuel valve must be test-

ed in the test rig.
See Procedure 909-11.1.

12. If the fuel valve is not to be mounted in the

engine immediately after the overhaul, cov-
er all openings of the valve with plastic to
prevent dirt from entering the valve during
storage. MN909-11.3 222 09

When referring to this page, please quote Procedure M90911 Edition 0235 Page 13 (14)
MAN B&W Diesel A/S
909-11.4 Fuel Valve
Mounting
Mounting
909-11.4

1.

Note!

All fuel valves must be function-tested

before being mounted in the cylinder
cover, see Procedure 909-11.1.

1. Before mounting the fuel valve, thoroughly

clean the valve bore in the cylinder cover
and check the seating in the bore for marks
which, if any, must be eliminated.
(For reconditioning of valve bore in cylinder
GN909-11.4 204 01

cover, see Procedure 901-1).

If not already done, mount new O-rings on

the fuel valve. Lubricate the valve with mo-
lybdenum Disulphide (MoS 2).
2.
2. Mount the valve in position in the cylinder
D09-41 cover.

Mount the tubular spacers and nuts. Tight-

en the nuts as stated in Data.

3. Lubricate the thread on the union nipple of

the fuel oil pipe with a heat resistant anti
seize grease before mounting.

Note!
GN909-11.2 204 02

It is recommended to overhaul the fuel oil

pipe before mounting.
See Procedure 909-14.3.

3. Mount the overhauled fuel oil pipe. See

Procedure 909-14.4.

Mount and tighten the union nuts.

Reconnect the return oil pipe to the fuel

valve.

Turn on the fuel oil supply.

GW909-11.4 235 03

Page 14 (14) When referring to this page, please quote Procedure M90911 Edition 0235
MAN B&W Diesel A/S
 Spindle Guide 109-12
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 D10912 Edition 0047 Page 1 (2)
MAN B&W Diesel A/S
109-12 Spindle Guide
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

P90966 Fuel Valve Nozzle - Tools

P90968 Fuel Valve - Inspection Tools
P90974 Fuel Valve Nozzle - Cleaning Tools

Page 2 (2) When referring to this page, please quote Data D10912 Edition 0047
MAN B&W Diesel A/S
 Spindle Guide 909-12.3
Overhaul
Spindle Guide
S50ME-C
0222
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 8000 hours of operation.

1. Clean the outside of the spindle guide in pure

gas oil or kerosene. The individual parts of the
spindle guide are not interchangeable, there-
fore only one guide is to be disassembled at
a time.

Note!
GW909-12.3 222 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
GW909-12.3 222 04

and the spindle guide and very carefully

force the fuel nozzle off the spindle guide.

When referring to this page, please quote Procedure M90912 Edition 0222 Page 1 (5)
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 kerosene or ‘Elec-

trocleaner’ and wipe dry with a clean piece
of cloth.

Place all the parts on a clean, lint-free cloth

and examine them through an 8-10 times
magnification magnifying glass and an in-
spection 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’.
GW909-12.3 222 05

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.

Page 2 (5) When referring to this page, please quote Procedure M90912 Edition 0222
MAN B&W Diesel A/S
 Spindle Guide 909-12.3
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 spray holes, us-
ing gas oil and the special drills supplied.

Note!

During this operation be very careful not

to push the drill too far to avoid scratch-
ing the snug-fit surface on the inside of
the fuel nozzle.

Clean the fuel nozzle with kerosene and

wipe dry with a clean cloth.

Then test the spray holes with the test pin.

If the test pin is able to enter just one of the
holes, the fuel nozzle must be discarded.

This also applies to nozzles with oval holes

(can be ascertained with a magnifying
glass).
GW909-12.3 222 07

Check the fuel nozzle before mounting on

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

changed whenever the spindle guide is
being overhauled.

When referring to this page, please quote Procedure M90912 Edition 0222 Page 3 (5)
MAN B&W Diesel A/S
909-12.3 Spindle Guide
Overhaul

9. 8. Lubricate the spindle and the thrust piece

with the cut-off slide with a little Molybde-
num Disulphide (MoS 2), see Procedure
913-11.

9. Assemble the thrust piece, the spindle and

the spindle guide and carefully knock the
parts together using a soft hammer.

10. 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

10.
GW909-12.3 222 10

Page 4 (5) When referring to this page, please quote Procedure M90912 Edition 0222
MAN B&W Diesel A/S
 Spindle Guide 909-12.3
Overhaul

11. Lubricate the sliding surfaces of the nozzle 11.

and the spindle with a little Molybdenum Di-
sulphide (MoS 2). See Procedure 913-11.

Mount the nozzle on the spindle guide.

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.

Press the nozzle on to the spindle guide.

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
GW909-12.3 222 11

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, by ‘shaking’
the spindle guide.

12. 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.

When referring to this page, please quote Procedure M90912 Edition 0222 Page 5 (5)
MAN B&W Diesel A/S
 Non-return Valve 109-13
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

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 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 D10913 Edition 0033 Page 1 (2)
MAN B&W Diesel A/S
109-13 Non-return 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

P90951 153 Flange for dismantling of non return valve

P90968 Fuel Valve - Inspection Tools

Page 2 (2) When referring to this page, please quote Data D10913 Edition 0033
MAN B&W Diesel A/S
 Fuel Valve Non-return Valve 909-13.3
Overhaul

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.

M90913
0207O01
Note!
Except for the slide valve spring, defec-
tive parts cannot be replaced individually
by new ones.
2.

Place the non-return valve as shown in Fig.

1 in a bench vice provided with “soft” jaws,
and disassemble the non-return valve, us-
ing the disassembling tool and a hammer
as shown.

2. Clean all the parts for the spindle guide in

gas oil and then blow clean.

Finally, clean in either gas oil, kerosene or

‘Electrocleaner', and blow the parts dry
M90913
0207O02

with compressed air as shown in Fig. 2.

3. Now place the parts on clean, lint-free rags

and examine with an 8-10 times enlarge-
ment magnifying glass, and an inspection
lamp with magnifying glass as shown in 3.
Fig. 3.
M90913
0207O03

When referring to this page, please quote Procedure M90913 Edition 0207 Page 1 (2)
MAN B&W Diesel A/S
909-13.3 Fuel Valve Non-return Valve
Overhaul

4. Examine the slide faces of movable parts

4. 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).
M90913
0207O04

5. Check spring C for the thrust piece for out-

side wear marks. If defective, it should be
exchanged.

Check the seat on thrust piece D/vent

5. slide, and the seat on vent slide/housing.
Use an inspection lamp and an 8-10 times
enlargement 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.

6. Mount the non-return valve as follows:

• Lubricate all movable parts with molyb-

denum disulphide (MoS2).
M90913
0207O05

• Place the loosely-assembled non-return

valve on the plane of a drilling machine,
with the tool positioned as shown in
Fig. 6.
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 overhaul, cover all openings of the non-
return valve with plastic to prevent dirt from
M90913
0207O06

entering the valve during storage.

Page 2 (2) When referring to this page, please quote Procedure M90913 Edition 0207
MAN B&W Diesel A/S
 Fuel Oil High-Pressure Pipe 109-14
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
Shut off cooling water
X Shut off fuel oil
Stop lubricating oil supply
Lock the turbocharger rotors

Data

Ref. Description Value Unit

D09-47 Fuel oil high-pressure pipe, tightening torque 100 Nm

D09-51 Distance from pipe end to thrust bushing lower edge 11 mm
D09-52 Fuel oil pipe 8 kg

When referring to this page, please quote D10914 Edition 0074 Page 1 (2)
MAN B&W Diesel A/S
109-14 Fuel Oil High-Pressure Pipe
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

P90951 104 Milling tool for fuel oil pipe

P90951 128 Crowfoot spanner
P90951 141 Crowfoot spanner
P90951 319 Hook wrench for hose pipe

Page 2 (2) When referring to this page, please quote Data D10914 Edition 0074
MAN B&W Diesel A/S
 Fuel Oil High-Pressure Pipe 909-14.2
Dismantling
Fuel Oil High-Pressure Pipe
S60MC-C
0234
Dismantling
909-14.2

2.
High-Pressure Pipe with Protective Hose

1. Close the fuel oil inlet and outlet valves.

2. Using a hook spanner, unscrew the union

nut at the fuel valve end of the high-pres-
sure pipe.

Pull the union nut and the protective hose

clear of the union nipple.

Unscrew the union nipple from the fuel

valve.

HN909-14.2 209 02
3. Using a hook spanner, unscrew the union
nut at the fuel pump end of the high-pres-
sure pipe.

Pull the union nut and the protective hose 3.

clear of the union nipple.

Unscrew the union nipple from the fuel

pump.

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

HN909-14.2 209 03

the high-pressure pipe before remounting

it on the engine.
See Procedure 909-14.3.

The overhaul should preferably take

4.
place immediately after the high-pres-
sure pipe has been dismantled.

D09-52
HN909-14.2 209 04

When referring to this page, please quote Procedure M90914 Edition 0234 Page 1 (4)
0$1% :'LHVHO$6
909-14.3 Fuel Oil High-Pressure Pipe
Overhaul
Overhaul
909-14.3

1. 1. Whenever the fuel oil high-pressure system

has been dismantled, it is necessary, be-
D09-51
fore remounting the high-pressure pipes, to
carefully inspect the tapered contact surfac-
es of the pipe ends, together with their
seats in fuel valves and fuel pump top cov-
er.

Furthermore, the position of the thrust

bushing on the pipe end must be checked.
If the distance is incorrect, compared with
the measurement stated in Data, it should
be adjusted by screwing the thrust bushing
up or down the pressure pipe.

2. If any of the pipe ends requires recondition-

ing, dismantle the high-pressure pipe as
HM909-7.0 59 01

follows:
D09-51
• Lift up the union nut with flexible protec-
tive hose, together with the coupling nut,
on the high-pressure pipe and screw off
2. the thrust bushing.

• Remove the coupling nut and, when the

thrust bushings at both ends of the pipe
have been dismounted, pull the flexible
protective hose with union nuts off the
high-pressure pipe.

3. Shape-up the threads on the pipe ends with

the nut die.
MC909-7.0 67 02

3.
MC909-7.0 67 04

Page 2 (4) When referring to this page, please quote Procedure M90914 Edition 0234
0$1% :'LHVHO$6
 Fuel Oil High-Pressure Pipe 909-14.3
Overhaul

4. Mount the guide on the pipe end, place the 4.

miller in the guide and lightly screw on the
union nut.

5. Turn the miller with, for instance, a tap

wrench while lightly tightening the union nut
to provide a suitable pressure between mill-
er and pipe end. During the milling, add
drilling oil emulsion liberally.

After completing the milling, carefully clean

the high-pressure pipe with diesel oil and
wipe dry with a clean piece of cloth.

MC909-7.0 67 03
6. When assembling the high-pressure pipe,
screw the thrust bushings so high up on the
thread of the pressure pipe that the dis-
tance between the pipe end and the bottom
edge of the thrust bushing is as stated in 5.
Data.

Replace the O-rings.

Before mounting a high-pressure pipe,

check the centre distances between pipe
ends and seats, and lubricate the threads
of the union nuts with molybdenum disul-
phide (MoS 2).

It is of great importance for the mounting,

and a condition for obtaining tight joints,
GN909-14.3 204 05

that the pipes fit the seats accurately.

For reconditioning of seat in fuel valve, see

Procedure 909-11.3.

For reconditioning of seat in fuel pump top 6.

cover, see Procedure 909-5.3.
D09-51
HM909-7.0 62 06

When referring to this page, please quote Procedure M90914 Edition 0234 Page 3 (4)
0$1% :'LHVHO$6
909-14.4 Fuel Oil High-Pressure Pipe
Mounting
Mounting
909-14.4

4. 1. Check that the distance between the thrust

bushing and the pipe end is correct at both
ends of the pipe. See Procedure 909-14.3.

2. Ensure that the fuel valve is fitted with a

D09-52 new O-ring. Lubricate the thread of the fuel
valve with a heat resistant grease.

3. Ensure that the union nipple at the fuel

pump 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.
HN909-14.4 209 04

4. Mount the high-pressure pipe between the

fuel valve and the fuel pump.

Screw the union nipples onto the fuel valve

5. and into the fuel pump top cover, by hand.

Note!

The nipples must be screwed by hand,

as the threads of the union nipples, fuel
valve or fuel pump top cover might other-
wise be damaged.
Tightening with a crowfoot wrench should
only be done after both of the union nip-
ples have been screwed into position.

5. Use a crowfoot wrench and a torque

HN909-14.4 209 05

D09-47
wrench to tighten the union nipple at the
fuel valve to the torque stated in Data.

Screw the union nut onto the union nipple

6. by hand, and tighten lightly with a hook
spanner.

6. Use a crowfoot wrench and a torque

wrench to tighten the union nipple at the
fuel pump to the torque stated in Data.

Screw the union nut onto the union nipple

by hand, and tighten lightly with a hook
spanner.

7. If dismantled, re-mount the return oil pipe

on the fuel valve. Open the fuel oil inlet and
outlet valves.
HN909-14.4 209 06

D09-47

Page 4 (4) When referring to this page, please quote Procedure M90914 Edition 0234
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 109-15
Data

SAFETY PRECAUTIONS
Special
D10915 Data 0050
109-15 Edition Fuel Pump
S50MC-C
Roller Guide

Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D09-53 Nut, reversing shaft, tightening torque 80 Nm

D09-54 Clearance A 2.8 - 5.3 mm
D09-55 Clearance B 0.7 - 3.2 mm
D09-56 Clearance C, max. 0.45 mm
D09-57 Roller/bushing/shaft pin, max. clearance 0.5 mm
D09-60 Housing for sealing arrangement 70 kg
D09-61 Fuel pump roller guide 60 kg
D09-62 Pump base 31 kg

When referring to this page, please quote Data D10915 Edition 0050 Page 1 (2)
MAN B&W Diesel A/S
109-15 Fuel Pump Roller Guide
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

P90851 173 Lifting tool for exhaust valve roller guide

Page 2 (2) When referring to this page, please quote Data D10915 Edition 0050
MAN B&W Diesel A/S
 Fuel Pump Roller Guide 909-15.1
Checking
Fuel Pump Roller Guide
S60MC-C
0226
Checking
909-15.1

3.
Roller guide mounted in engine

1. The fuel pump roller guide can be partially

checked while mounted on the engine, us-
ing the following procedure:

2. Lift the fuel pump roller guide.

See Procedure 909-10.

3. Remove the cover on the camshaft housing

to inspect the fuel pump roller guide.

Turn the engine to provide the maximum

HN909-10.1 205 01
space between the roller guide and the cam
disc.

Turn the roller by hand to check that it can

move freely and without unnecessary re-
sistance or “hard” points. 5.

Also inspect the surface of the roller for

possible damage marks, seizures or
scratches. Make sure that there are no trac-
es of bearing metal left in the roller guide
housing.

Check the clearance in the slide bearing by

lifting the roller relative to the roller guide
and measuring the difference in distance
between the cam disc and the roller in the
upper and lower positions of the roller.

4. Lower the roller guide onto the fuel cam

again.
See Procedure 909-10.

5. Using the telegraph, move the roller guide

to the AHEAD position.
GN909-15.1 203 05

Check that the reversing link is fully tilted

over in AHEAD position.

Carry out the same check in the ASTERN po-

sition.

When referring to this page, please quote Procedure 909-15.1 Edition 0226 Page 1 (10)
0$1% :'LHVHO$6
909-15.1 Fuel Pump Roller Guide
Checking

7. Roller guide removed from engine

A more suitable and reliable method is to check

the roller guide and the bearing clearance after
the roller guide has been dismounted:

6. Dismount the roller guide from the engine.

See Procedure 909-15.2.

7. Check the surface of the roller and the slid-

ing surfaces of the roller guide, and meas-
ure any ovalness.

8. Turn the roller guide upside down and land

it in a vertical position on a couple of
planks, with the roller hanging freely.

Measure the clearance in the slide bearing

by placing a dial gauge against the roller
and lifting the roller as much as the clear-
ance permits.
MA909-8.0 70 07

8.

D09-57
MA909-8.0 70 06

Page 2 (10) When referring to this page, please quote Procedure 909-15.1 Edition 0226
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 909-15.2
Dismantling
Dismantling
909-15.2

1.
Note!

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.

1. Dismantle the top cover of the fuel pump.

See Procedure 909-5.2.

2. Dismantle the fuel pump barrel assembly.

See Procedure 909-6.2.

GN909-5.2 204 03

2.
GN909-6.2 204 06

When referring to this page, please quote Procedure 909-15.2 Edition 0226 Page 3 (10)
0$1% :'LHVHO$6
909-15.2 Fuel Pump Roller Guide
Dismantling

3. 3. Dismantle the fuel pump housing, see Pro-

cedure 909-4.2.

Note!

When lifting the fuel pump housing, take

care not to damage the threads on the
studs.

4. Loosen and remove the screws from the

sealing cap on top of the roller guide inside
the pump base.

Remove the sealing cap from the roller

guide/pump base.

Dismantle the lubricating oil pipe and the

GN909-15.2 203 03

drain pipe from the pump base.

5. Remove the cover on the camshaft housing

to inspect the position of the roller guide.
Turn the engine until the roller guide is at
4.
BDC.
HN909-15.2 206 04

5.
HN909-10.1 205 01

Page 4 (10) When referring to this page, please quote Procedure 909-15.2 Edition 0226
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 909-15.2
Dismantling

6. Loosen the nuts on the two threaded studs 6.

successively until the roller guide springs
are relieved.

Remove the nuts, mount two eye bolts in

the pump base and lift it away. D09-62
When lifting, take care that the bushing of
the pump base slides against the neck of
the roller guide without scratching.

Remove the springs from the roller guide.

7. Mount the roller guide lifting tool as follows:

• Lift the lock plate of the tool up on the

shaft of the tool.

• Position the tool so that its foot rests on

the thrust piece in the bayonet joint of the
roller guide.
HN909-15.2 206 06

• Turn the tool 90° so as to allow the foot to

engage properly in the bayonet joint.

• Lower the lock plate, thereby securing

the foot in the locked position.
7.
Lift the roller guide out of the roller guide
housing, using the crane.

When lifting, take care that the slide surfac-

es of the roller guide do not scrape against
the roller guide bushing. D09-61

Land the roller guide on wooden planks.

8. Check the roller guide.

See Procedure 909-15.1.
GN909-15.2 203 07

When referring to this page, please quote Procedure 909-15.2 Edition 0226 Page 5 (10)
0$1% :'LHVHO$6
909-15.3 Fuel Pump Roller Guide
Overhaul
Overhaul
909-15.3

1. 1. Inspect and check the fuel pump roller

guide.
See Procedure 909-15.1.

2. It is recommended that the roller guide

D09-61 should ONLY be dismantled if

• irregularities when turning the roller,

• damage to the roller,

• larger clearance than stated on the Data

sheet,

• seizure marks on the slide surfaces,

have been observed when checking the

roller guide.

Note!

For disassembling of the roller guide,

MA909-8.0 70 07

contact an MAN B&W authorized repair

shop.

3. If no irregularities are found, just clean and

3. lubricate the roller guide before remounting
it in the roller guide bushing.
HN909-15.3 206 03

Page 6 (10) When referring to this page, please quote Procedure 909-15.3 Edition 0226
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 909-15.4
Mounting
Mounting
909-15.4

1. Lubricate the roller guide with plenty of 1.

camshaft lubricating oil, and mount it in the
roller guide bushing, using the lifting tool.

During mounting, take care not to scratch

the sliding surfaces of the roller guide.
D09-61
Make sure that the pin of the reversing link
fits in the bracket of the reversing shaft.

2. After mounting the roller guide with the re-

versing link, check the clearance between
the roller guide and the guide plate mount-
ed in the roller guide bushing.

Turn the camshaft so that the roller guide is

lifted approx. 20 mm.

The clearance C between the roller guide

and the guide plate must be the same at
both ends +/– 0.1 mm.
HN909-15.4 206 01

The clearances A and B between the

guideway and the pin of the reversing link
(arm) must be checked in the AHEAD and
ASTERN positions.

Connect working air to the air cylinder, and 2.

check that the reversing mechanism is
working smoothly.

The clearances A and B must be approx.

the same in both positions. See Data.

D09-54
D09-56

D09-55
HN909-15.4 206 02

When referring to this page, please quote Procedure 909-15.4 Edition 0226 Page 7 (10)
0$1% :'LHVHO$6
909-15.4 Fuel Pump Roller Guide
Mounting

3. 3. If adjustment is necessary, it must take

place in the ASTERN position.

Remove the cover over the shaft connec-

tion.

Loosen the nut on the reversing shaft and

carry out the adjustment.

After adjustment, shift to AHEAD position

and check the clearances A and B once
more.

Finally, shift again to ASTERN.

Tighten the nut on the reversing shaft to the

D09-53 torque stated in Data, and lock the nut with
Loctite type: Screw Lock No. 59.

Mount the cover over the shaft connection.

4. Turn the engine until the roller guide is at

HN909-15.4 206 03

BDC.

5. Mount the springs and the spring seat discs

over the roller guide.

5. Mount the pump base over the roller guide

and the springs.

Mount the two special nuts on the threaded

studs.

Using the special tube-shaped socket

D09-62 wrench, tighten the nuts until the pump
base is fastened tightly to the roller guide
bushing.
HN909-15.2 206 06

Page 8 (10) When referring to this page, please quote Procedure 909-15.4 Edition 0226
0$1% :'LHVHO$6
 Fuel Pump Roller Guide 909-15.4
Mounting

6. Check the movement of the reversing link. 6.

See Procedure 909-15.1.

7. Replace the scraper rings in the sealing

cap as follows:

Loosen and remove the screws and nuts

from the bottom of the cap, remove the re-
taining flange and ring holder with scraper
ring.

8. Replace the O-ring in the top of the cap.

Replace the axial scraper ring in the bottom

of the cap. Check that the O-ring and scrap-

GN909-15.1 203 05
er ring are mounted correctly. See the
sketch.

7.
GN909-15.4 203 07

8.
MA909-8.0 70 21

When referring to this page, please quote Procedure 909-15.4 Edition 0226 Page 9 (10)
0$1% :'LHVHO$6
909-15.4 Fuel Pump Roller Guide
Mounting

9. 9. Remove the scraper ring and O-ring from

the ring holder.

Place the new O-ring in the ring holder.

Before mounting, the new scraper ring must

be heated in 100°C hot water or oil for at
least five minutes.

Note!

When mounting the scraper ring in the

groove, fold the ring without making any
AM909-8.0 31 16

sharp edges, and be careful not to cut

the scraper ring on the edge of the ring
groove when pressing it in.

10. Check that the O-ring and scraper ring are

mounted correctly. See the sketch.

10. Assemble the sealing cap, the ring holder

and retaining flange.

Tighten the nuts on the screws.

After tightening, check that the holder can

be moved.

11. Mount the lubricating oil pipe and the drain

pipe on the pump base.
GN909-15.4 203 10

Mount the sealing cap on top of the roller

guide, over the sealing bush inside the
pump base.

11. Tighten the screws and lock with locking

wire.

12. Mount the fuel pump housing.

See Procedure 909-4.4.

Mount the barrel assembly.

See Procedure 909-6.4.

Mount the top cover.

See Procedure 909-5.4.
HN909-15.4 206 11

Page 10 (10) When referring to this page, please quote Procedure 909-15.4 Edition 0226
0$1% :'LHVHO$6
 Fuel Pump Special Running 109-16
Data

SAFETY PRECAUTIONS
Special Edition
S46MC-C
D10916
109-16 Data 0016 Fuel Pump Special Running

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
X Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D10916 Edition 0S16 Page 1 (2)
MAN B&W Diesel A/S
109-16 Fuel Pump Special Running
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

P90951 82 Lifting tool for fuel pump roller guide

Page 2 (2) When referring to this page, please quote Data D10916 Edition 0S16
MAN B&W Diesel A/S
S50MC-C Fuel Pump Emergency Running 909-16

Fuel Pump Emergenc y Running

S50MC-C
201
909-16

2.
Disengagement of fuel pump

Warning !

Disengagement or re-engagement of the

fuel pump roller guide or the exhaust
valve roller guide must only take place at
engine standstill.

1. Engine trouble might require a cylinder to

be taken out of action. The engine can con-
tinue operation with the fuel and exhaust

GN909-16 201 02
systems of a single cylinder disconnected.
See Volume I, Section 704.

To disconnect the fuel pump of a single cyl-

inder, proceed as follows:
3.
2. Remove the puncture valve from the fuel
pump.

Plug the air supply pipe to the puncture

valve.

Note !

Before dismantling any part of the fuel

pump, make sure that the pump has
been relieved of pressure and that all oil
has been drained off.
GN909-16 201 03

3. Remove the cover on the camshaft hous-

ing. Turn the engine until the fuel pump roll-
er is at TDC.
4.
4. Mount the lifting tool on the fuel pump top
cover and secure it in position with the two
screws.

Turn the uppermost nut to screw the spindle

of the lifting tool into the fuel pump plunger.
GN909-16 201 04

When referring to this page, please quote Procedure 909-16 Edition 204 Page 1 (2)
MAN B&W Diesel A/S
909-16 Fuel Pump Emergency Running S50MC-C

5. 5. Tighten the lowermost nut on the tool to pull

the roller guide upwards as far as possible.

Tighten the middle nut of the tool against

the lowermost nut to secure the roller guide
in this position.

6. Turn the engine one full revolution and in-

spect through the opening in the camshaft
housing to make sure that the roller guide
is clear of the fuel cam.

7. If necessary, disengage the exhaust valve

GN909-16 201 05

actuator.
See Procedure 908-7.

The engine can now operate on the remain-

ing cylinders. See Volume I, Section 704.
6.
Re-engagement of fuel pump

Warning !

Re-engagement of the fuel pump must

only take place at engine standstill.

8. Remove the cover on the camshaft hous-

ing. Turn the engine until the circular sec-
tion of the fuel cam is positioned upwards.

9. Lower the roller guide on to the fuel cam in

GN909-16 201 03

the reverse order to lifting.

10. Remove the lifting tool and re-mount the

puncture valve.
10.
GN909-16 201 10

Page 2 (2) When referring to this page, please quote Procedure 909-16 Edition 204
MAN B&W Diesel A/S
 Fuel Valve and Fuel Pump Panel Plate
P90951-0442

307

When referring to this page, please quote Plate P90951 Edition 0442 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve and Fuel Pump Panel
P90951-0442

Item Item Description Item Item Description

No. No.

010 Panel for tools

021 Name plate
045 Measuring tool, fuel pump lead
057 Lifting tool for fuel pump plunger barrel
069 Lifting tool, fuel pump
070 Lifting tool, fuel pump housing
082 Lifting tool, fuel pump roller guide
094 Milling tool, fuel oil pipe seats
104 Milling tool, fuel oil pipe
116 Crowfoot spanner
128 Crowfoot spanner
130 Crowfoot spanner
141 Crowfoot spanner
153 Flange, dismantling of non return
valve
165 Grinding mandrel, valve head
177 Grinding mandrel, thrust spindle
189 Grinding mandrel, holder - outside
190 Grinding mandrel for holder - inside
200 Screw, topcover
224 Tool for P.max rack
236 Neck spanner
248 Hook spanner
250 Drift, spindle guide
261 Drift for puncture valve
273 Drift, non return valve
297 Assembly tool, fuel valve
307 Hook spanner

Page 2 (2) When referring to this page, please quote Plate P90951 Edition 0442
MAN B&W Diesel A/S
 Fuel Valve - Tools Plate
P90961-0059

When referring to this page, please quote Plate P90961 Edition 0059 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve - Tools
P90961-0059

Item Item Description Item Item Description

No. No.

014 Test rig, complete

026 Rig fuel oil valve
038 High-pressure hose
051 Table
063 High-pressure pump
099 Gasket
109 Plug screw
110 Angle union
122 Hose
134 Cover, test rig
158 Connecting piece

Page 2 (2) When referring to this page, please quote Plate P90961 Edition 0059
MAN B&W Diesel A/S
 Fuel Valve Nozzle - Tools Plate
P90966-0008

When referring to this page, please quote Plate P90966 Edition 0008 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Tools
P90966-0008

Item Item Description Item Item Description

No. No.

011 Tool box

023 Extractor for atomizer
035 Drift for atomizer
047 Cleaning brush
060 Instruction plate
202 Toolset, complete

Note:

When odering new cleaning tool,

please state P/N on fuel nozzle.

Page 2 (2) When referring to this page, please quote Plate P90966 Edition 0008
MAN B&W Diesel A/S
 Fuel Puncture Valve - Tools Plate
P90967-0001

When referring to this page, please quote Plate P90967 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Puncture Valve - Tools
P90967-0001

Item Item Description Item Item Description

No. No.

017 Tool for tightening of puncture valve

Page 2 (2) When referring to this page, please quote Plate P90967 Edition 0001
MAN B&W Diesel A/S
 Fuel Valve - Inspection Tools Plate
P90968-0001

When referring to this page, please quote Plate P90968 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve - Inspection Tools
P90968-0001

Item Item Description Item Item Description

No. No.

012 Probe light with magnifier, complete

Page 2 (2) When referring to this page, please quote Plate P90968 Edition 0001
MAN B&W Diesel A/S
 Fuel Valve Nozzle - Cleaning Tools Plate
P90974-0001

When referring to this page, please quote Plate P90974 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Fuel Valve Nozzle - Cleaning Tools
P90974-0001

Item Item Description Item Item Description

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.

Page 2 (2) When referring to this page, please quote Plate P90974 Edition 0001
MAN B&W Diesel A/S
 Mounting Tools - Pump Barrel Seals Plate
P90977-0001
Mounting Tools - Pump Barrel Seals
0001
P90977

When referring to this page, please quote Plate P90977 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Mounting Tools - Pump Barrel Seals
P90977-0001

Item Item
Item Description Item Description
No. No.

011 Cone
023 Pushing tool
035 Compression tool
047 Cone
059 Pushing tool
060 Compression tool
072 Spacer ring

Page 2 (2) When referring to this page, please quote Plate P90977 Edition 0001
MAN B&W Diesel A/S
 Mounting Tools - Suction Valve Seals Plate
P90979-0001
Mounting Tools - Suction Valve Seals
0001
P90979

When referring to this page, please quote Plate P90979 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Mounting Tools - Suction Valve Seals
P90979-0001

Item Item
Item Description Item Description
No. No.

012 Cone
024 Pushing tool
036 Compression tool

Page 2 (2) When referring to this page, please quote Plate P90979 Edition 0001
MAN B&W Diesel A/S
 Mounting Tools - Air Piston Seals Plate
P90980-0001
Mounting Tools - Air Piston Seals
0001
P90980

When referring to this page, please quote Plate P90980 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate Mounting Tools - Air Piston Seals
P90980-0001

Item Item
Item Description Item Description
No. No.

018 Cone
020 Pushing tool
031 Compression tool
043 Cone
055 Pushing tool
067 Compression tool
079 Cone

Page 2 (2) When referring to this page, please quote Plate P90980 Edition 0001
MAN B&W Diesel A/S
 Air Cooler Element 110-1
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

Special Data
S50MC-C
0032
110-1 Air Cooler Element

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
X Shut off cooling water
2 x 2000 kg
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Air cooler element 1550 kg

When referring to this page, please quote Data D11001 Edition 0032 Page 1 (2)
MAN B&W Diesel A/S
110-1 Air Cooler Element
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D11001 Edition 0032
MAN B&W Diesel A/S
 Air Cooler Element 910-1.1
Checking
Air Cooler Element
S80MC
0229
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 instruction book Vol-
ume I, Chapter 706.

2. An increase in the air pressure drop across

the scavenge air cooler indicates fouling of

GN910-1.1 206 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, it is
recommended to inspect the air cooler ele-
ments as follows:

4. Remove the front end cover of the air cool-

er.

5. Visually inspect the air cooler element

through the opening.

Clean the element if it is fouled.

See Procedure 910-1.3.
GN910-1.1 206 04

If the element needs to be dismantled for

further inspection or replacement, see Pro-
cedure 910-1.2.

5.
GN910-1.1 206 06

When referring to this page, please quote Procedure M91001 Edition 0229 Page 1 (9)
MAN B&W Diesel A/S
910-1.2 Air Cooler Element
Dismantling
Dismantling
910-1.2

1. The cooler element normally does not need to

be dismantled for inspection purposes. It is only
in the event that the cooler element has suf-
fered damage that it has to be dismantled and
replaced.

Note!

During dismantling, take care not to dam-

age the cooler element.

1. Close the cooling water inlet and outlet

GN910-1.2 206 01

valves. Open the drain cocks in the aft end

cover to drain off the cooling water.

2. Dismount the cooling water inlet and outlet

pipes from the aft end cover.
2.
3. Release the screws and remove the frame
around the front end cover.

Remove and discard the O-ring.

Remove the sealing plate.

GN910-1.2 206 02

3.
GN910-1.2 206 03

Page 2 (9) When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
 Air Cooler Element 910-1.2
Dismantling

4. Mount the first set of guide rails on the 4.

frame around the front end cover.

5. When mounting the guide rails, hold them

up against the wheels of the cooler element
and mount, but do not tighten, the lower-
most screws. Mount and tighten the upper-
most screws.

Finally, tighten the lowermost screws and

the thrust nuts on the uppermost screws si-
multaneously. This results in loosening and
lifting the cooler element.

JN910-1.2 213 04
6. Mount the lifting bracket on the aft end cov-
er.

Mount a travelling trolley on the beam

above the aft end cover. 5.

Mount a tackle between the travelling trolley

and the lifting bracket, and use the tackle to
lift the air cooler element approx. 1-2 mm.
GN910-1.2 206 05

6.
GN910-1.2 228 06

When referring to this page, please quote Procedure M91001 Edition 0229 Page 3 (9)
MAN B&W Diesel A/S
910-1.2 Air Cooler Element
Dismantling

7. 7. Mount a second tackle on the lifting brack-

et, and use it to pull out the air cooler ele-
ment approx. half a metre.

8. Mount the second set of guide rails on the

frame around the air cooler element.

9. Pull out the air cooler element until the front

end cover of the air cooler element is clear
of the air cooler housing.

Mount a second travelling trolley on the

beam above the air cooler.
GN910-1.2 228 07

Mount a tackle between the second travel-

ling trolley and the lifting holes in the upper
corners of the front end cover of the air
cooler element.
8.
Using the tackles, lift the air cooler element
away and land it on a couple of wooden
planks.

Note!

Depending on the engine layout and

engine room installation, it may be nec-
essary to remove some pipes or floor
plates.
GN910-1.2 228 08

9.

D-2
GN910-1.2 228 09

Page 4 (9) When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
 Air Cooler Element 910-1.3
Overhaul
Overhaul
910-1.3

Cleaning the air side: 1.

The air side of the cooler is cleaned by injecting

a chemical fluid through the spray pipe arrange-
ment fitted to the air chamber above the cooler
element.

It is recommended to use one of the following

cleaning fluids, or a similar product.

1) Product: ACC 9, produced by

Drew Chemical Corp., New York, USA

GN910-1.3 206 01
2) Product: 80B, produced by
Vecom Int., Maassluis, Holland

Cleaning should be carried out in the following

sequence:
2.
1. Do not start cleaning until the engine has
been at a standstill for about 30 minutes.
Do not disconnect the compressed air sup-
ply to the exhaust valve.

2. 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.

3. Continue the cleaning process for at least

30 minutes. The time required depends on
the frequency with which cleaning is carried
out and on the chemical product used.

4. After cleaning, flush the cooler with clean

water until the water appearing in the sight
glasses is clean and pure.

5. Inspect the element either by removing the

cover on top of the cooler or by dismantling
KE910-5.1 61 02

the charging air pipe.

When referring to this page, please quote Procedure M91001 Edition 0229 Page 5 (9)
MAN B&W Diesel A/S
910-1.3 Air Cooler Element
Overhaul

6. Cleaning the water side

6. Close the cooling water inlet and outlet

valves. Remove the plug screws from the
front end cover and the aft end cover to
drain off the cooling water.

7. Dismount the cooling water inlet and outlet

pipes from the aft end cover.

8. Screw two eye bolts into the upper flange of

the aft end cover. Mount a lifting wire rope
between the eye bolts.
GN910-1.2 206 01

Mount a travelling trolley on the beam

above the aft end cover.

Mount a tackle between the travelling trolley

7. and the lifting wire rope. Tighten up the
tackle.
GN910-1.2 206 02

8.
GN910-1.3 206 03

Page 6 (9) When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
 Air Cooler Element 910-1.3
Overhaul

9. Mount a shackle in each of the two lifting 9.

eyes on the front end cover.

Mount two tackles above the front end of

the air cooler.

Hook the tackles on to the shackles and

tighten up.

10. Remove the screws of the front end and aft

end covers.

Lower both covers and land them on a cou-

ple of wooden planks. Discard the gaskets.

GN910-1.3 206 04
11. Clean the inside of the tubes, using the
cleaning brush mounted on a drilling ma-
chine. In the event of leakages between
cooling tube and tube plate, the tubes are 10.
rolled with the tube expander.

Tools for tube cleaning and the tube ex-

pander are supplied by the air cooler man-
ufacturer.

Clean the front-end and aft-end covers in-

side with a stiff brush and then rinsed with
fresh water.

Replace the anti-corrosion blocks, if neces-

sary.
GN910-1.3 206 05

Note!
D-1 D-3
D

If damaged, the coating inside the covers

is to be repaired with the original coating
or a similar product. 11.

12. When cleaning is complete, mount the cov-

ers in the reverse order to dismantling.
GN910-1.3 206 06

When referring to this page, please quote Procedure M91001 Edition 0229 Page 7 (9)
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 front

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

Remove the tackle from the front end of the

cooler.

2. Push the air cooler element inwards ap-

prox. one metre.
D-2
Remove the guide rails from the aft end of
the air cooler housing.
GN910-1.4 228 01

3. Clean the frame around the air cooler ele-

ment and the contact surface of the aft end
cover.

2. Apply a thin layer of silicone paste to the

frame around the air cooler element and the
contact surface of the aft end cover.

Push the air cooler element fully into the air

cooler housing.
GN910-1.4 228 02

3.
GN910-1.4 228 03

Page 8 (9) When referring to this page, please quote Procedure M91001 Edition 0229
MAN B&W Diesel A/S
 Air Cooler Element 910-1.4
Mounting

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

end cover.

Remove the tackle and the lifting bracket

from the aft end cover.

5. Remove the guide rails from the front end

cover.

6. Mount the sealing plate, a new O-ring and

the frame around the front end cover.

7. Mount the cooling water inlet and outlet

GN910-1.4 228 04
pipes on the aft end cover.

8. Close the drain cocks, and open the cooling

water inlet and outlet valves.

5.
Note!

Remember to vent trapped air from the

air cooler element.
JN910-1.4 213 04

6.
GN910-1.2 206 03

When referring to this page, please quote Procedure M91001 Edition 0229 Page 9 (9)
MAN B&W Diesel A/S
 Non-Return Valve 110-2
Data
N
SAFETY PRECAUTIONS For detailed sketch, see 900-2
D
X Stopped engine
R
X Shut off starting air supply – At starting air receiver
X Block the main starting valve B
X Shut off starting air distributor/distributing system supply I
X Shut off safety air supply – Not ME-engines
E
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 D11002 Edition 0009 Page 1 (2)
MAN B&W Diesel A/S
110-2 Non-Return 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

Page 2 (2) When referring to this page, please quote Data D11002 Edition 0009
MAN B&W Diesel A/S
 Non-Return Valve 910-2.3
Overhaul
Non-Return Valv e
S50MC-C
205
Overhaul
910-2.3

1.
The non-return valves are accessed from the
scavenge air receiver.

Note!

Access to the scavenge air receiver must

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

GN910-2.3 205 01
Main Non-Return Valve

1. Inside the scavenge air receiver, lift up the

valve flap of the valve that is to be over- 2.
hauled.

2. Remove the screws behind 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.
GN910-2.3 205 02

4. For further dismantling, remove the two

screws which hold the clamp and the sup-
port together as an assembly.

Clean the valve shaft and the slide bearings 3.

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

5. Assemble the valve

After the overhaul, it must be possible to

move the valve flap by the light touch of a
MC910-6.0 26 02

finger.

6. Re-mount the valve in the scavenge air re-

ceiver.
4.
MC910-6.0 26 03

When referring to this page, please quote Procedure 910-2.3 Edition 205 Page 1 (1)
MAN B&W Diesel A/S
 Auxiliary Blower 110-3
Data

SAFETY PRECAUTIONS
Special Edition
D11003
110-3 Data 0018 Auxiliary
S50ME-C Blower

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D10-09 Weight of blower unit, complete * up to 800 kg

*) Depending on electric motor type and number of
cylinders of engine (size and capacity of auxiliary blower)

When referring to this page, please quote Data D11003 Edition 0018 Page 1 (2)
MAN B&W Diesel A/S
110-3 Auxiliary Blower
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

P91356 Lifting Tools, etc.

P91361 Combination Wrenches

Page 2 (2) When referring to this page, please quote Data D11003 Edition 0018
MAN B&W Diesel A/S
 Auxiliary Blower 910-3.3
Overhaul

When referring to this page, please quote Procedure M91003 Edition S234
0219 Page 1 (1)
(2)
0$1% :'LHVHO$6
 Butterfly Valves 110-4
Data

SAFETY PRECAUTIONS
Special Edition
S46MC-C
D11004
110-4 Data 0004 Butterfly Valves

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D11004 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
110-4 Butterfly Valves
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

P91361 Combination Wrenches

Page 2 (2) When referring to this page, please quote Data D11004 Edition 0004
MAN B&W Diesel A/S
 Butterfly Valves 910-4.1
Checking
Butterfly Valves
S60MC-C
0207
Checking
910-4.1

1.
1. It is important that the automatic non-return
valves (butterfly valves) are always able to
function easily and unimpeded.

The movability of the valve flaps should

therefore be checked at suitable intervals.
The valves shall open for the air flow from
the scavenge air cooler housings to the
auxiliary blowers.

2. To check the valve, remove the cover on the

top of the butterfly valve.

GN910-4.1 203 01
Reach down through the opening in the top
of the valve and move the valve flaps.

3. If the valve flaps in one of the butterfly

valves cannot be moved by a light touch of
2.
a fingertip, it must be dismantled and over-
hauled.

4. Re-mount the cover on the top of the but-

terfly valve.
XZ910-9.0 15 02

When referring to this page, please quote Procedure M91004 Edition 0207 Page 1 (1)
0$1% :'LHVHO$6
 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 910-5.1
MAN B&W Cleaning

The dry cleaning method employs compressed

air to blow dry, solid, granules through the tur-
bocharger, 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. 2.8 mm are particularly suited as blasting
agents.

For exact information about cleaning agent

size, see manufactors documentation.

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 de-

posits with this dry cleaning method.

Therefore, in order to prevent the build
up of

thick deposits, the turbine must be cleaned af-
ter every 24 to 50 hours of operation.

Generally, turbocharger cleaning can be carried

out without, or with very little, reduction of the
engine load.

More detailed information regarding the amount

of granules to be used is stated on the instruc-
tion plate located close to the turbocharger.

Note!
Regarding water washing of turbocharg-
er turbine, see turbine manufacturer’s
instructions.
See also Volume I, Chapter 706.

When referring to this page, please quote Procedure M91005 Edition 0216 Page 1 (2)
910-5.1 Turbocharger Turbine
Cleaning MAN B&W

Cleaning Procedure:
1.
1. Carry out cleaning for every 24 to 50 hours
of operation, based on observations.
A C 2. Clean the turbocharger at an engine load
between 50%-90%. Do not clean below
half load.
B
3. Close valve A.

4. Open valves B and C, to blow out any de-

posits and/or condensate in the connecting
pipe.
M91005-0215O01

After about two minutes, close valves B

and C.

5. Slowly open valve A to relieve the pressure

2. in the tank.
Amount
TC type
dm3 6. Fill the tank with the quantity of granules
0.5 specified in the table.
TCA 33
TCA 44 0.5 7. Close valve A.
TCA 55 1.0
TCA 66 1.5 8. Open valves B and C, to blow
in the gran-
2.0 ules. After one to two minutes, close valves
TCA 77
B and C.
TCA 88 2.5
TCA 99 3.0 9. Slowly open valve A to relieve the pressure
TPL 61 0.5 in the tank.
TPL 65 0.6
Caution!
TPL 69 0.9
TPL 73 1.2 1.The drain openings in the gas casings
must remain closed while dry cleaning
TPL 77 1.5 the turbine.
TPL 80 2.0
TPL 85 3.0 2. It is possible that during dry cleaning
0.4 of the turbine, some of the blown
in solid
MET 33
particles or sparks will escape through
MET 42 0.7 the funnel.
MET 53 1.6
MET 60 2.1
MET 66 2.6
MET 71 3.0
M91005
0216O02

MET 83 3.5
MET 90 3.5

Page 2 (2) When referring to this page, please quote Procedure M91005 Edition 0216
 Water Mist Catcher 110-6
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
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 100 kg

When referring to this page, please quote Data D11006 Edition 0040 Page 1 (2)
110-6 Water Mist Catcher
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

P91356 Lifting Tools, Etc.

Page 2 (2) When referring to this page, please quote Data D11006 Edition 0040
 Water Mist Catcher 910-6.2
Dismantling

When referring to this page, please quote Procedure M91006 Edition S221
0221 Page
Page11 (2)
(3)
0$1% :'LHVHO$6
910-6.4 Water Mist Catcher
Mounting

Page 2 (3) When referring to this page, please quote Procedure M91006 Edition S221
0221
Page 2 (2) 0$1% :'LHVHO$6
 Turbocharger System - Tools Plate
P91061-0071
Turbocharger System - Tools
0071
P91061

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

Item Item
Item Description 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
MAN B&W Diesel A/S
 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
 Travelling Trolley Plate
P91064-0002

When referring to this page, please quote Plate P91064 Edition 0002 Page 1 (2)
MAN B&W Diesel A/S
Plate Travelling Trolley
P91064-0002

Item Item Description Item Item Description

No. No.

010 Travelling trolley*

Note:

* When ordering this tool, please state

load and track width.

Page 2 (2) When referring to this page, please quote Plate P91064 Edition 0002
MAN B&W Diesel A/S
 Air Cooler - Lifting Tools Plate
P91066-0001
Air Cooler - Lifting Tools
0001
P91066

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

Item Item
Item Description 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
MAN B&W Diesel A/S
 Relief Valve 111-2
Data
SAFETY PRECAUTIONS For detailed sketch, see 900-2

X 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
X 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 D11102 Edition 0013 Page 1 (2)
MAN B&W Diesel A/S
111-2 Relief 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

Page 2 (2) When referring to this page, please quote Data D11102 Edition 0013
MAN B&W Diesel A/S
 Relief Valve 911-2.1
Checking
60&
Relief Valve
0211
Checking
911-2.1

1.
1. During running of the engine, check if there
are any leaks.

If a leak occurs, replace the O-ring inside

the relief valve. See separate instructions
from the valve manufacturer.

2. If work involving risks of mechanical dam-

age to the flame arrester has taken place,
a visual inspection of the flame arrester
should always be performed before starting
the engine.

Check on the whole circumference that all

the plates in the flame arrester are evenly
distributed and that no local openings exist.

If one or more plates in the flame arrester

are damaged, the relief valve must be dis-
assembled and the flame arrester replaced.
See separate instructions from the valve
manufacturer.
XZ911-2.1 209 01

Note!

The complete flame arrester has to be

2.
replaced after a crankcase explosion.
XZ911-2.1 207 03

When referring to this page, please quote Procedure M91102 Edition 0211 Page 1 (1)
0$1% :'LHVHO$6
 Scavenge Air Receiver Safety Valve 111-3
Data

SAFETY PRECAUTIONS
Special Edition
S60MC-C
D11103
111-3 Data 0001 Scavenge Air Receiver Safety Valve

X Stopped engine
X Block the starting mechanism
X Shut off starting air supply
X Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
X Lock turbocharger rotors

Data
Ref. Description Value Unit

When referring to this page, please quote Data D11103 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
111-3 Scavenge Air Receiver Safety 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

Page 2 (2) When referring to this page, please quote Data D11103 Edition 0001
MAN B&W Diesel A/S
 Scavenge Air Receiver Safety Valve 911-3.1
Checking
Scavenge Air Receiver Safety Valve
0001
Checking
911-3.1

2.
1. The scavenge air receiver safety valve is
calibrated at the factory and does not re-
quire any adjustment.

2. Check the scavenge air receiver safety

valve by loosening the counter nut and turn
the forced opening screw to open the valve
approx. 10 millimetres.

Use a piece of cloth to wipe out any dirt

from the O-ring packing and close the valve
again. Tighten the counter nut.

911-1.1 0001 01
If this operation cannot be performed
smoothly, the safety valve must be disman-
tled and cleaned.

When referring to this page, please quote Procedure M91103 Edition 0001 Page 1 (5)
MAN B&W Diesel A/S
911-3.2 Scavenge Air Receiver Safety Valve
Dismantling
Dismantling
911-3.2

1. 1. Dismount the safety valve from the scav-

enge air receiver.
911-1.1 0001 02

Page 2 (5) When referring to this page, please quote Procedure M91103 Edition 0001
MAN B&W Diesel A/S
 Scavenge Air Receiver Safety Valve 911-3.3
Overhaul
Overhaul
911-3.3

1. Remove the split pin. 1.

Unscrew the nut thereby relieving the

spring tension.

Remove the nut, spring retainer and wash-

ers.

Keep count of the washers.

Pull out the spring.

2. Pull out the valve flap with spindle. If the O-

ring seal is damaged remove it without

911-1.1 0001 03
damaging the O-ring groove.

3. Clean the metal surfaces thoroughly.

911-1.1 0001 04 2.

When referring to this page, please quote Procedure M91103 Edition 0001 Page 3 (5)
MAN B&W Diesel A/S
911-3.3 Scavenge Air Receiver Safety Valve
Overhaul

4. 4. If the O-ring seal has been removed mount

a new one using Locktite type AVX and Loc-
tite activator type T or similar.

5. Push in the valve flap and spindle while tak-

ing care not to damage the O-ring seal.

6. Mount the spring, spring retainer and all the

washers.

Tighten the nut until the split pin can be

mounted.

7. Check the valve according to 91101.1.

911-1.1 0001 05

5.
911-1.1 0001 01

6.
911-1.1 0001 03

Page 4 (5) When referring to this page, please quote Procedure M91103 Edition 0001
MAN B&W Diesel A/S
 Scavenge Air Receiver Safety Valve 911-3.4
Mounting
Mounting
911-3.4

1. Mount the safety valve on the scavenge air 1.

receiver.

911-1.1 0001 07

When referring to this page, please quote Procedure M91103 Edition 0001 Page 5 (5)
MAN B&W Diesel A/S
 Holding Down and End Chock Bolts 112-2
Data

SAFETY PRECAUTIONS Standard Tools: See Section 913

.0&
Special Data
112-2
0007 Holding Down and End Chock Bolts

Stopped engine
Block the starting mechanism
Shut off starting air supply
Engage turning gear
Shut off cooling water
Shut off fuel oil
Shut off lubricating oil
Lock turbocharger rotors

Data
Ref. Description Value Unit

D-1 Tightening pressure for

holding down bolts and
end chock bolts 1500 bar

D-2 Check holding down bolts

and end chock bolts for cor-
rect tightening after the fol-
lowing service hours:

1st check 500 hours

2nd check 1000 hours
3rd check 2000 hours
4th check 4000 hours
5th check 8000 hours
Subsequently at
intervals of 8000 hours

Engine on Epoxy supporting chocks

When referring to this page, please quote Data D11202 Edition 0007 Page 1 (2)
MAN B&W Diesel A/S
112-2 Holding Down and End Chock Bolts
Data

Spare Parts

Plate – Item No. Description Qty

Page 2 (2) When referring to this page, please quote Data D11202 Edition 0007
MAN B&W Diesel A/S
 Holding Down and End Chock Bolts 912-2.1
Checking
.0&
Holding Down and End Chock Bolts
0208
Checking
912-2.1

Note!

The hydraulic jack used for tightening the

holding down bolts is marked with:

For: Holding down bolts

The larger jack used for tightening the

end chock bolts is marked with:

For: End chock bolts

Hydraulic tightening of holding down bolts and

end chock bolts is carried out as detailed in
Section 913-1. The normal tightening pressure
is indicated on the Data sheet and is also
stamped on the tightening tool.

When referring to this page, please quote Procedure M91202 Edition 0208 Page 1 (5)
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking

1. Checking the Bolt Tightening

1. The holding down bolts and end chock bolts

must be checked for correct tightness at the
intervals indicated on the Data sheet.

For this purpose, raise the pressure on the

hydraulic tool slowly while constantly at-
tempting to loosen the nut with the tommy
bar. The oil pressure indicated on the pres-
sure gauge when the nut comes loose
(‘loosening pressure') is to be noted down
in the checking tables, see pages 4 and 5,
following which the bolts are tightened to
the normal tightening pressure.

The condition of the bolted joints, and thus

the general condition of the foundation, can
be effectively checked by comparing the ta-
bles from successive bolt checks.

If the ‘loosening pressure' is below 80 per

cent of the tightening pressure, the relative
EN912-1.1 205 01

chocks shall always be checked for possi-

ble defects. If the chocks are in position and
in order, the bolts should be taken out for
inspection of threads and contact faces.

Checking of Epoxy Supporting Chocks

2. If a number of measuring pins have been

welded to the tanktop, the heights of the
epoxy supporting chocks are to be checked
immediately after finishing the checking of
the loosening pressures of the holding
down bolts and the retightening of these.

The distance between the measuring pins

and the bedplate is to be measured with a
blade gauge and noted down. Any possible
settling of the chocks during the intervals
between measurements can thereby be fol-
lowed.

Page 2 (5) When referring to this page, please quote Procedure M91202 Edition 0208
0$1% :'LHVHO$6
 Holding Down and End Chock Bolts 912-2.1
Checking

Side Chocks and Side Chock Liners 3.

3. After fitting the liners to an 80 per cent con-

tact area on both sides of the liners, knock
the liners a further 3 to 4 mm inwards.

The liners located in way of each main

bearing on either side of the engine must
be fitted and knocked into position simulta-
neously.

The first time the ship is sailing in a fully-

loaded condition after the engine has been
operating for 1,000 hours, all side chocks
should be checked to see whether the lin-
ers can be knocked further inward.

GN912-2.1 203 03
The fit of the side chock liners should be
checked with a feeler gauge each time the
loosening pressure of the holding down
bolts is checked, and thus at the same time
intervals.

The feeler gauge is applied at the 7 points

indicated in the table on page 5, and the
measurements found are to be entered in
the relevant table. These results are used
to determine whether refitting or, possibly,
replacement of the liners is necessary.

If the measurements at 3 points or more have

increased 5/100 mm or more from the initial re-
sults, we recommend that the following proce-
dure is followed:

1. Loosen the hexagon screws.

2. Try to knock the liner further inward.

3. Measure again at the 7 points indicated in

the table.

If this procedure does not improve the situation,

the liner must be removed, and it must be
checked that the actual contact area is more
than 80 per cent of the possible contact surface
areas on both sides of the liner.

The liners are secured in their correct position

by means of hexagon socket set screws with
cup point.

When referring to this page, please quote Procedure M91202 Edition 0208 Page 3 (5)
0$1% :'LHVHO$6
912-2.1 Holding Down and End Chock Bolts
Checking

Holding Down Bolts

Engine Port side Cylinder Starboard side Engine
frame Bolt Bolt frame
No. No. pressure % dev. remarks No. pressure % dev. remarks No. No.
1 1
2 2
1 3 3 1
4 4
1
1 1
2 2
2 3 3 2
4 4
1 2 1
2 2
3 3 3 3
4 4
1 3 1
2 2
4 3 3 4
4 4
1 1
2 2
5 3 3 5
4 4
1 1
2 2
6 3 3 6
4 4
1 1
2 2
7 3 3 7
4 4
1 1
2 2
8 3 3 8
4 4
1 1
2 2
9 3 3 9
4 4
1 1
2 2
10 3 3 10
4 4
1 1
2 2
11 3 3 11
4 4
1 1
2 2
12 3 3 12
4 4
1 1
2 2
13 3 3 13
4 4
1 1
2 2
14 3 3 14
4 4
1 1

Page 4 (5) When referring to this page, please quote Procedure M91202 Edition 0208
0$1% :'LHVHO$6
 Holding Down and End Chock Bolts 912-2.1
Checking

Side Chocks and End Chock Bolts

Port side Starboard side
Chock Point Point Chock
Cylinder
No. A B c d e f g No. A B c d e f g No.

1 1
2 1 2
3 2 3
4 3 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
A, B
FORE A, B
A
d
c

A
d

c
e

e
g
B

f
f

g
B

c, d, e, f, g c, d, e, f, g

Port side Starboard side

Pres- Devi- Devi- Pres-
Ch Bolt sure ation Point Point ation sure Bolt Ch
2) (kp/cm 2 )
No. No. (kp/cm
bar % a b c d e a b c d e % bar
No. No.

1 1
E E
2 2
b c d d c b

a e e a

No. 2 Contact face No. 1 No. 2

AFT
B1

B2

B2

B1

When referring to this page, please quote Procedure M91202 Edition 0208 Page 5 (5)
0$1% :'LHVHO$6
 Stay Bolts 112-3
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
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

D12-04 Check measurement 148±3 mm

D13-01 Hydraulic pressure, mounting 1500 bar
D13-02 Hydraulic pressure, dismantling 1400-1650 bar

When referring to this page, please quote Data D11203 Edition 0030 Page 1 (2)
112-3 Stay Bolts
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

P91261 Large Parts - Tools

P91351 010 Hydraulic pump, pneumatically operated

P91351 046 Hose with unions (1500 mm), complete
P91351 058 Hose with unions (3000 mm), complete
P91351 105 3-way distributor block, complete

Page 2 (2) When referring to this page, please quote Data D11203 Edition 0030
 Stay Bolts 912-3.1
Checking
Stay Bolts
S60MC-C
0212
Checking
912-3.1

1.
1. This check can be performed during several
periods of stopped engine, but must be per- One Group
formed on complete twin stay bolt groups at One Group
a time, thereby ensuring uniform tension in
the affected bearings.

Note!

The first time this check is performed it

has to be completed in one operation.

NA912-3.1 210 01
The following checks have to be com-
pleted within a 500-hour period.

2. Before retightening the stay bolts, remove

the protective caps. 2.

3. Check for loose staybolt nuts with the tom-

my bar.

If a loose nut is found, unscrew the nut until

a gap occurs between cylinder frame and
nut.
GN912-3.1 202 01

Loosen and unscrew the nut on the oppo-

site stay bolt.

Check for the correct mounting of the stay

bolt by comparing with the check measure-
ment on the Data Sheet. 3.
D13-02
If the check measurement is not reached,
indicating that the stay bolt is not screwed
properly down in the thread of the bedplate,
apply a screw and a counternut in the
D12-04
thread in the top of the stay bolt, and turn
the stay bolt until the check measurement
GN912-3.0 39 09

data is met.

4. Retighten the stay bolts in pairs (athwart-

ship), working from fore to aft of the engine.
4.

D13-01
GN912-3.1 202 03

When referring to this page, please quote Procedure M91203 Edition 0212 Page 1 (2)
0$1% :'LHVHO$6
912-3.1 Stay Bolts
Checking

5. 5. Clean the contact faces and mount the hy-

draulic tools on a pair of stay bolts posi-
tioned opposite each other.

Connect the high-pressure pump by means

of the high-pressure hoses, so that the two
D13-01 stay bolts are tightened in one operation.

6. Maintain the mounting pressure, and

retighten the stay bolt nuts with a tommy
bar. Before relieving the system of pres-
sure, check with a feeler gauge that the
nuts bear against their contact faces.
GN912-3.1 202 02

7. When all stay bolts have been retightened,

reconnect the hydraulic tools to the pair of
stay bolts first tightened. Tighten to 10%
below the mounting pressure and check
6. whether the nut is loose.

If the nut is not loose:

Tighten the stay bolts concerned to the
mounting pressure.

If the nut is loose:

Tighten all stay bolts once again to the
mounting pressure.

8. After completing the retightening proce-

dure, mount the protective caps.
HM912-3.0 28 04

7.
HM912-3.0 28 05

Page 2 (2) When referring to this page, please quote Procedure M91203 Edition 0212
0$1% :'LHVHO$6
 Crankcase Oil Outlet 912-5.1
MAN B&W Diesel Checking

The crankcase oil outlets guide the lubricating

oil from the crankcase to the lubricating oil 1.
bottom tank. The sealings of the crankcase oil
outlets must be checked at regular intervals,
for example during dockings. The crankcase oil
outlets may be equipped with either rubber
diaphragm sealing or metal bellow sealing. E F G D C B A
Note!
If the water content of the main engine
lube oil is rising, this may indicate that
the crankcase oil outlet sealings are frac-
tured.

M91205
0201C01
Rubber diaphragm sealing

1. To access the rubber diaphragm sealing

remove:
Screws A 2.
Grating B
Screws C
Cover plate D
Screws E
Steel ring F.

2. Lift away the rubber sealing diaphragms G

and examine each diaphragm closely. In
case of any rips or tears in the diaphragms,
they must be replaced.
M91205
0201C02

Note!
It is strongly recommended to always re-
place the diaphragms during inspection.
If unavailable, new diaphragms may be
made from three layers of 2 mm thick oil
and temperature resistant rubber.

3. Mount:
Rubber sealing diaphragms G
Steel ring F
Screws E
Cover plate D
Screws C
Grating B
Screws A.

Note!
Remember to fit new locking plates at
screws A.

When referring to this page, please quote Procedure M91205 Edition 0201 Page 1 (2)
912-5.1 Crankcase Oil Outlet
Checking MAN B&W Diesel

Metal bellow sealing

4.
4. Remove all screws A and grating B.

5. Remount four of the screws A at diametri-

C B cally opposite positions.
D A
6. Remove:
F Screws C
Cover plate D
Screws E.
E
G 7. Lift away metal bellow sealing F and exam-
ine it closely. If any cracks or punctures are
M91205
0201C04

found in the metal bellow sealing, it must

H be replaced.

Note!
7. It is recommended to always replace the
metal bellow sealing during inspection.

8. Replace gaskets G and H.

9. Mount metal bellow sealing F.

10. Mount:
Screws E
Cover plate D
Screws C.
M91205
0201C07

11. Remove the four screws A.

12. Mount grating B.

13. Mount all screws A.

Page 2 (2) When referring to this page, please quote Procedure M91205 Edition 0201
 Large Parts - Tools Plate
P91261-0073

When referring to this page, please quote Plate P91261 Edition 0073 Page 1 (2)
MAN B&W Diesel A/S
Plate Large Parts - Tools
P91261-0073

Item Item Description Item Item Description

No. No.

023 Hydraulic jack, complete

035 Support
047 Tommy bar
050 Sealing ring with back-up ring
060 Sealing ring with back-up ring
084 Spanner
106 Stud setter
202 Hydraulic tool set, complete

Page 2 (2) When referring to this page, please quote Plate P91261 Edition 0073
MAN B&W Diesel A/S
 Hydraulic Tools - Holding Down Bolts Plate
(Epoxy Chocks) P91265-0003
Hydraulic Tools - Holding Down Bolts (Epoxy Chocks)
0003
P91265

When referring to this page, please quote Plate P91265 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Hydraulic Tools - Holding Down Bolts
P91265-0003 (Epoxy Chocks)

Item Item
Item Description Item Description
No. No.

025 Hydraulic jack, complete

037 Support
049 O-ring with back-up ring
050 O-ring with back-up ring
074 Tommy bar
098 Key, hexagon socket screw
204 Hydraulic tool set, complete

Page 2 (2) When referring to this page, please quote Plate P91265 Edition 0003
MAN B&W Diesel A/S
 HydraulicTools - End Chock Bolts Plate
P91268-0001
(Iron Chocks)

When referring to this page, please quote Plate P91268 Edition 0001 Page 1 (2)
MAN B&W Diesel A/S
Plate HydraulicTools - End Chock Bolts
P91268-0001
(Iron Chocks)
Item Item Description Item Item Description
No. No.

021 Hydraulic jack, complete

033 Support
057 O-ring with back-up ring
069 O-ring with back-up ring
094 Tommy bar
104 Spanner
200 Hydraulic toolset, complete

Page 2 (2) When referring to this page, please quote Plate P91268 Edition 0001
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.1
Description

A. Snap-on coupling
1. A
B. Tool attachment thread C B
C. Bleed screw D
D. Piston E
E. Cylinder
F. Sealing rings
F
G. Spacer ring G S
H. Tommy bar
I. Nut
J. Stud or bolt

M91301
0215C01
H
K. Extension stud U
I
L. Lifting tool
S. Clearance
J
U. Milled recess for feeler gauge 2.

Studs or bolts provided with threads for at-

taching hydraulic tools and with circular nuts L
must only be loosened and tightened up by
means of the hydraulic tools supplied.

The jack(s) is/are connected, via a distributor I

block, to a high-pressure pump, which is set to
deliver hydraulic oil at the pressure indicated
D
on the jack and on the data sheet in the rel- C F
evant section of this instruction book. The stud E
or bolt concerned is thereby lengthened rela-
tive to the oil pressure applied and the piston
area, and the nut can be loosened or tight-
ened, as required, with the aid of a tommy bar. A F

The jacks must never be overloaded or ex- G K

posed to blows or impacts. They are marked 3. B
with a “Max. lift”, which must not be exceeded. H
J
1. The hydraulic tools, except those for the
M91301
0215C02

main bearings and the cylinder cover, con- U

sist of a jack with an internal thread to suit
the tool attachment thread on the stud or I
bolt, and a spacer ring which is to be
placed under the jack and around the nut
that is to be loosened or tightened.

2. For the main bearings, the hydraulic tool

consists of a double jack with two exten-
sion studs. This jack is designed for the si-
multaneous dismantling of both nuts on
one side of the main bearing.

When referring to this page, please quote Procedure M91301 Edition 0215 Page 1 (12)
MAN B&W Diesel A/S
913-1.1 Hyraulic Tools
Description

3. For the cylinder cover, the hydraulic tool

3. consists of eight individual jacks sus-
pended from a common lifting tool. A
spacer ring is mounted below each jack
using two spring pins.

Operation of the cylinder cover jacks is

identical to the operation of the single hy-
draulic jacks.

4. The hydraulic jacks are so designed that, in

the event that the “Max. lift” limit is ex-
ceeded, the pressure is relieved at the bot-
tom of the pressure chamber and the oil
M91301
0215C03

will be pressed out into the space between

the stud and the spacer ring.

When the pressure is relieved in this way,

the lowermost sealing ring will in most
4. cases be damaged. Therefore inspect and,
if necessary, replace this sealing ring.

The oil used must be pure hydraulic oil or

turbine oil (with a viscosity of about SAE
20). Oils such as, for instance, lubricating
oil (system oil) or cylinder lubricating oil
must not be used, as these oils are nor-
mally alkaline and can thus damage the
back-up rings.

The following instructions must be closely

followed to prevent accidents or damage,
and after use the jacks should be cleaned
and kept in the wooden boxes supplied.

Warning!

Eye protectors and gloves must be used

when using hydraulic tools.
M91301
0215C04

Page 2 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.2
Dismantling

Single Hydraulic Jack

1.
1. Carefully clean the tool attachment thread,
the nut and the surrounding parts.

Grease the tool attachment thread with

molybdenum disulphide grease or with
graphite and oil or similar.

Place the spacer ring around the nut in

such a position that the tommy bar can be MoS2
applied through the slot when the nut is to
be loosened.

2. Screw the jack on to the tool attachment

thread of the bolt/stud, until the cylinder of
the jack bears firmly against the spacer
ring.

Screw back the jack a number of turns, ac-

cording to the table shown on the sketch,
to produce a clearance between the jack
and the spacer ring.
M91301
0215D01

The clearance between the jack and spacer

ring ensures dismantling of the jack after
loosening the nut.

When loosening nuts on very long bolts 2.

(e.g. staybolts) it is recommended to un- Max. lift =
screw the jack an additional half turn.
Max. lift 10 mm 25 mm
Connect the hydraulic jack, the distributor Loosening 1 turn 3 turn
block and the high pressure pump by Tightening 1/4 trun 1/4 turn
means of high pressure hoses.

Loosen the bleed screw in the jack and fill

up the system with oil until oil without
bubbles, flows out of the bleed hole. Then
tighten the bleed screw again.

After adjustment, check that the parts are

guided correctly together and that there is
no clearance between the piston and cylin-
der of the jack.
M91301
0215D02

When referring to this page, please quote Procedure M91301 Edition 0215 Page 3 (12)
MAN B&W Diesel A/S
913-1.2 Hydraulic Tools
Dismantling

3. Increase the oil pressure to the prescribed

3. value. If the nut does not come loose, the
pressure may be increased by approx. 150
bar.

4. Unscrew the nut with the tommy bar, mak-

ing sure that the nut is not screwed up
against the jack.

5. Relieve the system of pressure, disconnect

the high-pressure pump, and remove the
hydraulic tools.
M91301
0215D03

Note!

Make sure not to exceed the “max lift”

stamped on the jack.

4.
M91301
0215D04

5.
M91301
0215D05

Page 4 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.2
Dismantling

Double Hydraulic Jack

6.
6. Carefully clean the tool attachment threads,
the main bearing studs, the nuts and the
surrounding parts.

Grease the tool attachment threads with

molybdenum disulphide grease or graphite
and oil or similar.

Mount the extension studs on the main

bearing studs.

Using the lifting tool, place the spacer ring

over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of loosening the
nuts.

Press the pistons and the cylinder of both

the hydraulic jacks firmly together.

Mount the two jacks (one by one using the

M91301
0215D06

lifting tool) over the extension studs and

land them on the spacer ring.

Make sure that both the cylinders of the

jacks and the spacer ring are guided cor-
rectly together. 7.

7. Screw the upper nuts on to the threads of

the extension studs until the cylinders of
the jacks bear firmly against each other
and against the spacer ring. MoS2
M91301
0215D07

When referring to this page, please quote Procedure M91301 Edition 0215 Page 5 (12)
MAN B&W Diesel A/S
913-1.2 Hydraulic Tools
Dismantling

8. The clearance between the pistons and the

8. cylinder of the top jack is adjusted by un-
Max. lift 10 mm
screwing the upper nuts 1 turn ª 3 mm.

The clearance between the jack and spacer

ring ensures dismounting of the jack after
3 mm loosening the nut.

Connect the hydraulic jacks, the distributor

block and the high pressure pump by
means of high pressure hoses.

Loosen the bleed screws in both jacks, and

fill up the system with oil until oil, without
M91301
0215D08

bubbles, flows out of the bleed holes.

Re-tighten the bleed screws.

9. Increase the oil pressure to the prescribed

9. value. If the nut does not come loose, the
pressure may be increased by approx. 150
bar.

10. Unscrew the lower nuts 1½ turns with the

tommy bar, making sure that the nuts are
not screwed up against the extension stud.

11. Relieve the system of pressure, disconnect

the high-pressure pump, and remove the
hydraulic tools.
M91301
0215D09

Note!
Make sure not to exceed the “max lift”
stamped on the jack.

Page 6 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.3
Overhaul

1. The hydraulic jacks require no maintenance

except replacement of defective sealing 1.
rings, each of which consists of an O-ring
and a back-up ring fitted in ring grooves in
the piston and cylinder.

The piston and cylinder are easily sepa-

rated by taking out the bleed screw and
pressing the parts apart with the help of Air
compressed air.

Warning!
Always use protective gloves and eye
protection when working with com-
pressed air.

Make sure that there are no marks or

scratches on the sliding surfaces of the
parts. The presence of metal particles will
damage the sealing rings.
M91301
0215O01

Keep the sliding surfaces and threads

coated with acid-free grease or molybde-
num disulphide grease.

2. The pistons and cylinders of the double

jacks are separated in the same easy way
as described for the single jack. 2.

Air

Air
M91301
0215O02

When referring to this page, please quote Procedure M91301 Edition 0215 Page 7 (12)
MAN B&W Diesel A/S
913-1.3 Hydraulic Tools
Overhaul

3. When changing the sealing rings, first

3. mount the back-up ring and then the O-
ring.

Note!

Note that the back-up ring (1) must be

away from the pressure chamber and
the O-ring (2) close to the pressure
chamber.
1
2
See the sketch for the correct mounting of
both the upper and the lower sealing rings.
The same principle applies to all the jacks.
2
1 4. After fitting the sealing rings, coat the pis-
ton and cylinder with molybdenum
disulphide grease and press the piston and
cylinder together. See that the rings do not
get stuck between the piston and cylinder.
M91301
0215O03

Page 8 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.4
Mounting

Single Hydraulic Jack

1.
1. Thoroughly clean the nut, the thread, the
contact faces, and the surrounding parts.

Clean and lubricate the tool attachment

thread and the thread in the nut with mo-
lybdenum disulphide grease or with graph-
ite and oil or similar.

Fit the round nut on the thread and tighten MoS2

it with the tommy bar.

Check with a feeler gauge that the contact

face of the nut bears on the entire circum-
ference.

Place the spacer ring around the nut in

such a position that the tommy bar can be
applied through the slot for the purpose of
tightening the nut.

2. Press the piston and the cylinder of the

M91301
0215D01

jack firmly together.

Screw the hydraulic jack on to the tool at-

tachment thread.

Make sure that the cylinder of the jack 2.

bears firmly against the spacer ring and Max. lift =
that the parts are guided correctly together
Max. lift 10 mm 25 mm
Connect the hydraulic jack, the distributor Loosening 1 turn 3 turn
block and the high-pressure pump by Tightening 1/4 trun 1/4 turn
means of high-pressure hoses.

Loosen the bleed screw in the jack and fill

up the system with oil, until oil without
bubbles flows out of the bleed hole.

Re-tighten the bleed screw.

M91301
0215D02

When referring to this page, please quote Procedure M91301 Edition 0215 Page 9 (12)
MAN B&W Diesel A/S
913-1.4 Hydraulic Tools
Mounting

3. Increase the oil pressure to the prescribed

3. value, and tighten the nut by means of the
tommy bar applied through the slot of the
spacer ring.

4. While maintaining the pressure, check with

a feeler gauge introduced through the re-
cess at the bottom of the spacer ring that
the nut bears against the contact face.

5. Relieve the system of pressure, disconnect

the pump, and remove the hydraulic jack.
M91301
0215M03

6. When new studs, bolts or nuts are tight-

ened for the first time, do not remove the
jacks, but loosen the nut as described un-
der ‘Loosening’, points 6-7-8, and then
tighten the nut again according to the pro-
cedure under ‘Tightening', points 17-18-19.
4.
M91301
0215M04

Page 10 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Hydraulic Tools 913-1.4
Mounting

Double Hydraulic Jack 5.

5. Thoroughly clean the nuts, the threads on

the main bearing studs, the contact faces,
and the surrounding parts.

Clean and lubricate the tool attachment

thread and the threads in the nuts with mo-
lybdenum disulphide grease or with graph- MoS2
ite and oil.

Fit the round nuts on the threads and

tighten them with the tommy bar.

M91301
0215M05
Check with a feeler gauge that the contact
faces of the nuts bear on the entire circum-
ference.

Mount the extension studs on the main 6.

bearing studs.

Using the lifting tool, place the spacer ring

over the extension studs in such a position
that the tommy bar can be applied through
the slots for the purpose of tightening the
nuts.

6. Press the piston and the cylinder of both

the hydraulic jacks firmly together.

Mount the two jacks (one by one using the

lifting tool) over the extension studs and
land them on the spacer ring.

Make sure that both the cylinders of the

jacks and the spacer ring are guided cor-
rectly together.

Screw the upper nuts on to the threads of

the extension studs until the cylinders of
M91301
0215D06

the jacks bear firmly against each other

and against the spacer ring.

When referring to this page, please quote Procedure M91301 Edition 0215 Page 11 (12)
MAN B&W Diesel A/S
913-1.4 Hydraulic Tools
Mounting

7. Connect the hydraulic jacks, the distributor

7. block and the high pressure pump by
means of high pressure hoses.

Loosen the bleed screws in both jacks, and

fill up the system with oil until oil, without
bubbles, flows out of the bleed holes.

Re-tighten the bleed screws.

8. Increase the oil pressure to the prescribed

value, and tighten the nuts by means of the
tommy bar applied through the slots of the
M91301
0215M07

spacer ring.

9. While maintaining the pressure, check with

a feeler gauge introduced through the re-
cesses at the bottom of the spacer ring
that the nuts bear against the contact face.
8.
10. Relieve the system of pressure, disconnect
the pump, and remove the hydraulic tools.

11. When new studs, bolts or nuts are tight-

ened for the first time, do not remove the
jacks, but loosen the nuts as described un-
der ‘Loosening', points 12-13-14, and then
tighten the nuts again according to the pro-
cedure under ‘Tightening', points 24-25-26.
M91301
0215M08

9.
M91301
0215M09

Page 12 (12) When referring to this page, please quote Procedure M91301 Edition 0215
MAN B&W Diesel A/S
 Standard Tightening Torques 913-4

.0&&
Standard Tightening Torques
0201
913-4

When tightening screws or nuts for which no

torque is specified in the instruction procedure
or the related data sheet, the standard torques
specified in this procedure are to be applied.

1. Standard screws and nuts lubricated with a

Molybdenum Disulphide (MoS 2) based lu-
bricant.

Thread Tightening Thread Tightening

torque torque
M8 17 Nm M22 400 Nm
M10 35 Nm M24 460 Nm
M12 50 Nm M27 610 Nm
M14 80 Nm M30 950 Nm
M16 135 Nm M33 1200 Nm
M18 190 Nm M36 1650 Nm
M20 260 Nm M39 2100 Nm

2. Self-locking nuts.

Thread Tightening Thread Tightening

torque torque
M8 20 Nm M22 430 Nm
M10 40 Nm M24 490 Nm
M12 60 Nm M27 650 Nm
M14 90 Nm M30 1000 Nm
M16 150 Nm M33 1250 Nm
M18 210 Nm M36 1700 Nm
M20 290 Nm M39 2200 Nm

3. Screws and nuts locked with glue/Loctite.

Thread Tightening Thread Tightening

torque torque
M8 23 Nm M22 580 Nm
M10 50 Nm M24 680 Nm
M12 70 Nm M27 900 Nm
M14 115 Nm M30 1350 Nm
M16 190 Nm M33 1700 Nm
M18 270 Nm M36 2350 Nm
M20 380 Nm M39 3000 Nm

When referring to this page, please quote Procedure M91304 Edition 0201 Page 1 (1)
0$1% :'LHVHO$6
 Torque Spanner 913-5

/0&
Torque Spanner
0205
913-5

Before screwing the nuts on, the threads and

the contact faces should be greased with a mix-
ture of graphite and oil or molybdenum disul-
phide with a friction coefficient µ = 0.1-0.12
(e.g. MOLYKOTE paste type G).

The nuts should fit easily on the thread, and it

should be checked that they bear on the entire
contact face.

In the case of new nuts and studs, the nuts are

to be tightened and loosened two or three times
so that the thread may assume its definite
shape; thus obviating the risk of loose nuts.

Nuts secured with a split pin are to be tightened

to the stated torque and then to the next split-
pin hole.

The torque spanner must not be used for tor-

ques higher than those stamped on it, and it
must not be damaged by hammering on it or the
like.

Rahsol Torque Spanner

The handle of the torque spanner is provided

with a scale indicating the torques at which the
spanner can be set.

For setting the spanner at the required torque,

there is a ball on a small arm at the end of the
handle.

When the ball is pulled, a small crank handle

appears. A spring-loaded slide in the handle is
provided with a mark which, when the crank
handle is turned, can be set at the required
torque on the scale. The torque spanner works
as follows:

The above-mentioned spring acts on a pawl

system in the handle. When the pre-set torque
has been reached, the pawl system is released,
at which moment a small jerk is felt in the span-
ner, and a small click is heard.

When the torque spanner is not in use, the

spring inside should be released by adjusting to
minimum torque.

When referring to this page, please quote Procedure M91305 Edition 0205 Page 1 (1)
0$1% :'LHVHO$6
 Tightening Gauge 913-6

Tightening Gauge
0205
913-6

Preparations

Before screwing on the nuts, grease the

threads and the contact faces with a mixture of
graphite and oil or molybdenum disulphide with
a friction coefficient.

µ = 0.1–0.12 (e.g. MOLYKOTE paste type G)

The nuts should fit easily on the thread, and it

should be checked that they bear on the entire
contact face.

Pre-tightening with a torque spanner

Before tightening the nuts according to a tight-

ening gauge or tightening angle, they must be
pre-tightened with a torque spanner.
See Procedure 913-5.

Apply a pre-tightening torque of:

– thread M8 – M20 = 50 Nm
– thread M22 – M27 = 100 Nm
– thread M30 – M39 = 150 Nm
– thread M42 – M48 = 200 Nm

This is in order to ensure a uniform basis for the

subsequent tightening with gauge or tightening
angle.

Tightening with a tightening gauge

After pre-tightening, place the tightening gauge

round the nut, and mark off with chalk on the
nut at slot A on the tightening gauge, and make
another chalk mark on the contact face at slot
B. Then tighten the nut until the two chalk
marks coincide.

Tightening without a tightening gauge

For tightening angles of e.g. 30°–45° and 60°,

we usually do not deliver a tightening gauge.
Therefore, after pre-tightening, mark the angle
on a corner of the nut and on the contact face,

respectively. Then tighten the nut until the two 

marks coincide. 
7;
GQ
D
When tightening new studs or bolts for the first 

time, loosen again and repeat the procedure – 
including pre-tightening with a torque spanner, 

to allow the parts to settle. 0
+
See Procedure 913-5.

When referring to this page, please quote Procedure M91306 Edition 0205 Page 1 (1)
0$1% :'LHVHO$6
 Screws and Nuts 913-7.1
MAN B&W Diesel Locking

Some screwed and bolted connections on the

1.
engine, as well as some movable joints, are se-
cured against untimely loosening by means of
different types of locking devices.

When reassembling the engine after overhauls,

it is vital that all such screws and nuts are
again locked correctly.

Note!
Make sure only to mount locking devices
on nuts and screws which have been
mounted with locking devices by the en-

M91307
0207C01
gine manufacturer.

1. Lock washers, tab washers, locking

plates, etc., must always be replaced. The
tab-like projections, etc., on the washers 2.
are to be bent back over one of the flats of
the screw or nut concerned.

2. Used spring washers must be replaced.

3. Self-locking nuts may only be used five

times. Therefore, give the nut a centre
punch mark each time it is loosened.

To tighten a self-locking nut to a specific

torque, first measure the torque required to
turn the nut itself, and then add this torque
M91307
0207C02

to the torque value stated on the data

sheet of a procedure.

3.
M91307
0207C03

When referring to this page, please quote Procedure M91307 Edition 0207 Page 1 (4)
913-7.1 Screws and Nuts
Locking MAN B&W Diesel

Locking wire should be fitted after the screws

Fig. 1 Fig. 2 or nuts have been tightened to the correct
torque. Do not overtighten or loosen the units
to get a correct alignment of the wire holes. Al-
ways fit new wire after tightening-up the units.

Any tendency of the screws or nuts to loosen

will be counteracted by a tightening of the
locking wire. Do not secure more than four
units in a series, unless otherwise specified.

Fig. 3 Fig. 4 Fig. 1: Insert wire, grasp the upper end of the
wire and bend it around the head of the screw,
then under the other end of the wire, be sure
that the wire is tight around the head.

Fig. 2: Twist the wire clockwise until it is just

short of the hole in the second screw. Keeping
the wire under tension, twist it until tight. When
the wire is tight, the wire shall have approxi-
Fig. 5 Fig. 6 mately 7-10 twists per 25 mm. One twist is a
twist of the wires through an arc of 180°, equal
to half of a complete turn.
M91307
0207C04

Fig. 3: Insert the uppermost wire in the second

screw, and pull it tight.

Fig. 4: Bend the lower wire around the screw,

and under the end protruding from the screw.

Fig. 5: Keeping the wire under tension, twist it

Fig. 7 min. 3 twists, counterclockwise until tight.

Fig. 6: During the final twisting motion, bend

the wire along the screw head. Cut off excess
wire.
Fig. 8
Fig. 7-9: Show the preferred ways of mounting
the locking wire on screws with wire holes ori-
ented in different angles.
M91307
0207C05

Fig. 9

Page 2 (4) When referring to this page, please quote Procedure M91307 Edition 0207
 Screws and Nuts 913-7.1
MAN B&W Diesel Locking

Fig. 10: Shows how to route the locking wire

on screws in different planes.

Fig. 11: Wire that passes over the top of a nut

is an acceptable alternative only if it routes
Fig. 10
around the protruding screw thread.

Fig. 12: Wire that passes over the top of a nut

is also an acceptable alternative if the hole is
located as shown in the figure. Fig. 11
Fig. 13: Where drilling of locking wire holes has
caused a thin wall section, route the wire as
shown in the figure, to prevent damage to the
nut. Fig. 12
Fig. 14: Locking wire can be mounted to any
other part of the assembly if nothing else is
possible. M91307
0207C06
Fig. 13

Fig. 14

When referring to this page, please quote Procedure M91307 Edition 0207 Page 3 (4)
913-7.1 Screws and Nuts
Locking MAN B&W Diesel

Cam Lock Washers with rising cams on one

Fig. 15 side and radial teeth on the other.

Fig. 15: The washers are installed in pairs, cam

face to cam face. When the bolt and/or nut is
tightened the teeth grip and seat the mating
surfaces. The cam lock washer is locked in
place, allowing movement only across the face
of the cams. Any attempt from the bolt/nut to
rotate loose is blocked by the wedge effect og
the cams.

Fig. 16: Different uses of the cam lock wash-

M91307
0207C15

ers.

Fig. 17: Don not use the cam lock washers in

conjunction with other loose washers.

Note!
Fig. 16.
Cam lock washers must be installed in
pairs and are not to be substituted by
other typers of washers.
M91307
0207C16

Fig. 17
M91307
0207C17

Page 4 (4) When referring to this page, please quote Procedure M91307 Edition 0207
 Lubricating Procedures 913-11

.0&&
Lubricating Procedures
0204
913-11

Molybdenum Disulphide (MoS2)

The following procedure is to be followed prior

to the mounting of metal surfaced parts which
are to function as seals.

• Clean the surface with a cleaning fluid

and ensure that the entire surface is
completely free of grease.

• Allow 5 minutes for the cleaning fluid to

evaporate.

• With a clean leathercloth, and using cir-

cular movements, rub a mixture of fine-
grained particles of Molybdenum Disul-
phide (MoS2) and mineral oil (e.g. Moly-
cote G-n Plus, or the like) hard onto the
metal surface.

• Remove any excessive paste and ensure

that the metal surface is only coated with
a thin, uniform, layer of the above mix-
ture.

• Protect the wet paste and cloth from dust

or other foreign particles.

When referring to this page, please quote Procedure M91311 Edition 0204 Page 1 (1)
0$1% :'LHVHO$6
 Accessories for Hydraulic Tools Plate
P91351-0037
Accessories for Hydraulic Tools
0037
P91351

Working Pressure 1500 bar

When referring to this page, please quote Plate P91351 Edition 0037 Page 1 (2)
MAN B&W Diesel A/S
Plate Accessories for Hydraulic Tools
P91351-0037

Item Item
Item Description Item Description
No. No.

010 Hydralic pump, pneumatic operated

022 Hydralic pump, hand operated
046 Hose with unions (1500mm), complete
058 Hose with unions (3000mm), complete
060 Hose with unions (5000mm), complete
105 3-way distributor block, complete
117 5-way distributor block, complete
130 9-way distributor block, complete
154 Conical valve, 0 - 15
166 Angle union
201 Quick coupling, male
213 Quick coupling, female
225 Disc, round-plain, Cu ø11x3mm
237 Bleeder screw
249 Disc, round-plain, Cu ø11x9mm

Page 2 (2) When referring to this page, please quote Plate P91351 Edition 0037
MAN B&W Diesel A/S
 Lifting Tools, Etc. Plate
P91356-0058
Lifting Tools, Etc.
0058
P91356

When referring to this page, please quote Plate P91356 Edition 0058 Page 1 (2)
MAN B&W Diesel A/S
Plate Lifting Tools, Etc.
P91356-0058

Item Item
Item Description Item Description
No. No.

020 Forged-bent screw shackle, 10mm

031 Forged-bent screw shackle, 12mm
043 Forged-bent screw shackle, 16mm
055 Forged-bent screw shackle, 20mm
067 Forged-bent screw shackle, 24mm
079 Forged-bent screw shackle, 30mm
114 Lifting eye bolts, 10mm
126 Lifting eye bolts, 12mm
138 Lifting eye bolts, 16mm
140 Lifting eye bolts, 20mm
151 Lifting eye bolts, 24mm
163 Lifting eye bolts, 30mm
210 Chain tackle, 500kg
222 Chain tackle, 1000kg
234 Chain tackle, 2000kg
258 Chain tackle, 3000kg
295 Pull lift, 3000kg
305 Wire rope, 6m

Page 2 (2) When referring to this page, please quote Plate P91356 Edition 0058
MAN B&W Diesel A/S
 Open Ended Spanners Plate
P91357-0005
Open Ended Spanners
0005
P91357

70
75

When referring to this page, please quote Plate P91357 Edition 0005 Page 1 (2)
MAN B&W Diesel A/S
Plate Open Ended Spanners
P91357-0005

Item Item
Item Description Item Description
No. No.

013 Open-ended spanner, size NV65mm

025 Open-ended spanner, size NV70mm
037 Open-ended spanner, size NV75mm
050 Open-ended spanner, size NV85mm

Page 2 (2) When referring to this page, please quote Plate P91357 Edition 0005
MAN B&W Diesel A/S
 Open-Ended Slugging Spanners Plate
P91358-0013
Open-Ended Slugging Spanners
0013
P91358

When referring to this page, please quote Plate P91358 Edition 0013 Page 1 (2)
MAN B&W Diesel A/S
Plate Open-Ended Slugging Spanners
P91358-0013

Item Item
Item Description Item Description
No. No.

127 Open-ended slugging spanner, size

NV65mm

Page 2 (2) When referring to this page, please quote Plate P91358 Edition 0013
MAN B&W Diesel A/S
 Torque Wrenches Plate
P91359-0003

When referring to this page, please quote Plate P91359 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Torque Wrenches
P91359-0003

Item Item Description Item Item Description

No. No.

014 Torque wrench, 8 - 400Nm

026 Adapter for socket wrench, 10 x 12.5
mm
038 Torque wrench, 40 - 200Nm
040 Torque wrench, 140 - 760Nm
051 Torque wrench, 750 - 2000Nm

Page 2 (2) When referring to this page, please quote Plate P91359 Edition 0003
MAN B&W Diesel A/S
 Pliers Plate
P91360-0003
P91360
Pliers
0003

When referring to this page, please quote Plate P91360 Edition 0003 Page 1 (2)
MAN B&W Diesel A/S
Plate Pliers
P91360-0003

Item Item
Item Description Item Description
No. No.

010 Pliers for retaining ring, size 0.9mm

021 Pliers for retaining ring, size 1.3mm
033 Pliers for retaining ring, size 1.8mm
128 Pliers for retaining ring, size 1.1mm
130 Pliers for retaining ring, size 1.8mm
141 Pliers for retaining ring, size 2.3mm
153 Pliers for retaining ring, size 3.2mm

Page 2 (2) When referring to this page, please quote Plate P91360 Edition 0003
MAN B&W Diesel A/S
 Combination Spanners Plate
P91361-0052
3
&RPELQDWLRQ6SDQQHUV


When referring to this page, please quote Plate P91361 Edition 0052 Page 1 (2)
MAN B&W Diesel A/S
Plate Combination Spanners
P91361-0052

Item Item
Item Description Item Description
No. No.

015 Combination spanners, size NV10mm

027 Combination spanners, size NV11mm
039 Combination spanners, size NV12mm
040 Combination spanners, size NV13mm
052 Combination spanners, size NV14mm
064 Combination spanners, size NV15mm
076 Combination spanners, size NV16mm
088 Combination spanners, size NV17mm
090 Combination spanners, size NV18mm
100 Combination spanners, size NV19mm
111 Combination spanners, size NV21mm
123 Combination spanners, size NV22mm
135 Combination spanners, size NV24mm
147 Combination spanners, size NV27mm
159 Combination spanners, size NV30mm
160 Combination spanners, size NV32mm
172 Combination spanners, size NV34mm
184 Combination spanners, size NV36mm
196 Combination spanners, size NV41mm
206 Combination spanners, size NV46mm
218 Combination spanners, size NV50mm
220 Combination spanners, size NV55mm
231 Combination spanners, size NV60mm

Page 2 (2) When referring to this page, please quote Plate P91361 Edition 0052
MAN B&W Diesel A/S
 Ring Slugging Spanner Plate
P91362-0064

When referring to this page, please quote Plate P91362 Edition 0064 Page 1 (2)
MAN B&W Diesel A/S
Plate Ring Slugging Spanner
P91362-0064

Item Item Description Item Item Description

No. No.

022 Slugging spanners, ring size

NV30mm
034 Slugging spanners, ring size
NV32mm
046 Slugging spanners, ring size
NV34mm
058 Slugging spanners, ring size
NV36mm
060 Slugging spanners, ring size
NV41mm
071 Slugging spanners, ring size
NV46mm
083 Slugging spanners, ring size
NV50mm
095 Slugging spanners, ring size
NV55mm
105 Slugging spanners, ring size
NV60mm
117 Slugging spanners, ring size
NV65mm
129 Slugging spanners, ring size
NV70mm
130 Slugging spanners, ring size
NV75mm
142 Slugging spanners, ring size
NV80mm

Page 2 (2) When referring to this page, please quote Plate P91362 Edition 0064
MAN B&W Diesel A/S
 Spanners Plate
P91363-0035

When referring to this page, please quote Plate P91363 Edition 0035 Page 1 (2)
MAN B&W Diesel A/S
Plate Spanners
P91363-0035

Item Item Description Item Item Description

No. No.

016 Tool set, complete size 12.7mm

028 Tool set, complete size 19.05mm
030 Box and Key set size 7-19mm
041 Adapter for socket wrench, size «”
hole x 3/4" sq.
100 Socket spanner, sq. drive, size NV
46mm x 3/4" sq.

Page 2 (2) When referring to this page, please quote Plate P91363 Edition 0035
MAN B&W Diesel A/S
 Open-ended Spanners Plate
P91364-0059

When referring to this page, please quote Plate P91364 Edition 0059 Page 1 (2)
MAN B&W Diesel A/S
Plate Open-ended Spanners
P91364-0059

Item Item Description Item Item Description

No. No.

011 Open ring wrench, 14 - 17mm

023 Open ring wrench, 19 - 22mm

Page 2 (2) When referring to this page, please quote Plate P91364 Edition 0059
MAN B&W Diesel A/S
 Instruments Plate
P91366-0066

When referring to this page, please quote Plate P91366 Edition 0066 Page 1 (2)
MAN B&W Diesel A/S
Plate Instruments
P91366-0066

Item Item Description Item Item Description

No. No.

012 Indicator, complete

024 Indicator paper
036 Plainmeter, complete
048 Autolog, measuring tool for crankshaft
050 Feeler gauge
061 Slide caliper
073 Dial gauge and stand tool*)
*)To be supplied by exh. grinding mashin maker

Page 2 (2) When referring to this page, please quote Plate P91366 Edition 0066
MAN B&W Diesel A/S
 Working Platforms Plate
P91368-0004
Working Platforms
0004
P91368

When referring to this page, please quote Plate P91368 Edition 0004 Page 1 (2)
MAN B&W Diesel A/S
Plate Working Platforms
P91368-0004

Item Item
Item Description Item Description
No. No.

013 Foot grating, 800 x 250 x 40mm

Page 2 (2) When referring to this page, please quote Plate P91368 Edition 0004
MAN B&W Diesel A/S